RENR5979-03 March 2004
Troubleshooting G3520C and G3520E Engines GDB1-Up (Engine) GHC1-Up (Engine) GHE1-Up (Engine) GHM1-Up (Engine) GHR1-Up (Engine)
i01658146
Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.
3 Table of Contents
Table of Contents Troubleshooting Section Electronic Troubleshooting System Overview .................................................. 10 Self-Diagnostics ..................................................... 11 Location of Components ....................................... 12 Electrical Connectors and Functions .................... 16 Electronic Service Tools ........................................ 18 Engine Monitoring System .................................... 20 Programming Parameters Programming Parameters ..................................... Customer Passwords ............................................ Factory Passwords ............................................... Factory Passwords Worksheet ............................. Flash Programming .............................................. System Configuration Parameters ........................ Replacing the ECM ............................................... Replacing the ITSM .............................................. Troubleshooting Data Sheet .................................
27 27 27 28 29 29 30 32 34
Troubleshooting without a Diagnostic Code Symptoms ............................................................. 36 Detonation ............................................................ 36 Driven Equipment ................................................. 38 ECM Will Not Accept Factory Passwords ............. 38 Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With an Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM)) ..................................... 38 Engine Coolant Temperature (High) ..................... 39 Engine Coolant Temperature (Low) ...................... 41 Engine Cranks but Will Not Start .......................... 41 Engine Misfires, Runs Rough or Is Unstable ........ 42 Engine Oil Filter Differential Pressure ................... 44 Engine Oil Pressure (Low) .................................... 44 Engine Oil Temperature (High) ............................. 45 Engine Overcrank ................................................. 46 Engine Overload ................................................... 47 Engine Overspeed ................................................ 47 Engine Shutdown .................................................. 48 Engine Shutdown (Unexpected) ........................... 48 Engine Shutdown without a Diagnostic Code ....... 50 Engine Starts but Stalls Immediately .................... 51 Engine Timing Does Not Match Programmed Timing ................................................................. 51 Engine Will Not Crank ........................................... 52 Exhaust Port Temperature (High) ......................... 53 Exhaust Port Temperature (Low) .......................... 54 Fuel Energy Content ............................................. 55 Fuel Metering Valve .............................................. 55 Fuel Pressure ....................................................... 55 Gas Fuel Differential Pressure (High) ................... 55 Gas Fuel Differential Pressure (Low) .................... 56 Gas Fuel Flow Rate (Low) .................................... 56 Gas Temperature (High) ....................................... 57 Generator Output Power Readings Do Not Match .................................................................. 58
Inlet Air Temperature (High) .................................. 59 Intermittent Engine Shutdown ............................... 60 Jacket Water Inlet Pressure (High) ....................... 60 Jacket Water Pressure (Low) ................................ 61 Jacket Water to Engine Oil Differential Temperature (Low) ................................................................... 61 System Voltage ..................................................... 62 Turbocharger Turbine Temperature (High) ........... 62 Turbocharger Turbine Temperature (Low) ............ 63 Troubleshooting with a Diagnostic Code Diagnostic Codes .................................................. 65 MID 033 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt ................................................................ 66 MID 033 - CID 0041 - FMI 04 8 Volt DC Supply short to ground ............................................................. 67 MID 033 - CID 0168 - FMI 02 System Voltage intermittent/erratic ............................................... 67 MID 033 - CID 0301 - FMI 05 Ignition Transformer Primary #1 open circuit ....................................... 67 MID 033 - CID 0301 - FMI 06 Ignition Transformer Primary #1 short .................................................. 68 MID 033 - CID 0303 - FMI 05 Ignition Transformer Primary #3 open circuit ....................................... 68 MID 033 - CID 0303 - FMI 06 Ignition Transformer Primary #3 short .................................................. 68 MID 033 - CID 0305 - FMI 05 Ignition Transformer Primary #5 open circuit ....................................... 69 MID 033 - CID 0305 - FMI 06 Ignition Transformer Primary #5 short .................................................. 69 MID 033 - CID 0307 - FMI 05 Ignition Transformer Primary #7 open circuit ....................................... 69 MID 033 - CID 0307 - FMI 06 Ignition Transformer Primary #7 short .................................................. 70 MID 033 - CID 0309 - FMI 05 Ignition Transformer Primary #9 open circuit ....................................... 70 MID 033 - CID 0309 - FMI 06 Ignition Transformer Primary #9 short .................................................. 71 MID 033 - CID 0311 - FMI 05 Ignition Transformer Primary #11 open circuit ..................................... 71 MID 033 - CID 0311 - FMI 06 Ignition Transformer Primary #11 short ................................................ 71 MID 033 - CID 0313 - FMI 05 Ignition Transformer Primary #13 open circuit ..................................... 72 MID 033 - CID 0313 - FMI 06 Ignition Transformer Primary #13 short ................................................ 72 MID 033 - CID 0315 - FMI 05 Ignition Transformer Primary #15 open circuit ..................................... 72 MID 033 - CID 0315 - FMI 06 Ignition Transformer Primary #15 short ................................................ 73 MID 033 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt ....................................................... 73 MID 033 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal ................................................... 74 MID 033 - CID 0401 - FMI 05 Ignition Transformer Secondary #1 open circuit .................................. 74 MID 033 - CID 0401 - FMI 06 Ignition Transformer Secondary #1 short to ground ............................. 74 MID 033 - CID 0403 - FMI 05 Ignition Transformer Secondary #3 open circuit .................................. 75 MID 033 - CID 0403 - FMI 06 Ignition Transformer Secondary #3 short to ground ............................. 75
4 Table of Contents
MID 033 - CID 0405 - FMI 05 Ignition Transformer Secondary #5 open circuit .................................. 75 MID 033 - CID 0405 - FMI 06 Ignition Transformer Secondary #5 short to ground ............................. 76 MID 033 - CID 0407 - FMI 05 Ignition Transformer Secondary #7 open circuit .................................. 76 MID 033 - CID 0407 - FMI 06 Ignition Transformer Secondary #7 short to ground ............................. 77 MID 033 - CID 0409 - FMI 05 Ignition Transformer Secondary #9 open circuit .................................. 77 MID 033 - CID 0409 - FMI 06 Ignition Transformer Secondary #9 short to ground ............................. 77 MID 033 - CID 0411 - FMI 05 Ignition Transformer Secondary #11 open circuit ................................. 78 MID 033 - CID 0411 - FMI 06 Ignition Transformer Secondary #11 short to ground ........................... 78 MID 033 - CID 0413 - FMI 05 Ignition Transformer Secondary #13 open circuit ................................ 79 MID 033 - CID 0413 - FMI 06 Ignition Transformer Secondary #13 short to ground ........................... 79 MID 033 - CID 0415 - FMI 05 Ignition Transformer Secondary #15 open circuit ................................ 79 MID 033 - CID 0415 - FMI 06 Ignition Transformer Secondary #15 short to ground ........................... 80 MID 033 - CID 0590 - FMI 09 Unable to communicate with Engine ECM ................................................ 80 MID 033 - CID 1501 - FMI 03 Cylinder #1 Detonation Sensor open/short to +batt ................................. 81 MID 033 - CID 1501 - FMI 04 Cylinder #1 Detonation Sensor short to ground ....................................... 81 MID 033 - CID 1505 - FMI 03 Cylinder #5 Detonation Sensor open/short to +batt ................................. 81 MID 033 - CID 1505 - FMI 04 Cylinder #5 Detonation Sensor short to ground ....................................... 82 MID 033 - CID 1509 - FMI 03 Cylinder #9 Detonation Sensor open/short to +batt ................................. 82 MID 033 - CID 1509 - FMI 04 Cylinder #9 Detonation Sensor short to ground ....................................... 82 MID 033 - CID 1513 - FMI 03 Cylinder #13 Detonation Sensor open/short to +batt ................................. 83 MID 033 - CID 1513 - FMI 04 Cylinder #13 Detonation Sensor short to ground ....................................... 83 MID 033 - CID 1517 - FMI 03 Cylinder #17 Detonation Sensor open/short to +batt ................................. 83 MID 033 - CID 1517 - FMI 04 Cylinder #17 Detonation Sensor short to ground ....................................... 84 MID 033 - CID 1748 - FMI 05 Ignition Transformer Secondary #17 open circuit ................................ 84 MID 033 - CID 1748 - FMI 06 Ignition Transformer Secondary #17 short to ground ........................... 84 MID 033 - CID 1750 - FMI 05 Ignition Transformer Secondary #19 open circuit ................................ 85 MID 033 - CID 1750 - FMI 06 Ignition Transformer Secondary #19 short to ground ........................... 85 MID 033 - CID 1752 - FMI 05 Ignition Transformer Primary #17 open circuit ..................................... 85 MID 033 - CID 1752 - FMI 06 Ignition Transformer Primary #17 short to ground ............................... 86 MID 033 - CID 1754 - FMI 05 Ignition Transformer Primary #19 open circuit ..................................... 86
MID 033 - CID 1754 - FMI 06 Ignition Transformer Primary #19 short to ground ............................... 87 MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open circuit ................................................................... 87 MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short to ground ............................................................. 87 MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve malfunction .......................................................... 88 MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt ................................................................ 88 MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short to ground ............................................................. 88 MID 036 - CID 0100 - FMI 03 Engine Oil Pressure open/short to +batt .............................................. 89 MID 036 - CID 0100 - FMI 04 Engine Oil Pressure short to ground .................................................... 89 MID 036 - CID 0106 - FMI 03 Air Inlet Pressure Sensor short to +batt .......................................... 90 MID 036 - CID 0106 - FMI 08 Air Inlet Pressure Sensor noisy signal ............................................. 90 MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure open/short to +batt .............................................. 90 MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal ............................. 91 MID 036 - CID 0110 - FMI 03 Engine Coolant Temperature open/short to +batt ......................... 91 MID 036 - CID 0110 - FMI 04 Engine Coolant Temperature short to ground ............................... 91 MID 036 - CID 0145 - FMI 03 12 Volt DC Power Supply short to +batt ........................................... 92 MID 036 - CID 0145 - FMI 04 12 Volt DC Power Supply short to ground ........................................ 92 MID 036 - CID 0168 - FMI 02 System Voltage intermittent/erratic ............................................... 92 MID 036 - CID 0172 - FMI 03 Intake Manifold Air Temp open/short to +batt .................................... 93 MID 036 - CID 0172 - FMI 04 Intake Manifold Air Temp short to ground .......................................... 93 MID 036 - CID 0175 - FMI 03 Engine Oil Temperature open/short to +batt .............................................. 93 MID 036 - CID 0175 - FMI 04 Engine Oil Temperature short to ground .................................................... 94 MID 036 - CID 0261 - FMI 13 Engine Timing calibration required ............................................. 94 MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power Supply short to +batt ................................ 95 MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power Supply short to ground ............................. 95 MID 036 - CID 0302 - FMI 05 Ignition Transformer Primary #2 open circuit ....................................... 96 MID 036 - CID 0302 - FMI 06 Ignition Transformer Primary #2 short .................................................. 96 MID 036 - CID 0304 - FMI 05 Ignition Transformer Primary #4 open circuit ....................................... 96 MID 036 - CID 0304 - FMI 06 Ignition Transformer Primary #4 short .................................................. 97 MID 036 - CID 0306 - FMI 05 Ignition Transformer Primary #6 open circuit ....................................... 97 MID 036 - CID 0306 - FMI 06 Ignition Transformer Primary #6 short .................................................. 97
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MID 036 - CID 0308 - FMI 05 Ignition Transformer Primary #8 open circuit ....................................... 98 MID 036 - CID 0308 - FMI 06 Ignition Transformer Primary #8 short .................................................. 98 MID 036 - CID 0310 - FMI 05 Ignition Transformer Primary #10 open circuit ..................................... 98 MID 036 - CID 0310 - FMI 06 Ignition Transformer Primary #10 short ................................................ 99 MID 036 - CID 0312 - FMI 05 Ignition Transformer Primary #12 open circuit ..................................... 99 MID 036 - CID 0312 - FMI 06 Ignition Transformer Primary #12 short .............................................. 100 MID 036 - CID 0314 - FMI 05 Ignition Transformer Primary #14 open circuit ................................... 100 MID 036 - CID 0314 - FMI 06 Ignition Transformer Primary #14 short .............................................. 100 MID 036 - CID 0316 - FMI 05 Ignition Transformer Primary #16 open circuit ................................... 101 MID 036 - CID 0316 - FMI 06 Ignition Transformer Primary #16 short .............................................. 101 MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt ..................................................... 101 MID 036 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal ................................................. 102 MID 036 - CID 0323 - FMI 03 Shutdown Lamp short to +batt .............................................................. 102 MID 036 - CID 0324 - FMI 03 Warning Lamp short to +batt .................................................................. 102 MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch inputs ................................................................ 103 MID 036 - CID 0402 - FMI 05 Ignition Transformer Secondary #2 open circuit ................................ 103 MID 036 - CID 0402 - FMI 06 Ignition Transformer Secondary #2 short to ground ........................... 103 MID 036 - CID 0404 - FMI 05 Ignition Transformer Secondary #4 open circuit ................................ 104 MID 036 - CID 0404 - FMI 06 Ignition Transformer Secondary #4 short to ground ........................... 104 MID 036 - CID 0406 - FMI 05 Ignition Transformer Secondary #6 open circuit ................................ 105 MID 036 - CID 0406 - FMI 06 Ignition Transformer Secondary #6 short to ground ........................... 105 MID 036 - CID 0408 - FMI 05 Ignition Transformer Secondary #8 open circuit ................................ 105 MID 036 - CID 0408 - FMI 06 Ignition Transformer Secondary #8 short to ground ........................... 106 MID 036 - CID 0410 - FMI 05 Ignition Transformer Secondary #10 open circuit .............................. 106 MID 036 - CID 0410 - FMI 06 Ignition Transformer Secondary #10 short to ground ......................... 107 MID 036 - CID 0412 - FMI 05 Ignition Transformer Secondary #12 open circuit .............................. 107 MID 036 - CID 0412 - FMI 06 Ignition Transformer Secondary #12 short to ground ......................... 107 MID 036 - CID 0414 - FMI 05 Ignition Transformer Secondary #14 open circuit .............................. 108 MID 036 - CID 0414 - FMI 06 Ignition Transformer Secondary #14 short to ground ......................... 108 MID 036 - CID 0416 - FMI 05 Ignition Transformer Secondary #16 open circuit .............................. 108 MID 036 - CID 0416 - FMI 06 Ignition Transformer Secondary #16 short to ground ......................... 109
MID 036 - CID 0443 - FMI 03 Crank Terminate Relay short to +batt ..................................................... 109 MID 036 - CID 0444 - FMI 05 Start Relay open circuit .................................................................. 110 MID 036 - CID 0444 - FMI 06 Start Relay short to ground ................................................................ 110 MID 036 - CID 0445 - FMI 03 Run Relay short to +batt ................................................................... 110 MID 036 - CID 0524 - FMI 03 Desired Engine Speed Sensor short to +batt ......................................... 111 MID 036 - CID 0524 - FMI 04 Desired Engine Speed Sensor short to ground ...................................... 111 MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil Pressure open/short to +batt ............................. 111 MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil Pressure short to ground ................................... 112 MID 036 - CID 1042 - FMI 09 Unable to communicate with ITSM ........................................................... 112 MID 036 - CID 1440 - FMI 09 Unable to communicate with Throttle Actuator Drv .................................. 113 MID 036 - CID 1446 - FMI 05 Fuel Metering Module open circuit ......................................................... 113 MID 036 - CID 1446 - FMI 09 Unable to communicate with Fuel Metering Module ................................. 113 MID 036 - CID 1446 - FMI 12 Fuel Metering Module malfunction ......................................................... 114 MID 036 - CID 1446 - FMI 13 Fuel Metering Module calibration required ............................................ 114 MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor Module malfunction ............................................ 114 MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation Sensor open/short to +batt ................................ 114 MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation Sensor short to ground ...................................... 115 MID 036 - CID 1506 - FMI 03 Cylinder #6 Detonation Sensor open/short to +batt ................................ 115 MID 036 - CID 1506 - FMI 04 Cylinder #6 Detonation Sensor short to ground ...................................... 115 MID 036 - CID 1510 - FMI 03 Cylinder #10 Detonation Sensor open/short to +batt ................................ 116 MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation Sensor short to ground ...................................... 116 MID 036 - CID 1514 - FMI 03 Cylinder #14 Detonation Sensor open/short to +batt ................................ 116 MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation Sensor short to ground ...................................... 117 MID 036 - CID 1518 - FMI 03 Cylinder #18 Detonation Sensor open/short to +batt ................................ 117 MID 036 - CID 1518 - FMI 04 Cylinder #18 Detonation Sensor short to ground ...................................... 117 MID 036 - CID 1636 - FMI 09 Loss of Communication with Engine #2 (Slave) ....................................... 118 MID 036 - CID 1719 - FMI 03 Generator Output Power Sensor open/short to +batt ..................... 118 MID 036 - CID 1719 - FMI 04 Generator Output Power Sensor short to ground ........................... 118 MID 036 - CID 1719 - FMI 12 Generator Output Power Sensor malfunction ................................. 119 MID 036 - CID 1720 - FMI 09 Turbocharger Compressor Bypass Valve Actuator not communicating on link ....................................... 119 MID 036 - CID 1749 - FMI 05 Ignition Transformer Secondary #18 open circuit ............................... 119
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MID 036 - CID 1749 - FMI 06 Ignition Transformer Secondary #18 short to ground ......................... 120 MID 036 - CID 1751 - FMI 05 Ignition Transformer Secondary #20 open circuit .............................. 120 MID 036 - CID 1751 - FMI 06 Ignition Transformer Secondary #20 short to ground ......................... 120 MID 036 - CID 1753 - FMI 05 Ignition Transformer Primary #18 open circuit ................................... 121 MID 036 - CID 1753 - FMI 06 Ignition Transformer Primary #18 short to ground ............................. 121 MID 036 - CID 1755 - FMI 05 Ignition Transformer Primary #20 open circuit ................................... 121 MID 036 - CID 1755 - FMI 06 Ignition Transformer Primary #20 short to ground ............................. 122 MID 111 - CID 0591 - FMI 12 EEPROM checksum fault or ECM not programmed ........................... 122 MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out Temp Sens short to +batt .................................. 122 MID 111 - CID 1489 - FMI 04 Left Turbo Turbine Out Temp Sens short to ground ............................... 123 MID 111 - CID 1489 - FMI 05 Left Turbo Turbine Out Temp Sens open circuit ..................................... 123 MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out Temp Sens short to +batt .................................. 123 MID 111 - CID 1490 - FMI 04 Rt Turbo Turbine Out Temp Sens short to ground ............................... 124 MID 111 - CID 1490 - FMI 05 Rt Turbo Turbine Out Temp Sens open circuit ..................................... 124 MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In Temp Sens short to +batt .................................. 124 MID 111 - CID 1491 - FMI 04 Rt Turbo Turbine In Temp Sens short to ground ............................... 125 MID 111 - CID 1491 - FMI 05 Rt Turbo Turbine In Temp Sens open circuit ..................................... 125 MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In Temp Sens short to +batt .................................. 125 MID 111 - CID 1492 - FMI 04 Left Turbo Turbine In Temp Sens short to ground ............................... 126 MID 111 - CID 1492 - FMI 05 Left Turbo Turbine In Temp Sens open circuit ..................................... 126 MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port Temp Sensor short to +batt ............................... 126 MID 111 - CID 1531 - FMI 04 Cyl #1 Exhaust Port Temp Sensor short to ground ............................ 127 MID 111 - CID 1531 - FMI 05 Cyl #1 Exhaust Port Temp Sensor open circuit ................................. 127 MID 111 - CID 1532 - FMI 03 Cyl #2 Exhaust Port Temp Sensor short to +batt ............................... 127 MID 111 - CID 1532 - FMI 04 Cyl #2 Exhaust Port Temp Sensor short to ground ............................ 128 MID 111 - CID 1532 - FMI 05 Cyl #2 Exhaust Port Temp Sensor open circuit ................................. 128 MID 111 - CID 1533 - FMI 03 Cyl #3 Exhaust Port Temp Sensor short to +batt ............................... 129 MID 111 - CID 1533 - FMI 04 Cyl #3 Exhaust Port Temp Sensor short to ground ............................ 129 MID 111 - CID 1533 - FMI 05 Cyl #3 Exhaust Port Temp Sensor open circuit ................................. 129 MID 111 - CID 1534 - FMI 03 Cyl #4 Exhaust Port Temp Sensor short to +batt ............................... 130
MID 111 - CID 1534 - FMI 04 Cyl #4 Exhaust Port Temp Sensor short to ground ............................ 130 MID 111 - CID 1534 - FMI 05 Cyl #4 Exhaust Port Temp Sensor open circuit ................................. 130 MID 111 - CID 1535 - FMI 03 Cyl #5 Exhaust Port Temp Sensor short to +batt ............................... 131 MID 111 - CID 1535 - FMI 04 Cyl #5 Exhaust Port Temp Sensor short to ground ............................ 131 MID 111 - CID 1535 - FMI 05 Cyl #5 Exhaust Port Temp Sensor open circuit ................................. 132 MID 111 - CID 1536 - FMI 03 Cyl #6 Exhaust Port Temp Sensor short to +batt ............................... 132 MID 111 - CID 1536 - FMI 04 Cyl #6 Exhaust Port Temp Sensor short to ground ............................ 132 MID 111 - CID 1536 - FMI 05 Cyl #6 Exhaust Port Temp Sensor open circuit ................................. 133 MID 111 - CID 1537 - FMI 03 Cyl #7 Exhaust Port Temp Sensor short to +batt ............................... 133 MID 111 - CID 1537 - FMI 04 Cyl #7 Exhaust Port Temp Sensor short to ground ............................ 133 MID 111 - CID 1537 - FMI 05 Cyl #7 Exhaust Port Temp Sensor open circuit ................................. 134 MID 111 - CID 1538 - FMI 03 Cyl #8 Exhaust Port Temp Sensor short to +batt ............................... 134 MID 111 - CID 1538 - FMI 04 Cyl #8 Exhaust Port Temp Sensor short to ground ............................ 135 MID 111 - CID 1538 - FMI 05 Cyl #8 Exhaust Port Temp Sensor open circuit ................................. 135 MID 111 - CID 1539 - FMI 03 Cyl #9 Exhaust Port Temp Sensor short to +batt ............................... 135 MID 111 - CID 1539 - FMI 04 Cyl #9 Exhaust Port Temp Sensor short to ground ............................ 136 MID 111 - CID 1539 - FMI 05 Cyl #9 Exhaust Port Temp Sensor open circuit ................................. 136 MID 111 - CID 1540 - FMI 03 Cyl #10 Exhaust Port Temp Sensor short to +batt ............................... 136 MID 111 - CID 1540 - FMI 04 Cyl #10 Exhaust Port Temp Sensor short to ground ............................ 137 MID 111 - CID 1540 - FMI 05 Cyl #10 Exhaust Port Temp Sensor open circuit ................................. 137 MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port Temp Sensor short to +batt ............................... 138 MID 111 - CID 1541 - FMI 04 Cyl #11 Exhaust Port Temp Sensor short to ground ............................ 138 MID 111 - CID 1541 - FMI 05 Cyl #11 Exhaust Port Temp Sensor open circuit ................................. 138 MID 111 - CID 1542 - FMI 03 Cyl #12 Exhaust Port Temp Sensor short to +batt ............................... 139 MID 111 - CID 1542 - FMI 04 Cyl #12 Exhaust Port Temp Sensor short to ground ............................ 139 MID 111 - CID 1542 - FMI 05 Cyl #12 Exhaust Port Temp Sensor open circuit ................................. 139 MID 111 - CID 1543 - FMI 03 Cyl #13 Exhaust Port Temp Sensor short to +batt ............................... 140 MID 111 - CID 1543 - FMI 04 Cyl #13 Exhaust Port Temp Sensor short to ground ............................ 140 MID 111 - CID 1543 - FMI 05 Cyl #13 Exhaust Port Temp Sensor open circuit ................................. 141 MID 111 - CID 1544 - FMI 03 Cyl #14 Exhaust Port Temp Sensor short to +batt ............................... 141
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MID 111 - CID 1544 - FMI 04 Cyl #14 Exhaust Port Temp Sensor short to ground ............................ 141 MID 111 - CID 1544 - FMI 05 Cyl #14 Exhaust Port Temp Sensor open circuit ................................. 142 MID 111 - CID 1545 - FMI 03 Cyl #15 Exhaust Port Temp Sensor short to +batt ............................... 142 MID 111 - CID 1545 - FMI 04 Cyl #15 Exhaust Port Temp Sensor short to ground ............................ 142 MID 111 - CID 1545 - FMI 05 Cyl #15 Exhaust Port Temp Sensor open circuit ................................. 143 MID 111 - CID 1546 - FMI 03 Cyl #16 Exhaust Port Temp Sensor short to +batt ............................... 143 MID 111 - CID 1546 - FMI 04 Cyl #16 Exhaust Port Temp Sensor short to ground ............................ 144 MID 111 - CID 1546 - FMI 05 Cyl #16 Exhaust Port Temp Sensor open circuit ................................. 144 MID 111 - CID 1547 - FMI 03 Cyl #17 Exhaust Port Temp Sensor short to +batt ............................... 144 MID 111 - CID 1547 - FMI 04 Cyl #17 Exhaust Port Temp Sensor short to ground ............................ 145 MID 111 - CID 1547 - FMI 05 Cyl #17 Exhaust Port Temp Sensor open circuit ................................. 145 MID 111 - CID 1548 - FMI 03 Cyl #18 Exhaust Port Temp Sensor short to +batt ............................... 145 MID 111 - CID 1548 - FMI 04 Cyl #18 Exhaust Port Temp Sensor short to ground ............................ 146 MID 111 - CID 1548 - FMI 05 Cyl #18 Exhaust Port Temp Sensor open circuit ................................. 146 MID 111 - CID 1549 - FMI 03 Cyl #19 Exhaust Port Temp Sensor short to +batt ............................... 147 MID 111 - CID 1549 - FMI 04 Cyl #19 Exhaust Port Temp Sensor short to ground ............................ 147 MID 111 - CID 1549 - FMI 05 Cyl #19 Exhaust Port Temp Sensor open circuit ................................. 147 MID 111 - CID 1550 - FMI 03 Cyl #20 Exhaust Port Temp Sensor short to +batt ............................... 148 MID 111 - CID 1550 - FMI 04 Cyl #20 Exhaust Port Temp Sensor short to ground ............................ 148 MID 111 - CID 1550 - FMI 05 Cyl #20 Exhaust Port Temp Sensor open circuit ................................. 148 Troubleshooting with an Event Code Event Codes ...................................................... E004 Engine Overspeed Shutdown .................... E016 High Engine Coolant Temperature Shutdown .......................................................... E017 High Engine Coolant Temperature Warning ............................................................. E019 High Engine Oil Temperature Shutdown ... E020 High Engine Oil Temperature Warning ...... E026 High Inlet Air Temperature Shutdown ........ E027 High Inlet Air Temperature Warning .......... E038 Low Engine Coolant Temperature Warning ............................................................. E040 Low Engine Oil Pressure Shutdown .......... E042 Low System Voltage Shutdown ................. E043 Low System Voltage Warning .................... E050 High System Voltage Warning ................... E053 Low Fuel Pressure Warning ...................... E096 High Fuel Pressure .................................... E100 Low Engine Oil Pressure Warning ............. E127 Engine Oil Filter Diff Pressure Low Warning .............................................................
150 152 152 153 153 153 153 154 154 154 155 155 155 155 156 156 156
E128 Engine Oil Filter Diff Pressure Low Shutdown .......................................................... E129 Engine Oil Filter Diff Pressure High Warning ............................................................. E130 Engine Oil Filter Diff Pressure High Shutdown .......................................................... E135 Low Jacket Water Pressure Shutdown ...... E223 High Gas Temperature .............................. E224 High Jacket Water Inlet Pressure .............. E225 Engine Overcrank ...................................... E226 Driven Equipment Not Ready .................... E229 Fuel Energy Content Setting Low .............. E230 Fuel Energy Content Setting High ............. E231 Fuel Quality Out of Range ......................... E243 High Left Turbo Turbine Outlet Temperature ...................................................... E244 High Right Turbo Turbine Outlet Temperature ...................................................... E245 High Right Turbo Turbine Inlet Temperature ...................................................... E246 High Left Turbo Turbine Inlet Temperature ...................................................... E264 Emergency Stop Activated ........................ E268 Unexpected Engine Shutdown .................. E269 Customer Shutdown Requested ............... E270 Driven Equipment Shutdown Requested .. E337 High Engine Oil to Engine Coolant Diff Temp ................................................................. E401 Cylinder #1 Detonation .............................. E402 Cylinder #2 Detonation .............................. E403 Cylinder #3 Detonation .............................. E404 Cylinder #4 Detonation .............................. E405 Cylinder #5 Detonation .............................. E406 Cylinder #6 Detonation .............................. E407 Cylinder #7 Detonation .............................. E408 Cylinder #8 Detonation .............................. E409 Cylinder #9 Detonation .............................. E410 Cylinder #10 Detonation ............................ E411 Cylinder #11 Detonation ............................ E412 Cylinder #12 Detonation ............................ E413 Cylinder #13 Detonation ............................ E414 Cylinder #14 Detonation ............................ E415 Cylinder #15 Detonation ............................ E416 Cylinder #16 Detonation ............................ E417 Cylinder #17 Detonation ............................ E418 Cylinder #18 Detonation ............................ E419 Cylinder #19 Detonation ............................ E420 Cylinder #20 Detonation ............................ E421 Cylinder #1 Detonation Shutdown ............. E422 Cylinder #2 Detonation Shutdown ............. E423 Cylinder #3 Detonation Shutdown ............. E424 Cylinder #4 Detonation Shutdown ............. E425 Cylinder #5 Detonation Shutdown ............. E426 Cylinder #6 Detonation Shutdown ............. E427 Cylinder #7 Detonation Shutdown ............. E428 Cylinder #8 Detonation Shutdown ............. E429 Cylinder #9 Detonation Shutdown ............. E430 Cylinder #10 Detonation Shutdown ........... E431 Cylinder #11 Detonation Shutdown ........... E432 Cylinder #12 Detonation Shutdown ........... E433 Cylinder #13 Detonation Shutdown ........... E434 Cylinder #14 Detonation Shutdown ........... E435 Cylinder #15 Detonation Shutdown ...........
156 157 157 157 158 158 158 158 159 159 159 159 160 160 161 161 161 161 162 162 163 163 163 163 164 164 164 164 165 165 165 165 166 166 166 166 167 167 167 167 168 168 168 168 169 169 169 169 170 170 170 171 171 171 171
8 Table of Contents
E436 Cylinder #16 Detonation Shutdown ........... E437 Cylinder #17 Detonation Shutdown ........... E438 Cylinder #18 Detonation Shutdown ........... E439 Cylinder #19 Detonation Shutdown ........... E440 Cylinder #20 Detonation Shutdown ........... E801 Cylinder #1 High Exhaust Port Temp ........ E802 Cylinder #2 High Exhaust Port Temp ........ E803 Cylinder #3 High Exhaust Port Temp ........ E804 Cylinder #4 High Exhaust Port Temp ........ E805 Cylinder #5 High Exhaust Port Temp ........ E806 Cylinder #6 High Exhaust Port Temp ........ E807 Cylinder #7 High Exhaust Port Temp ........ E808 Cylinder #8 High Exhaust Port Temp ........ E809 Cylinder #9 High Exhaust Port Temp ........ E810 Cylinder #10 High Exhaust Port Temp ...... E811 Cylinder #11 High Exhaust Port Temp ....... E812 Cylinder #12 High Exhaust Port Temp ...... E813 Cylinder #13 High Exhaust Port Temp ...... E814 Cylinder #14 High Exhaust Port Temp ...... E815 Cylinder #15 High Exhaust Port Temp ...... E816 Cylinder #16 High Exhaust Port Temp ...... E817 Cylinder #17 High Exhaust Port Temp ...... E818 Cylinder #18 High Exhaust Port Temp ...... E819 Cylinder #19 High Exhaust Port Temp ...... E820 Cylinder #20 High Exhaust Port Temp ...... E821 Cyl #1 Exhaust Port Temp Deviating High .. E822 Cyl #2 Exhaust Port Temp Deviating High .. E823 Cyl #3 Exhaust Port Temp Deviating High .. E824 Cyl #4 Exhaust Port Temp Deviating High .. E825 Cyl #5 Exhaust Port Temp Deviating High .. E826 Cyl #6 Exhaust Port Temp Deviating High .. E827 Cyl #7 Exhaust Port Temp Deviating High .. E828 Cyl #8 Exhaust Port Temp Deviating High .. E829 Cyl #9 Exhaust Port Temp Deviating High .. E830 Cyl #10 Exhaust Port Temp Deviating High ................................................................... E831 Cyl #11 Exhaust Port Temp Deviating High ................................................................... E832 Cyl #12 Exhaust Port Temp Deviating High ................................................................... E833 Cyl #13 Exhaust Port Temp Deviating High ................................................................... E834 Cyl #14 Exhaust Port Temp Deviating High ................................................................... E835 Cyl #15 Exhaust Port Temp Deviating High ................................................................... E836 Cyl #16 Exhaust Port Temp Deviating High ................................................................... E837 Cyl #17 Exhaust Port Temp Deviating High ................................................................... E838 Cyl #18 Exhaust Port Temp Deviating High ................................................................... E839 Cyl #19 Exhaust Port Temp Deviating High ................................................................... E840 Cyl #20 Exhaust Port Temp Deviating High ................................................................... E841 Cyl #1 Exhaust Port Temp Deviating Low .. E842 Cyl #2 Exhaust Port Temp Deviating Low .. E843 Cyl #3 Exhaust Port Temp Deviating Low .. E844 Cyl #4 Exhaust Port Temp Deviating Low .. E845 Cyl #5 Exhaust Port Temp Deviating Low ..
172 172 172 173 173 173 173 174 174 175 175 175 176 176 177 177 177 178 178 179 179 179 180 180 180 181 181 182 182 183 183 183 184 184 185 185 185 186 186 187 187 187 188 188 189 189 189 190 190 191
E846 Cyl #6 Exhaust Port Temp Deviating Low .. E847 Cyl #7 Exhaust Port Temp Deviating Low .. E848 Cyl #8 Exhaust Port Temp Deviating Low .. E849 Cyl #9 Exhaust Port Temp Deviating Low .. E850 Cyl #10 Exhaust Port Temp Deviating Low ................................................................... E851 Cyl #11 Exhaust Port Temp Deviating Low ................................................................... E852 Cyl #12 Exhaust Port Temp Deviating Low ................................................................... E853 Cyl #13 Exhaust Port Temp Deviating Low ................................................................... E854 Cyl #14 Exhaust Port Temp Deviating Low ................................................................... E855 Cyl #15 Exhaust Port Temp Deviating Low ................................................................... E856 Cyl #16 Exhaust Port Temp Deviating Low ................................................................... E857 Cyl #17 Exhaust Port Temp Deviating Low ................................................................... E858 Cyl #18 Exhaust Port Temp Deviating Low ................................................................... E859 Cyl #19 Exhaust Port Temp Deviating Low ................................................................... E860 Cyl #20 Exhaust Port Temp Deviating Low ................................................................... E864 Low Gas Fuel Differential Pressure ........... E865 High Gas Fuel Differential Pressure .......... E866 Low Gas Fuel Flow Rate ........................... E867 Improper Gas Flow Control Valve Response .......................................................... E868 Gas Flow Control Valve Malfunction .........
191 191 192 192 193 193 193 194 194 195 195 195 196 196 197 197 197 197 198 198
Diagnostic Functional Tests +5V Sensor Voltage Supply ................................ 199 +8V Sensor Voltage Supply ................................ 206 Analog Sensor Signal ......................................... 214 CAT Data Link ..................................................... 223 Compressor Bypass ........................................... 229 Desired Speed Input (4 - 20 mA) ........................ 235 Detonation Sensors ............................................ 239 ECM Output Circuit (Fuel Control) ...................... 248 ECM Output Circuit (Starting Motor) ................... 257 ECM Status Indicator Output .............................. 269 Electrical Power Supply ...................................... 275 Engine Speed/Timing Sensor ............................. 282 Fuel Metering Valve ............................................ 289 Generator Output Power Sensor ........................ 298 Ignition Transformers Primary Circuit ................. 305 Ignition Transformers Secondary Circuit and Spark Plugs ................................................................. 316 Inspecting Electrical Connectors ........................ 322 Integrated Temperature Sensing Module (ITSM) ............................................................... 327 PWM Sensor ....................................................... 335 Throttle Actuator ................................................. 342 Calibration Procedures Engine Speed/Timing Sensor - Calibrate ............ 349 Generator Output Power Sensor - Calibrate ....... 351
9 Table of Contents
Index Section Index ................................................................... 355
10 Troubleshooting Section
Troubleshooting Section Electronic Troubleshooting i02072648
System Overview SMCS Code: 1900
Introduction Two Electronic Control Modules (ECM) are used to control the engine. One module is the master ECM and the other module is the slave ECM. Each module is an environmentally sealed unit that is mounted in a terminal box on the engine. The master ECM controls most of the functions of the engine. The master ECM monitors various inputs from sensors in order to activate relays, solenoids, etc at the appropriate levels. The master ECM supports the following five primary functions:
Desired engine speed is determined by the status of the idle/rated switch, the desired speed input (analog voltage or 4 to 20 mA), and parameters such as maximum engine high idle speed that are programmed into the software. Actual engine speed is detected via a signal from the speed/timing sensor. Parameters such as governor gain can be programmed with Cat ET.
Air/Fuel Ratio Control The master ECM provides control of the air/fuel mixture for performance and for efficiency at low emission levels. The system consists of an electronic fuel metering valve, output drivers in the master ECM, and maps in the master ECM. The control compensates for changes in the BTU of the fuel in order to maintain desired emission levels. The following steps describe the basic operation: 1. The master ECM determines the desired flow rates for the air and for the fuel. The flow rates are determined by these factors:
• Desired engine speed
• Engine speed governing
• Actual engine speed
• Air/fuel ratio control
• Calculated engine load
• Start/stop sequencing • Engine monitoring and protection • Control of the ignition and detonation of the left cylinder bank
The slave ECM primarily supports the control of ignition and of detonation of the right cylinder bank.
Engine Speed Governing The master ECM maintains the desired engine speed by controlling the actuator for the throttle. The actuator is located at the inlet to the aftercooler. The actuator is electrically controlled and electrically actuated. The master ECM issues a throttle command that represents a percent of the level of electrical current. The output can be viewed on the Caterpillar Electronic Technician (ET).
2. The command for the flow of the fuel is sent to the electronic fuel metering valve via the CAN data link. This process is repeated continuously during engine operation.
Start/Stop Sequencing The master ECM contains the logic and the outputs for control of starting and of shutdown. The customer programmable logic responds to signals from the following components: engine control, emergency stop switch, remote start switch, data link, and other inputs. When the programmable logic determines that it is necessary to crank the engine, the master ECM supplies +Battery voltage to the relay for the starting motor. The master ECM removes the voltage when the programmable crank terminate speed is reached or when a programmable cycle crank time has expired.
11 Troubleshooting Section
The engine must be equipped with an energize-to-run type of gas shutoff valve (GSOV). The source of the voltage to the GSOV depends on the engine’s configuration. The GSOV may be energized by the customer’s equipment or by the engine’s control system.
The master ECM and the slave ECM provide extensive diagnostics for the ignition system. The master ECM also provides a switch for ignition timing in order to allow operation with alternate fuels such as propane that require a timing offset.
If the engine’s control system controls the GSOV, the master ECM supplies +Battery voltage to the GSOV whenever the programmable logic determines that fuel is required to operate the engine.
i01804722
For more information on programmable parameters, see Troubleshooting, “Programming Parameters”.
Engine Monitoring and Protection The master ECM monitors both the engine operation and the electronic system. Problems with engine operation such as low oil pressure produce an event code. The master ECM can issue a warning or a shutdown. This depends on the severity of the condition. For more information, see Troubleshooting, “Troubleshooting With An Event Code”. Problems with the electronic system such as an open circuit produce a diagnostic code. For more information, see Troubleshooting, “Troubleshooting With A Diagnostic Code”.
Ignition Control Each ECM provides variable ignition timing that is sensitive to detonation. Each cylinder has an ignition transformer that is located under the valve cover for the cylinder. To initiate combustion, an ECM sends a pulse of approximately 100 volts to the primary coil of an ignition transformer at the appropriate time and for the appropriate duration. The transformer steps up the voltage in order to create a spark across the spark plug electrode. Detonation sensors monitor the engine for excessive detonation. The G3520C Engine has ten detonation sensors. Each sensor monitors two adjacent cylinders. The sensors generate data on vibration that is processed by each ECM in order to determine detonation levels. If detonation reaches an unacceptable level, the appropriate ECM retards the ignition timing of the affected cylinder or cylinders. If retarding the timing does not limit detonation to an acceptable level, the master ECM shuts down the engine.
Self-Diagnostics SMCS Code: 1901 Each Electronic Control Module (ECM) has the ability to detect problems with the electronic system and with engine operation. When an ECM detects a problem, the ECM generates a code. An alarm may also be generated. There are two types of codes:
• Diagnostic • Event Diagnostic Code – When a problem with the electronic system or a component is detected, the master ECM or the slave ECM generates a diagnostic code. The code indicates the specific problem with the circuitry. Diagnostic codes can have two different states:
• Active • Logged Active Code – An active diagnostic code indicates that an active problem has been detected. Active codes require immediate attention. Always service active codes prior to servicing logged codes. Logged Code – Every generated code is stored in the memory of the ECM that detected the problem. The code is logged. Each ECM can store a maximum of ten different codes at one time. Logged codes remain in the memory of the ECM even if the power is removed from the ECM. Logged codes may be useful to help troubleshoot intermittent problems. Logged codes can also be used to review the performance of the engine and the electronic system. Logged codes may not indicate that a repair is needed. The problem may have been temporary. The problem may have been resolved since the logging of the code. For example, if the system is powered and a sensor is disconnected, an ECM will detect the problem. The ECM will generate an active diagnostic code for the problem. The ECM will also log the code. When the sensor is connected, the active code will disappear. The logged code will remain in the memory of the ECM until the code is cleared. A code is cleared from memory when one of the following conditions occur:
12 Troubleshooting Section
• The service technician manually clears the code.
Actuators
• The code does not recur for 1000 hours. • A new code is logged and there are already ten
codes in memory. In this case, the oldest code is cleared.
Event Code – An event code is generated when an ECM detects an abnormal engine operating condition. For example, an event code will be generated if the oil pressure is too low. In this case, the event code indicates the symptom of a problem. i02087842
Location of Components SMCS Code: 1900
Fuel Metering Valve Illustration 2
g01012402
Right side view (1) Throttle actuator (2) Actuator for the compressor bypass valve
Throttle actuator (1) and the actuator for the compressor bypass valve (2) are electrically controlled and electrically actuated. The master ECM issues commands to the actuators via the CAN data link.
Sensors Sensors provide information to the electronic control modules. The information enables the modules to control the engine as efficiently as possible over a wide range of operating conditions. The information is used for monitoring engine operation. The sensors also enable the activation of alarms and of shutoffs in response to abnormal operation. Illustrations 3, 4, and 5 show the locations of the sensors. Refer to Systems Operation/Testing and Adjusting, “Engine Sensors” for the descriptions of the sensors. Illustration 1
g01016786
Top view of the engine. The 60 Hz configuration is shown. The 50 Hz configuration is similar.
The fuel metering valve is electrically controlled and electrically actuated. The fuel metering valve and the master Electronic Control Module (ECM) communicate via the CAN data link.
13 Troubleshooting Section
g01064731
Illustration 3 Right side view (1) Engine oil temperature sensor (2) Pressure switch for the coolant pump (inlet) (3) Pressure sensor for unfiltered oil (4) Pressure sensor for filtered oil
g01064733
Illustration 4 Top view (5) Engine coolant temperature sensor (6) Engine coolant pressure sensor (outlet)
(7) Inlet air temperature sensor (8) Inlet air pressure sensor
14 Troubleshooting Section
Illustration 5
g01064734
Left side view (9) Detonation sensor (10) Speed/timing sensor
Thermocouples Thermocouples provide information to the Integrated Temperature Sensing Module (ITSM). The information is used to monitor engine operation. The thermocouples also enable alarms and shutoffs to be activated. Illustration 6 shows the locations of the thermocouples. Refer to Systems Operation/Testing and Adjusting, “Integrated Temperature Sensing Module” for the descriptions of the thermocouples.
15 Troubleshooting Section
g01064747
Illustration 6 Locations of the thermocouples (1) Thermocouple for the temperature of a cylinder exhaust port (2) Thermocouple for the temperature of an exhaust inlet to a turbocharger turbine
(3) Thermocouples for the temperature of the turbocharger exhaust outlets (4) Thermocouple for the temperature of the turbocharger exhaust outlet
Integrated Temperature Sensing Module The Integrated Temperature Sensing Module (ITSM) (5) monitors all of the thermocouples. The ITSM broadcasts the temperature readings of the thermocouples over the CAT data link for use by other modules. Illustration 7 shows the location of the ITSM. Refer to Systems Operation/Testing and Adjusting, “Integrated Temperature Sensing Module” for the description of the ITSM.
Illustration 7
g01066046
Integrated temperature sensing module on the left side of the engine
16 Troubleshooting Section
i02088018
Terminal Box
Electrical Connectors and Functions SMCS Code: 7553-WW
Harness Wire Identification Caterpillar identifies different wires with eleven different solid colors. Table 1 lists the color codes of the wiring. Table 1
Color Codes for Wiring Code
Color
BK
Black
BR
Brown
BU
Blue
GN
Green
GY
Gray
OR
Orange
PK
Pink
PU
Purple
RD
Red
WH
White
YL
Yellow
In addition to the color, the entire length of each wire is stamped with a specific circuit number that is repeated on every 25 mm (1 inch) of the wire. The actual wires are identified on the schematic. For example, a code of J011-RD on the schematic identifies a red wire that is stamped with the circuit number J011. This particular wire is the engine harness wire for the primary signal of the transformer in the number one cylinder. For all Caterpillar engine harnesses with electronic ignition systems, the code of J011-RD identifies the wire for the primary signal of the transformer in the number one cylinder. The schematic also identifies the size of the wire. The size or gauge of the wire is called the American Wire Gauge (AWG). Unless the schematic specifies a different size, you may assume that the wire is 16 AWG.
Illustration 8
g01064774
Rear view (1) Terminal box (2) Emergency stop button
The terminal box contains the master Electronic Control Module (ECM) and the slave ECM. The electrical connectors for the terminal box are located between the terminal box and the engine.
17 Troubleshooting Section
g01064776
Illustration 9 Components inside the terminal box (3) Master ECM (4) Slave ECM (5) Ground strap for the master ECM (6) P3 connector for the slave ECM (7) Master ECM connector P2 (8) P4 connector for the slave ECM
(9) Master ECM connector P1 (10) Ignition harness for the left bank (11) Ground strap for the slave ECM (12) Ignition harness for the right bank (13) Service tool connector J5 for the Caterpillar Electronic Technician (ET)
(14) J10/P10 connector for the terminating resistor for the CAN data link (15) J6 connector for the customer (16) J9 connector (17) J7 connector (18) J8 connector for the detonation sensors
18 Troubleshooting Section
Junction Box
g01059145
Illustration 10 The junction box is located on left side of the engine. (1) Junction box (2) 2.5 amp circuit breaker for the engine control (3) 10 amp circuit breaker for the customer (4) 35 amp circuit breaker for the engine
(5) 2.5 amp circuit breaker for the start command from the master ECM (6) Positive terminal for the connection of the engine’s power supply (7) Negative terminal for the connection of the engine’s power supply
The junction box contains all of the circuit breakers for the engine. The junction box also contains the magnetic switches for the electric starting motors. i02088034
Electronic Service Tools SMCS Code: 0785 Caterpillar Electronic Service Tools are designed to help the service technician perform the following functions:
• Obtain data. • Diagnose problems. • Read parameters. • Program parameters. • Calibrate sensors.
The tools that are listed in Table 2 are required in order to enable a service technician to perform the procedures.
19 Troubleshooting Section
Table 2
Service Tools Pt. No.
Description
Functions
N/A
Personal Computer (PC)
The PC is required for the use of Cat ET.
“JERD2124”
Software
Single user license for Caterpillar Electronic Technician (ET) Use the most recent version of the software.
“JERD2129”
Software
Data subscription for all engines
171-4400
Communication Adapter Gp
This group provides the communication between the PC and the engine.
7X-1414
Data Link Cable As
This cable connects the communication adapter to the service tool connector on the engine.
237-7547
Adapter Cable As
This cable connects to the USB port on computers that are not equipped with a serial port.
8T-8726
Adapter Cable As
This breakout harness is for use between the jacks and the plugs of the sensors.
151-6320
Wire Removal Tool
This tool is used for the removal of pins and of sockets from Deutsch connectors and AMP connectors.
1U-5804
Crimp Tool
This tool is used for work with CE electrical connectors.
146-4080
Digital Multimeter
The multimeter is used for the testing and for the adjusting of electronic circuits.
7X-1710
Multimeter Probes
The probes are used with the multimeter to measure voltage in wiring harnesses without disconnecting the harnesses.
(1)
(1)
The 7X-1700 Communication Adapter Gp may also be used.
Note: For more information regarding the use of Cat ET and of the PC requirements for Cat ET, refer to the documentation that accompanies your Cat ET software.
Caterpillar Electronic Technician (ET) The Caterpillar Electronic Technician (ET) is designed to run on a personal computer. Cat ET can display the following information:
• Parameters • Diagnostic codes • Event codes • Engine configuration • Status of the monitoring system Cat ET can perform the following functions:
• Diagnostic tests • Sensor calibration • Flash downloading • Set parameters
Connecting Cat ET with the 171-4401 Communication Adapter II The engine’s power supply supplies the communication adapter with 24 VDC. Use the following procedure to connect Cat ET and the communication adapter to the engine. 1. Set the engine control to the OFF/RESET mode.
20 Troubleshooting Section
6. Connect cable (5) to the service tool connector on terminal box (6). 7. Set the engine control to the STOP mode. The engine should be OFF. If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, “Electronic Service Tool Will Not Communicate With ECM”. If Cat ET displays “Duplicate Type on data link. Unable to Service”, check the harness code for the slave ECM. The harness inside the terminal box for the slave ECM has a jumper wire (harness code) that connects terminals J3-29 and J3-60. The ECM that is connected to the harness reads the harness code. This allows the ECM to operate as the slave ECM. The jumper wire must be connected in order for the Cat ET to communicate with the modules. The jumper wire must be connected in order for the engine to crank. The jumper wire must remain connected in order for the engine to run. Check the continuity between terminals J3-29 and J3-60. Verify that the jumper wire is in good condition. Make repairs, as needed. i02088048
Engine Monitoring System SMCS Code: 7490 Illustration 11
g01059043
Right side view (1) (2) (3) (4) (5) (6)
PC 196-0055 Serial Cable 171-4401 Communication Adapter II 207-6845 Adapter Cable 7X-1414 Data Link Cable Terminal box
Note: Items (2), (3), and (4) are part of the 171-4400 Communication Adapter Gp. 2. Connect cable (2) to the RS232 serial port of PC (1). Note: If your PC is not equipped with a serial port, use the 237-7547 Adapter Cable As in order to connect to the USB port. Connect one end of the adapter to the end of cable (2). Connect the other end of the adapter to a USB port on the PC. 3. Connect cable (2) to communication adapter (3). 4. Connect cable (4) to communication adapter (3). 5. Connect cable (4) to cable (5).
The master Electronic Control Module (ECM) monitors the operating parameters of the engine. The master ECM can initiate responses if a specific engine parameter exceeds an acceptable range. Two possible responses may be available for each parameter: “WARNING” and “SHUTDOWN”. Some of the responses are not available for some of the parameters. Use the Caterpillar Electronic Technician (ET) to perform the following activities:
• Select the available responses. • Program the level for monitoring. • Program delay times for each response. The default settings for the parameters are programmed at the factory. To accommodate unique applications and sites, the parameters may be reprogrammed with Cat ET. The screens of Cat ET provide guidance for the changing of trip points. Note: Some of the parameters are protected by factory passwords. Other parameters can be changed with customer passwords.
21 Troubleshooting Section
Changing the Settings of the Monitoring System Use the following procedure to change settings of the parameters: 1. Use Cat ET and select the “Service/Monitoring System” screen. 2. Highlight the desired parameter. Then click on the “Change” button in the lower left corner of the screen. The “Change Monitor System” screen will appear. 3. Change the “State” to “On” or “Off”. 4. Set the “Trip Point” and the “Delay Time” according to the “Allowed Values” in the lower half of the screen. 5. Click the “OK” button. If a password is required, the “Enter Passwords” screen will appear. Enter the correct passwords and then click the “OK” button. The new settings will be effective immediately.
Monitoring Parameters
“Engine Overspeed” The trip point for this parameter is set at the factory. This parameter is always ON. This parameter cannot be turned off. If the engine speed increases to the trip point or if the engine speed exceeds the trip point, the ECM will activate an engine shutdown. A typical trip point is 118 percent of the engine’s rated speed for generator set applications.
“High Engine Oil Temperature” The trip point for a warning for this parameter can be programmed by the customer. The trip point for a shutdown is set at the factory. This parameter is always ON. This parameter cannot be turned off. If the engine oil temperature increases to the trip point or if the engine oil temperature exceeds the trip point, the ECM will generate a warning or a shutdown.
“High Oil Filter Differential Pressure” The trip point for a warning for this parameter can be programmed by the customer. The trip point for a shutdown is set at the factory. This parameter is always ON. This parameter cannot be turned off. If the engine oil filter differential pressure increases to the trip point or if the engine oil filter differential pressure exceeds the trip point, the ECM will generate a warning or a shutdown.
“Low System Voltage”
“Low Oil Filter Differential Pressure”
The trip point for this parameter is set at the factory. The trip point cannot be changed. This parameter is always ON. This parameter cannot be turned off. If the system voltage decreases to the trip point or if the system voltage goes below the trip point, the ECM will generate a warning or a shutdown.
The trip point for a warning for this parameter can be programmed by the customer. The trip point for a shutdown for this parameter is set at the factory. This parameter is always ON. This parameter cannot be turned off. If the engine oil filter differential pressure decreases to the trip point or if the engine oil filter differential pressure goes below the trip point, the ECM will generate a warning or a shutdown.
“High Engine Coolant Temperature” The trip points for this parameter can be programmed by the customer. The shutdown response is always ON. The shutdown response cannot be turned off. If the engine coolant temperature increases to the trip point or if the engine coolant temperature exceeds the trip point, the ECM will generate a warning or a shutdown.
“Low Engine Coolant Temperature” The trip point for this parameter can be programmed by the customer. If the engine coolant temperature decreases to the trip point or if the engine coolant temperature goes below the trip point, the ECM will generate a warning.
“High Fuel Temperature” The trip point for this parameter can be programmed by the customer. If the fuel temperature increases to the trip point or if the fuel temperature exceeds the trip point, the ECM will generate a warning.
“Low Fuel Pressure” The trip point for this parameter can be programmed by the customer. If the fuel pressure decreases to the trip point or if the fuel pressure goes below the trip point, the ECM will generate a warning.
22 Troubleshooting Section
“High Engine Oil to Engine Coolant Differential Temperature” The trip point for a warning for this parameter can be programmed by the customer. The trip point for a shutdown for this parameter is set at the factory. The shutdown response is always ON. The shutdown response cannot be turned off. If the differential temperature of the jacket water and the engine oil increases to the trip point or if the differential temperature of the jacket water and the engine oil exceeds the trip point, the ECM will generate a warning or a shutdown.
“Low Gas Fuel Differential Pressure” The trip point for this parameter can be programmed by the customer. If the fuel differential pressure decreases to the trip point or if the fuel differential pressure goes below the trip point, the ECM will generate a warning.
“High Gas Fuel Differential Pressure” The trip point for this parameter can be programmed by the customer. If the fuel differential pressure increases to the trip point or if the fuel differential pressure exceeds the trip point, the ECM will generate a warning.
“High System Voltage” The trip point for this parameter is set at the factory. The trip point cannot be changed. This parameter is always ON. This parameter cannot be turned off. If the system voltage increases to the trip point or if the system voltage exceeds the trip point, the ECM will generate a warning.
Trip Points of the Engine Load for High Inlet Air Temperature The trip points for these parameters can be programmed by the customer. The shutdown response is always ON. The shutdown response cannot be turned off. This feature provides a trip point between high engine load and low engine load. The trip point is used for events that involve high inlet air temperature. The trip point for the events is based on the engine load. The possible responses of the system include a warning or a shutdown. If the load is greater than the trip point, the trip point for the “High Inlet Air Temperature at High Engine Load” event is used for the logging of the high inlet air temperature.
If the load is less than the trip point, the trip point for the “High Inlet Air Temperature at Low Engine Load” event is used for the logging of the high inlet air temperature.
“High Inlet Air Temperature at Low Engine Load” The “Service/Configuration” screen of Cat ET defines the “High Inlet Air Temp Engine Load Set Point”. The ECM can activate a warning or a shutdown if the inlet air temperature increases to the trip point or if the inlet air temperature exceeds the trip point during the low load operation that is defined.
“High Inlet Air Temperature at High Engine Load” The “Service/Configuration” screen of Cat ET defines the “High Inlet Air Temp Engine Load Set Point”. The ECM can activate a warning or a shutdown if the inlet air temperature increases to the trip point or if the inlet air temperature exceeds the trip point during the high load operation that is defined.
“High Fuel Pressure” The trip point for this parameter can be programmed by the customer. The ECM will activate a warning if the fuel pressure increases to the trip point or if the fuel pressure exceeds the trip point.
Default Settings of the Monitoring System Examples of the default settings for the parameters are listed in Table 3. The values may have changed. Use the Cat ET to determine the programming for your engine. Many of the items can be reprogrammed in order to accommodate the requirements of individual sites.
23 Troubleshooting Section
Table 3
Default Settings of the Programmable Monitoring System Parameter
Event Code
System Response
“Low System Voltage”
E043 (1)
Warning
E042 (3)
Shutdown
“E017 (1)”
Warning
“E016 (3)”
Shutdown
“High Engine Coolant Temperature”
State
On
(1)
On On
(1)
Trip Point
Delay in Seconds
20 volts
20
18 volts
10
Security Level Password
109 °C 113 °C
80 to 129 °C 20
Warning
“Engine Overspeed”
E004 (3)
Shutdown
1770 rpm
“High Engine Oil Temperature”
E020 (1)
Warning
102 °C
E019 (3)
Shutdown
104 °C
“High Oil Filter Differential Pressure”
E129 (1)
Warning
E130 (3)
Shutdown
138 kPa
“Low Oil Filter Differential Pressure”
E127 (1)
Warning
35 kPa
Customer
E128 (3)
Shutdown
5 kPa
Factory
“High Fuel Temperature” “Low Fuel Pressure” “High Engine Oil to Engine Coolant Differential Temperature”
(1)
E223 (1) E053 (1)
E337 (3)
E864 (1)
“High Gas Fuel Differential Pressure”
E865 (1)
“High System Voltage”
E050 (1)
5 °C
Warning
On
5 to 80 °C 0 20
103 kPa
60 °C
E337 (1)
“Low Gas Fuel Differential Pressure”
105 kPa
Factory
1200 to 2125 rpm
Customer
85 to 102 °C
Factory
85 to 104 °C
Customer 10
Factory
20 10
0
80 to 138 kPa
5 to 80 kPa 0 to 60 °C
Customer
100 to 135 kPa
1 to 60
14 °C Shutdown
On
(1)
20 °C
20
Factory
0 to 20 °C
5 kPa 10
On
On
E027 (1) E026 (3)
Shutdown
“High Inlet Air Temperature at High Engine Load”
E027 (1)
Warning
E026 (3)
Shutdown
E096 (1)
Warning
Customer
0 to 35 kPa
35 kPa
Warning
“High Inlet Air Temperature at Low Engine Load”
“High Fuel Pressure”
(1)
1 to 60
Customer
E038 (1)
On
Range of the Delay in Seconds
This item cannot be programmed.
“Low Engine Coolant Temperature”
On
Range
(1)
On On
(1)
On On
(1)
On
34 volts
20
This item cannot be programmed.
69 °C
32 to 85 °C
73 °C 53 °C
20 Customer
32 to 100 °C
57 °C 135 kPa
This parameter is permanently active. The parameter cannot be turned off.
10
100 to 135 kPa
1 to 60
24 Troubleshooting Section
Separate timers are used in the master ECM for each response that is associated with a parameter. If a trip point is exceeded, the timer for that event is started. For example, the warning for “High Engine Coolant Temperature E017 (1)” can be set to 95 °C with a five second delay. The timer starts counting if the coolant temperature exceeds 95 °C. If the temperature is not reduced to less than 95 °C within five seconds, the event becomes active and the event is logged.
Conditions for Parameters Some of the programmable parameters are dependent on the status of a master ECM output before the parameters are allowed to function. Some of the parameters are allowed to function after the crank terminate relay has been energized for more than 30 seconds. Other parameters are allowed to function after the output for the fuel control relay is energized. Some parameters are not dependent upon any conditions. The conditions are designed to eliminate false events during start-up if the customer has programmed a delay time to zero. The conditions are listed in Table 4. Table 4
Conditions for Activation for Monitoring the Parameters Parameter
Condition
“Low System Voltage”
None
“High Engine Coolant Temperature”
The crank terminate relay is energized for more than 30 seconds.
“Low Engine Coolant Temperature”
None
“Engine Overspeed”
None
“High Engine Oil Temperature”
The crank terminate relay is energized for more than 30 seconds.
“High Oil Filter Differential Pressure” “Low Oil Filter Differential Pressure” “High Fuel Temperature” “Low Fuel Pressure”
The fuel control relay is energized.
“High Engine Oil to Engine Coolant Differential Temperature”
The crank terminate relay is energized for more than 30 seconds.
“Low Gas Fuel Differential Pressure”
The fuel control relay is energized.
“High Gas Fuel Differential Pressure” “High System Voltage”
None
“High Inlet Air Temperature at Low Engine Load”
The crank terminate relay is energized for more than 30 seconds.
“High Inlet Air Temperature at High Engine Load” “High Fuel Pressure”
The fuel control relay is energized.
25 Troubleshooting Section
Use care when you program the trip points and the delay times. Ensure that the response of the master ECM is correct for the application. The monitoring system will accept any settings within the ranges. If the trip point for a shutdown is programmed to activate before the trip point for a warning, the engine will shut down and the warning will not be activated.
Programmable Parameters of the Integrated Temperature Sensing Module The Integrated Temperature Sensing Module (ITSM) monitors the temperatures of the cylinder exhaust ports, of the inlets of the turbocharger turbine, and of the outlets of the turbocharger turbines. If a temperature exceeds an acceptable range, the ITSM can initiate a “WARNING” or “SHUTDOWN”. Both of the responses are available for all of the parameters. Use Cat ET to perform the following activities:
• Select the available responses. • Program the level for monitoring. • Program delay times for each response. Note: To initiate the responses, the ITSM sends commands to the master ECM via the Cat Data Link. If the connection between the ITSM and the master ECM is not correct, the ITSM cannot initiate any response. The default settings for the parameters are programmed at the factory. To accommodate unique applications and sites, the parameters may be reprogrammed with Cat ET. The screens of Cat ET provide guidance for changing trip points. Table 5 lists default examples of the values for the parameters. However, the values may have changed. Use Cat ET to determine the programming for your engine. The items can be reprogrammed in order to accommodate the requirements of individual sites. Use care when you program the trip points and the delay times. Ensure that the response of the ITSM is correct for the application. The monitoring system will accept any setting within the ranges. If the trip point for a shutdown is programmed to activate before the trip point for a warning, the engine will shut down and the warning will not be activated.
26 Troubleshooting Section
Table 5
Default Settings for the Integrated Temperature Sensing Module Parameter
“High Exhaust Temperature”
“Exhaust Port Temperature High Deviation”
“Exhaust Port Temperature Low Deviation”
“High Turbo Turbine Inlet Temperature”
“High Turbo Turbine Outlet Temperature”
Event Code
System Response
State
Trip Point
E801 (1) through E820 (1)
Warning
E801 (3) through E820 (3)
Shutdown
665 °C
E821 (1) through E840 (1)
Warning
E821 (3) through E840 (3)
Shutdown
E841 (1) through E860 (1)
Warning
E841 (3) through E860 (3) E245 (1) E246 (1)
Delay in Seconds
Security Level Password
Range
Range of the Delay in Seconds
655 °C 30
100 to 665 °C
1 to 60
50 °C
60
10 to 50 °C
1 to 60
200 °C
10
100 to 200 °C
1 to 10
50 °C
60
10 to 50 °C
1 to 60
Shutdown
200 °C
10
10 to 200 °C
1 to 10
Warning
710 °C
On
30
E245 (3) E246 (3)
Shutdown
730 °C
E243 (1) E244 (1)
Warning
615 °C
E243 (3) E244 (3)
Shutdown
60
Separate timers are used in the ITSM for each response that is associated with a parameter. If a trip point is exceeded, the timer for that event is started. For example, the warning for the “High Exhaust Temperature” (E801 (1)) can be set to 655 °C with a 30 second delay. The timer starts counting if the exhaust port temperature of the number 1 cylinder reaches 655 °C. If the temperature is not reduced to less than 655 °C within 30 seconds, the event becomes active and the event is logged.
625 °C
Customer
100 to 710 °C 100 to 730 °C 100 to 625 °C
1 to 60
1 to 60
27 Troubleshooting Section
Programming Parameters i01829539
Programming Parameters SMCS Code: 1901 Programmable parameters enable the engine to be configured in order to meet the requirements of the application. The system configuration parameters must be programmed when the application is installed. Perform this programming before the initial engine start-up. Data from a gas analysis and data on engine performance are required in order to determine the correct settings for the ignition timing and the fuel control. Incorrect programming of parameters may lead to complaints about performance and/or to engine damage. Programmable parameters can be classified into the following types: engine identification, timing control, air/fuel ratio control, speed control, and start/stop control. If an Electronic Control Module (ECM) is replaced, the appropriate parameters must be copied from the old ECM. This can be done with the “Copy Configuration” feature of the Caterpillar Electronic Technician (ET). Alternatively, the settings can be recorded on paper and then programmed into the new module. NOTICE Changing the parameters during engine operation can cause the engine to operate erratically. This can cause engine damage. Only change the settings of the parameters when the engine is STOPPED.
After the customer passwords are entered, the passwords are required in order to change certain parameters. Once the passwords are entered successfully, the passwords are not requested again until another screen is accessed or the data link is interrupted. This feature is enabled by programming two customer passwords. Use the following procedure to program the passwords. The same procedure is used to change the passwords: 1. Access the “Service/Configuration” screen of the Caterpillar Electronic Technician (ET). 2. Highlight the “Customer Password #1” parameter. Click on the “Change” button in the lower right corner of the screen. Note: Be sure to record the customer passwords. Store the passwords securely. The passwords can have a maximum of eight characters. Alphanumeric characters may be used. The passwords are case sensitive. 3. Enter the password in the “Change Parameter Value” dialog box and click on the “OK” button. 4. Highlight the “Customer Password #2” parameter. Click on the “Change” button in the lower right corner of the screen. 5. Enter the password in the “Change Parameter Value” dialog box and click on the “OK” button. The passwords are now programmed into the memory of the Master Electronic Control Module (ECM). Make a copy of Table 6 and record your passwords. Store the passwords securely. Table 6
Customer Passwords i01902441
Customer Passwords
Customer Password #1 Customer Password #2
SMCS Code: 0785 Certain monitoring system parameters and system configuration parameters may be protected with customer passwords. Use of the passwords helps to prevent free access to the modification of the parameters. If the customer passwords are not programmed, all of the parameters are unprotected. The customer passwords can be changed, if necessary. The customer passwords or a factory password is needed in order to change the customer passwords. If the customer passwords are forgotten, factory passwords can be acquired from Caterpillar.
i01865997
Factory Passwords SMCS Code: 0785 Factory level security passwords are required for clearing certain logged events and for changing certain programmable parameters. Because of the passwords, only authorized personnel can make changes to some of the programmable items in an Electronic Control Module (ECM). When the correct passwords are entered, the changes are programmed into the master ECM.
28 Troubleshooting Section
Factory passwords are required to program the following shutdowns:
• “Engine Overspeed”
i02089534
Factory Passwords Worksheet SMCS Code: 0785
• “High Engine Oil Temperature” • “High Oil Filter Differential Pressure” • “Low Oil Filter Differential” • “High Engine Oil to Engine Coolant Differential Temperature”
The “Enter Factory Passwords” screen on Cat ET will display the following parameters. To obtain the proper passwords, the information must be given to an authorized Caterpillar dealer:
• Current master ECM
The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Note: A mistake in recording this information will result in incorrect passwords. Table 7
Factory Passwords Worksheet
• Serial number of the service tool
Dealer Code
• Serial number of the engine
Customer’s Name
• Serial number of the master ECM
Address
• Diagnostic clock • Total Tattletale • Reason The old interlock code is required to change the interlock code on a used ECM. The passwords are controlled by Caterpillar. The passwords may only be obtained by an authorized Caterpillar dealer.
Telephone Number Information from the “Enter Factory Passwords” Screen on the Caterpillar Electronic Technician (Cat ET) Serial Number for Cat ET Engine Serial Number ECM Serial Number
The passwords may only be used for one programming session. After you exit the “Enter Factory Passwords” screen on Cat ET, a different set of passwords will be required before you can program the master ECM.
Total Tattletale
Factory passwords are not required for the first hour of operation for a new master ECM. After the hour expires, factory passwords are required for some of the programming.
Factory Password (No. 2)
Reason Code Factory Passwords Factory Password (No. 1)
29 Troubleshooting Section
i01866010
Flash Programming SMCS Code: 1901-591 Software is located in the flash memory of the master Electronic Control Modules (ECM), the slave ECM, and the Integrated Temperature Sensing Module (ITSM). The Caterpillar Electronic Technician (ET) can be used to flash new software into an ECM or the ITSM. This is the only method for updating the software. The component that contains the software cannot be physically removed from the module. This eliminates the risk of moisture entry into a module due to improper seal installation. The flash is accomplished by transferring the data from Cat ET to the module via data link wiring. The Software, JERD2124 or Software, JERD2129 is used.
Flash Programming If the slowest baud rate of Cat ET is selected, flash programming can last up to 15 minutes. Be sure to set the baud rate to the fastest rate for your PC. To select the baud rate, use the “Utilities/Preferences” option on the Cat ET. Select the “Communications” tab and click on “Advanced...”. Then select the baud rate from the “Advanced Communication Settings” menu and click the “OK” button. If a communication error occurs, select a slower baud rate in order to improve the reliability. 1. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. 2. Set the engine control to the STOP mode. Cat ET will not flash if the engine control is in the OFF/RESET or START mode. 3. Select “WinFlash” from the “Utilities” menu on the Cat ET. “WinFlash” will try to detect an ECM. Allow a few moments for “WinFlash” to detect the electronic control modules and connect to the electronic control modules. 4. When an ECM has been detected, the “ECM Selector” window will appear. Select the appropriate ECM and then select “OK”. The “Flash File Selection” window will appear. 5. The flash files are located on a disk drive and in a directory. Select the correct disk drive and the directory from “Drives” and “Directories” on Cat ET.
A list of flash files will appear. 6. Select the correct file from the list of flash files. Read the “Description” and the “File Info” in order to verify that the correct file is selected. Select “Open”. 7. Select the “Begin Flash” button in order to program the personality module. When the flash is completed, this message will appear: “Flash Completed Successfully”. 8. Program the configuration parameters and the monitoring system parameters. The parameters must be programmed in order to ensure proper engine operation. Refer to Troubleshooting, “Engine Monitoring System” and Troubleshooting, “System Configuration Parameters”. 9. Start the engine and check for proper operation. a. If a diagnostic code of 268-02 “Check Programmable Parameters” is generated, program any parameters that were not in the original software. b. Access the “Configuration” screen under the “Service” menu in order to determine the parameters that require programming. Look under the “Tattletale” column. All of the parameters should have a tattletale of 1 or more. If a parameter has a tattletale of 0, program that parameter.
“WinFlash” Error Messages If you receive any error messages during flash programming, click on the “Cancel” button in order to stop the process. Access the information about the “ECM Summary” under the “Information” menu. Make sure that you are flashing the correct file for your engine. i01945454
System Configuration Parameters SMCS Code: 1901 Certain parameters are unique for each engine application. Table 8 is a list of the parameters that can be configured for G3520C Engines. The parameters are programmed into the Electronic Control Module (ECM) via the Caterpillar Electronic Technician (Cat ET). The values of the parameters can be viewed on the “Configuration” screen of Cat ET.
30 Troubleshooting Section
Refer to Systems Operation/Testing and Adjusting, “Electronic Control System Parameters” for the descriptions of the parameters. Table 8
Configuration Parameters for G3520C Engines Timing Control
(Table 8, contd)
Configuration Parameters for G3520C Engines Power Monitoring “Generator Output Power Sensor Scale Factor” “Generator Output Power Sensor Offset” “Engine Output Power Configuration”
“First Desired Timing”
“Engine Driven Accessory Load Configuration”
“Second Desired Timing”
Information for the ECM
Air/Fuel Ratio Control
“Engine Serial Number”
“Fuel Quality”
“Equipment ID”
“Gas Specific Gravity”
“Customer Password #1”
“Fuel Specific Heat Ratio”
“Customer Password #2”
“Desired Emission Gain Adjustment”
“Total Tattletale”
“Air/Fuel Proportional Gain” “Air/Fuel Integral Gain”
i02088063
Speed Control
Replacing the ECM
“Low Idle Speed” “Minimum High Idle Speed”
SMCS Code: 1901-510
“Maximum High Idle Speed”
Electronic control modules contain no moving parts. Replacement of an Electronic Control Module (ECM) can consume much time. Before you replace an ECM, follow the troubleshooting procedures in this manual in order to be sure that replacement of the ECM will correct the problem.
“Engine Accel. Rate” “Desired Speed Input Configuration” “Governor Type Setting” “Engine Speed Droop”
Note: The master ECM and the slave ECM should not be interchanged in order to determine if an ECM is faulty. If the master ECM and the slave ECM are interchanged, all of the configuration data for each ECM must be transferred into the Caterpillar Electronic Technician (ET). The appropriate configuration data must then be re-entered into the appropriate ECM. Failure to program each ECM correctly may result in improper engine operation.
“Governor Proportional Gain” “Governor Integral Gain” “Governor Derivative Gain” “Auxiliary Proportional Governor Gain 1” “Auxiliary Integral Governor Gain 1” “Auxiliary Derivative Governor Gain 1” Start/Stop Control
Verify that the suspect ECM is the cause of the problem. Install a test ECM in place of the suspect ECM. Transfer the software from the suspect ECM to the test ECM. Program all the parameters for the test ECM in order to match the parameters of the suspect ECM. The parameters must match. Refer to the following test steps for details on programming the parameters.
“Driven Equipment Delay Time” “Crank Terminate Speed” “Engine Purge Cycle Time” “Engine Cooldown Duration” “Cycle Crank Time” “Engine Overcrank Time”
If the test ECM resolves the problem, reconnect the suspect ECM. Verify that the problem recurs. If the problem recurs, replace the suspect ECM with the test ECM.
“Engine Speed Drop Time” “Engine Pre-lube Time Out Period” Monitoring and Protection “High Inlet Air Temp Load Set Point” (continued)
Note: If the parameters cannot be read from the suspect ECM, the parameters must be obtained from records or from the factory.
31 Troubleshooting Section
Perform the following procedure to replace the ECM. 1. Use the “Service/Copy Configuration/ECM Replacement” function of the Caterpillar Electronic Technician (ET). Save the file. You can select “Load from ECM”. You may also select the “Print” function in order to obtain a paper copy of the parameter settings. Note: Before you replace an ECM, record all of the logged events. a. Connect the Cat ET with the communications adapter. Select “Service/Copy Configuration/ECM Replacement” from the drop-down menu on Cat ET. Cat ET will load the configuration parameters and the monitoring system parameters of the suspect ECM. b. Select “Load from ECM” in the lower left corner of the Cat ET screen. Select the suspect ECM and select “OK”. After the loading is complete, the Cat ET will display this message: “The data has been successfully loaded from the ECM”. Select “OK”.
Illustration 12
g01054206
Junction box (1) 35 amp circuit breaker
b. Switch 35 amp circuit breaker (1) to the OFF position.
c. Select “File/Disconnect F8” from the drop-down menu. Note: Do not terminate the Cat ET. 2. Replace the ECM. Note: This procedure describes replacement of the master ECM. Replacement of the slave ECM is similar. a. Set the engine control to the OFF/RESET mode.
Illustration 13
g01064809
The master ECM is on the left side of the terminal box. The slave ECM is on the right side of the terminal box. (2) Mounting nut (3) P2 connector (4) P1 connector
c. Use a 4 mm allen wrench to disconnect connectors (3) and (4). d. Remove mounting nut (2) in order to disconnect the ground strap. Remove the three remaining mounting nuts.
32 Troubleshooting Section
Note: Rubber grommets behind the ECM are held in place by the mounting studs. The grommets help to reduce vibration. The grommets may fall when the ECM is removed. Be sure not to lose the grommets.
5. Calibrate the speed/timing sensor. See Troubleshooting, “Engine Speed/Timing Sensor - Calibrate”.
e. Remove the ECM from the terminal box. 3. Install the replacement ECM. a. Use the mounting hardware to install the new ECM. Use a mounting nut to fasten the ground strap for the ECM to the upper left mounting stud. Then install the other three mounting nuts. Check the mounting hardware and the ECM for correct installation. A correctly installed ECM will move slightly on the rubber grommets. If the ECM cannot move slightly on the grommets, check that the washers, spacers, and grommets are positioned correctly. b. Use a 4 mm allen wrench to connect the P1 and P2 connectors to the ECM. Tighten the screws to a torque of 6 ± 1 N·m (55 ± 9 lb in). 4. Program the configuration parameters and the monitoring system parameters into the replacement ECM. a. Switch 35 amp circuit breaker (1) to the ON position. b. Set the engine control to the “STOP” mode. c. Select “File/Select ECM” from the drop-down menu. d. Select the replacement ECM and click “OK”. e. Select “Service/Copy Configuration/ECM Replacement” from the drop-down menu. Click “OK” on the window. f. Select “Program ECM” from the lower left corner of the screen. Select the replacement ECM and click “OK”. If the correct ECM is shown, select “Yes”. g. After the loading is complete, a window with the message “Programming Conflict Warning” will appear. Select “OK”. h. A window with the message “Program ECM Results” will appear. Select “OK”. Note: When you program a new ECM, factory passwords are not required for the first hour of operation. After one hour, factory passwords are required for changing the parameters that are normally protected with factory passwords.
i02088110
Replacing the ITSM SMCS Code: 1901-510 The Integrated Temperature Sensing Module (ITSM) contains no moving parts. Replacement of the ITSM can consume much time. Before you replace an ITSM, follow the troubleshooting procedures in this manual in order to be sure that replacement of the ITSM will correct the problem. Use the following guidelines to verify that the suspect ITSM is the cause of the problem: Install a test ITSM in place of the suspect ITSM. Transfer the software from the suspect ITSM to the test ITSM. Program all the parameters for the test ITSM in order to match the parameters of the suspect ITSM. The parameters must match. Refer to the following steps for details on programming the parameters. If the test ITSM resolves the problem, reconnect the suspect ITSM. Verify that the problem recurs. If the problem recurs, replace the suspect ITSM with the test ITSM. Use the following procedure to replace the ITSM: Note: If the parameters cannot be read from the suspect ITSM, the parameters must be obtained from records or from the factory. 1. Use the “Service/Copy Configuration/ECM Replacement” function of the Caterpillar Electronic Technician (ET) in order to transfer the software from the suspect ITSM. You may also select the “Print” function in order to obtain a paper copy of the parameter settings. Note: Before you replace an ITSM, record all of the logged events. a. Connect Cat ET with the communications adapter. Select “Service/Copy Configuration/ECM Replacement” from the drop-down menu. Cat ET will load the configuration parameters and the monitoring parameters from the ECM.
33 Troubleshooting Section
b. Select “Load from ECM” in the lower left corner of the screen. Select the suspect ITSM and select “OK”. After the loading is complete, Cat ET will display this message: “The data has been successfully loaded from the ECM”. Select “OK”. c. Select “File/Disconnect F8” from the drop-down menu. Note: Do not exit from Cat ET. 2. Replace the ITSM. a. Set the engine control to the OFF/RESET mode.
Illustration 15
g01064840
Rear view (2) Connectors for the harness to the thermocouples (3) Connectors for the harness to the terminal box for the master ECM
c. Disconnect connectors (2) and (3) from the ITSM.
Illustration 14
g01054206
Junction box (1) 35 amp circuit breaker
b. Switch 35 amp circuit breaker (1) to the OFF position.
Illustration 16
g01064841
Mounting hardware for the ITSM (4) (5) (6) (7)
Nut Ground strap Washer Mounting flange on the ITSM
d. Remove four nuts (4) and washers (6) from mounting flanges (7) of the ITSM. Ground strap (5) must also be lifted from one of the studs. e. Remove the ITSM from the engine.
34 Troubleshooting Section
3. Install the replacement ITSM. Orient the 54-pin connector toward the bottom of the engine. a. Use the mounting hardware to install the new ITSM. Be sure to install ground strap (5) between one of the washers on the mounting flange and the nut. Note: One of the washers is a lock washer. Be sure to install the lock washer between ground strap (5) and mounting flange (7). The lock washer improves the electrical conductivity between the ground strap and the mounting flange. Check the mounting hardware and the ITSM for correct installation. A properly installed ITSM will move slightly on the rubber grommets. If the ITSM cannot move slightly on the grommets, check that the mounting hardware is installed correctly. b. Connect connectors (2) and (3) to the ITSM. 4. Program the configuration parameters and the monitoring system parameters into the replacement ITSM. a. Switch 35 amp circuit breaker (1) to the ON position. b. Set the engine control to the STOP mode. c. Select “File/Select ECM” from the drop-down menu of Cat ET. d. Select the “Replacement ITSM” and click “OK”. e. Select “Service/Copy Configuration/ECM Replacement” from the drop-down menu. Click “OK” on the window. f. Select “Program ECM” from the lower left corner of the screen. Select the replacement ITSM and click “OK”. g. After the loading is complete, a window with the message “Programming Complete” will appear. Select “OK”. Note: When you program a new ITSM, factory passwords are not required. Also, the ITSM does not require calibration.
i02089781
Troubleshooting Data Sheet SMCS Code: 0785 To help troubleshoot a gas engine, complete the information in Illustration 17. Be sure to include the units of measurement.
35 Troubleshooting Section
Illustration 17
g01013492
Data sheet for troubleshooting
Report the Service Information After you have successfully repaired the engine, it is important to provide good information about the repair. The following topics are recommended for your report: Complaint – Include a description of the customer’s complaint in the report. Cause – Provide a specific description of the cause of the failure. Include the method that was used in order to diagnose the problem. If diagnostic codes or event codes were generated, include all of the codes and the status of the codes. Indicate your determination of the problem. For example, if you performed a diagnostic functional test, identify the test procedure. For example, a visual inspection revealed abrasion of a wire in a harness. Be specific: dynamometer testing of the engine produced power below specifications at 1800 rpm due to the loss of an ignition transformer.
Repair – Explain your repair of the problem. For example, you may have installed a new wiring harness. You may have replaced the ignition transformer per instructions from the factory. The providing of complete, accurate information will help Caterpillar to provide better service to you and to the customer.
36 Troubleshooting Section
Troubleshooting without a Diagnostic Code i01970297
Narrow the probable cause. Consider the operator information, the conditions of operation, and the history of the engine.
Operator Information
Symptoms
Obtain the following information from the operator:
SMCS Code: 1000-035
• The occurrence and the time of the occurrence
Some engine symptoms can be unrelated to the electronic control system. This section is for troubleshooting problems that have symptoms without active diagnostic codes. Conditions such as poor fuel quality or improperly adjusted valves can cause some engine symptoms.
• Determine the conditions for the occurrence. The
For basic troubleshooting of the engine, perform the following steps first in order to diagnose a malfunction.
• Determine whether any other occurrences
1. Gather information about the complaint from the operator. 2. Verify that the complaint is not due to normal engine operation. Verify that the complaint is not due to error of the operator. 3. Perform a visual inspection. Inspect the following items:
conditions will include the engine rpm and the load.
• Determine if there are any systems that were
installed by the dealer or by the customer that could cause the symptom. happened in addition to the symptom.
Diagnostic Codes and Event Codes Examine the following information regarding any codes:
• The probable cause of the symptom is correlated to the code.
• The code was generated when the symptom occurred.
• Fuel supply
• Codes that are repeatedly logged
• Oil level
• The complaint is not due to normal engine
• Oil supply
operation.
• Coolant level
Other Symptoms
• Wiring
If other occurrences happened in addition to the symptom, investigate the following conditions:
• Connectors 4. Check the diagnostic codes and event codes. Repair any active codes. If these inspections do not reveal any problems, identify the probable causes with the procedures in this manual that best describe the symptoms. Refer to Troubleshooting, “Troubleshooting With A Diagnostic Code” or refer to Troubleshooting, “Troubleshooting With an Event Code”. Check each probable cause according to the tests that are recommended. Be sure to check the connectors. This is specially true for problems that are intermittent. Refer to Troubleshooting, “Inspecting Electrical Connectors”.
• The other occurrences are related to the symptom. • The symptoms have a probable cause that is common.
i02064369
Detonation SMCS Code: 1000-035
Probable Causes • Excessive load • Excessive inlet manifold air pressure • High inlet air temperature
37 Troubleshooting Section
• Incorrect air/fuel ratio
Check the Base Timing
• Incorrect base timing
Verify that the base timing is correct. Refer to Systems Operation/Testing and Adjusting, “Ignition Timing - Adjust”.
• Changes in the fuel quality • The engine speed/timing sensor is not calibrated. • Faulty circuit for the detonation sensor(s) • Excessive deposits in the combustion chamber
Recommended Repairs
Check for Event Codes Regarding the Fuel Check for the following event codes:
• “E229 (1) Fuel Energy Content Setting Low” (warning)
Excessive Load
• “E230 (1) Fuel Energy Content Setting High”
Make sure that the load is not excessive. Reduce the load. If necessary, disengage the driven equipment and test the engine.
• “E231 (3) Fuel Quality Out Of Range” (shutdown)
Check the Inlet Manifold Air Pressure The calculated engine load increases when the inlet manifold air pressure increases. Measure the inlet manifold air pressure during engine operation with a load. For specific data on the engine, refer to the engine Technical Marketing Information.
Check the Inlet Air Temperature High inlet air temperature can cause detonation. Check the inlet air temperature. Look for the following event codes:
• “E026 (3) High Inlet Air Temperature” (shutdown)
(warning)
Refer to Troubleshooting, “Fuel Energy Content”.
Calibrate the Engine Speed/Timing Sensor Note: Only perform this procedure if work on the engine may have affected the engine timing. Also, perform this procedure if the engine speed/timing sensor has not been calibrated. Calibrate the engine speed/timing sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor Calibrate”.
Check the Detonation Sensors
• “E027 (1) High Inlet Air Temperature” (warning)
Troubleshoot the detonation sensors. Refer to Troubleshooting, “Detonation Sensors”.
Refer to Troubleshooting, “Inlet Air Temperature (High)”.
Check for Deposits in the Cylinders
Air/Fuel Ratio
Overfilling of engine oil can lead to deposits. Make sure that the engine oil level is correct.
An air/fuel mixture that is too rich will cause detonation. Verify that the exhaust emissions are correct. Refer to Systems Operation/Testing and Adjusting, “Air/Fuel Ratio Control - Adjust”. A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis. The fuel supply pressure must be adequate and stable. Make sure that the fuel metering valve is operating correctly.
Note: Excessive deposits contribute to guttering of the valves. Use a borescope to inspect the cylinders. Look for the following conditions:
• Deposits on the valve seats • Deposits on the valve faces • Deposits on the cylinder walls that are above the upper limit of the piston stroke
• Signs of internal leaks Signs of internal leaks include excessive consumption of engine oil, blue smoke, and excessive detonation.
38 Troubleshooting Section
If excessive deposits and/or signs of internal leaks are found, investigate the cause of the condition. Make repairs, as needed. i02088119
Driven Equipment
• Total Tattletale • Reason Code
Recommended Repairs 1. Verify that the correct passwords were entered. Check every character in each password. Set the engine control to the OFF/RESET mode for 30 seconds and then retry.
SMCS Code: 1400-035
Probable Causes • The master Electronic Control Module (ECM) has received a “Start Inhibit” or a “Shutdown” signal. • The circuit for the signal is faulty.
2. Verify that Cat ET is on the “Factory Password” screen. 3. Verify that the following information from Cat ET has been recorded correctly:
• Serial Number of the engine
Recommended Repairs
• Serial Number of the Electronic Control Module
Check the Driven Equipment
(ECM)
Determine whether the driven equipment has generated a “Start Inhibit” or “Shutdown” request. Determine the cause for the request. Service the driven equipment according to the recommendations of the OEM of the equipment.
• Serial Number of the Cat ET
Check the Circuit for the Switch
• Diagnostic Clock
The circuit for the switch must remain closed in order to allow the engine to run. Check the wiring between the driven equipment and the ECM connector for damage and/or corrosion. Refer to Troubleshooting, “Inspecting Electrical Connectors”. Repair the wiring, as needed. Check the resistance of the circuit between terminals P1-21 and P1-31 at the master ECM. The correct resistance of the circuit is 5 Ohms or less. If the resistance is greater than 5 Ohms, locate the source of the excessive resistance. Make repairs, as needed. i01804809
ECM Will Not Accept Factory Passwords
• Total Tattletale • Reason Code
i01804831
Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With an Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM)) SMCS Code: 0785-035
SMCS Code: 1901-035
Probable Causes
Probable Causes
• Electrical power supply
One of the following items may not be recorded correctly on the Caterpillar Electronic Technician (ET):
• Passwords • Serial Numbers
• Electrical connectors • Communication adapter and/or cables • Electronic service tool • A problem with the harness code for the slave ECM
39 Troubleshooting Section
Recommended Repairs Electrical Power Supply Check power to the module. Refer to Troubleshooting, “Electrical Power Supply”. Note: If a module is not receiving power, the module will not communicate.
Electrical Connectors
If the jumper wire is disconnected, the slave ECM will assume the function of a master ECM. Cat ET will not communicate with any of the modules. Cat ET will display “Duplicate Type on data link. Unable to Service”. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Check the continuity between terminals J3-29 and J3-60. Verify that the jumper wire is in good condition. Make repairs, as needed.
Check the following components:
i01974132
• Power supply connections and ground to the
Engine Coolant Temperature (High)
• Wiring harnesses and the connectors for the
SMCS Code: 1395-035
module module
Refer to Troubleshooting, “Inspecting Electrical Connectors”.
Communication Adapter and/or Cables 1. Check the condition of the fuse for the communication adapter. 2. Disconnect the communication adapter and the cables from the service tool connector. Then reconnect the communication adapter. If you are using the 171-4401 Communication Adapter II, refer to Manual, “Communication Adapter II User’s Manual”. 3. Verify that power supply voltage is present between terminals A and B of the J5 service tool connector. If the communication adapter is not receiving power, the display will be blank.
Probable Causes • High ambient temperature and/or high inlet air temperature
• Low coolant level and/or coolant leakage • Insufficient flow of air or coolant through the radiator or heat exchanger
• Faulty water temperature regulators • Faulty coolant temperature sensor and/or circuit • Insufficient flow of coolant through the engine • Exhaust restriction • Excessive load • Incorrect base timing
Electronic Service Tool
• Incorrect air/fuel ratio
In order to eliminate Cat ET as the problem, connect Cat ET to a different engine. If the same problem occurs with a different engine, check Cat ET and the related equipment in order to determine the cause of the problem.
Recommended Repairs
Check the Harness Code for the Slave ECM
Determine if the ambient air temperature is within the design specifications for the cooling system.
The harness inside the terminal box has a jumper wire (harness code) that connects terminals J3-29 and J3-60. The ECM that is connected to the harness reads the harness code. This allows the ECM to operate as the slave ECM.
Check for high inlet air temperature. Refer to Troubleshooting, “Inlet Air Temperature (High)”.
Check for High Ambient Temperature and/or High Inlet Air Temperature
Determine the cause of the high air temperature. Make corrections, when possible.
40 Troubleshooting Section
Check for a Low Coolant Level and/or Coolant Leakage Note: Low coolant level can be the effect of overheating rather than the cause.
If the reading on Cat ET for the coolant temperature is not reasonable, troubleshoot the circuit and the coolant temperature sensor. Refer to Troubleshooting, “Analog Sensor Signal”.
Check the coolant level.
Check the Flow of Coolant Through the Engine
Run the engine to operating temperature. Inspect the cooling system for leaks.
During normal operation, check the status of the following components:
Determine whether the leak occurs before the engine overheats.
• Switch for the inlet pressure of the jacket water
Add coolant, if necessary. If leaking is found, make the necessary repairs.
Check for Insufficient Flow of Air and Coolant Through the Radiator or Heat Exchanger Radiator Check the fins of the radiator for obstructions. Check the fan for proper operation. If the radiator fins are obstructed, clean the fins. If the fan does not operate properly, make the necessary repairs. Heat Exchanger Check for sufficient flow and temperature of the cooling water through the heat exchanger. If the flow of cooling water through the heat exchanger is insufficient, determine the location of the obstruction. If the temperature of the cooling water is too high, determine the cause. Make the necessary repairs.
Check the Water Temperature Regulators Check the water temperature regulators for proper operation. Refer to Systems Operation/Testing and Adjusting, “Testing the Cooling System”.
• Sensor for the outlet pressure of the jacket water If the flow of coolant through the engine is not sufficient, determine the cause of the obstruction. Make necessary repairs.
Check the Exhaust Restriction Check the back pressure of the exhaust system. Refer to Systems Operation/Testing and Adjusting, “Air Inlet and Exhaust System”. If the back pressure exceeds the specifications for the engine, determine the cause of the excessive back pressure. Make the necessary repairs.
Excessive Load Make sure that the load is not excessive. Reduce the load. If necessary, disengage the driven equipment and test the engine.
Check the Base Timing Verify that the base timing is correct. Refer to Systems Operation/Testing and Adjusting, “Ignition Timing - Adjust”.
Air/Fuel Ratio
Replace the water temperature regulators, if necessary.
An air/fuel mixture that is too rich will cause overheating. Verify that the exhaust emissions are correct. Refer to Systems Operation/Testing and Adjusting, “Air/Fuel Ratio Control - Adjust”.
Check the Coolant Temperature Sensor and/or the Circuit
A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis.
Check the reading of the coolant temperature on the Caterpillar Electronic Technician (ET). The temperature should rise steadily as the engine is warmed. Ensure that the temperature is reasonable.
The fuel supply pressure must be adequate and stable.
41 Troubleshooting Section
Strike the gas pressure regulator with a soft hammer. If the engine speed changes, inspect the internal parts of the gas pressure regulator for wear. Inspect the gas pressure regulator’s diaphragm for leaks. Make sure that the valve moves freely. The valve must seat correctly. Ensure that the fuel metering valve is operating correctly. i01727368
If the water temperature regulators are malfunctioning, check the water temperature regulators according to Systems Operation/Testing and Adjusting, “Testing the Cooling System”. Replace the water temperature regulators, if necessary. i02088134
Engine Cranks but Will Not Start
Engine Coolant Temperature (Low)
SMCS Code: 1000-035; 1400-035
SMCS Code: 1395-035
• Fuel supply
Probable Causes
• Electrical connectors or power supply
• Faulty jacket water heater
• No signal from the speed/timing sensor
• Faulty coolant temperature sensor and/or circuit
• Ignition system
• Faulty water temperature regulators
• Incorrect base timing
Recommended Repairs
• Excessive load
Check the Jacket Water Heater
Recommended Repairs
Determine if the jacket water heaters are functioning properly.
Fuel Supply
If the jacket water heaters are not functioning properly, determine the cause of the malfunction of the heaters. Make the necessary repairs.
Check the Coolant Temperature Sensor and/or the Circuit Check the reading of the coolant temperature with the Caterpillar Electronic Technician (ET). The temperature should rise steadily as the engine is warmed. Ensure that the temperature is reasonable. If the reading on Cat ET for the coolant temperature is not reasonable, troubleshoot the circuit and the coolant temperature sensor. Refer to Troubleshooting, “Analog Sensor Signal”.
Check the Water Temperature Regulators The water temperature regulators should not begin to open until jacket water reaches opening temperature for the regulators. Allow the engine to cool and then start the engine. Check the hose at the outlet for the jacket water. If the hose is warm and normal operating temperature is not achieved yet, a regulator may be stuck open.
Probable Causes
Make sure that fuel is supplied at a sufficient pressure that is stable. Make sure that the size of the fuel line is sufficient. Inspect the fuel system for leaks. The following conditions can cause the engine to malfunction:
• Low fuel pressure • High fuel pressure • Poor fuel quality Make sure that the fuel pressure is correct. When possible, interview the operator in order to determine if fuel quality is in question. Try to determine if the source of the fuel was changed. Inspect the fuel system components: fuel filter, gas pressure regulator, gas shutoff valve, and fuel metering valve. Verify that the system’s components are operating correctly. Replace the fuel filter, if necessary.
42 Troubleshooting Section
Electrical Connectors or Power Supply
• Electrical connectors or power supply
There may be an intermittent interruption of power. Check the wiring harnesses and the connectors. Inspect the connectors in the terminal box. Inspect the power supply connections and the ground.
• Ignition system
Inspect the wiring from the power supply to the master ECM and to the slave ECM. Check the power and ground connections. Refer to Troubleshooting, “Electrical Power Supply”.
• Fuel supply • Incorrect air/fuel ratio • Incorrect governor adjustment • Compressor bypass valve
No Signal from the Engine Speed/Timing Sensor
• Air inlet restriction
Make sure that the speed/timing sensor is installed correctly. Refer to Troubleshooting, “Engine Speed/Timing Sensor”.
• Binding of the throttle actuator
Make sure that the timing wheel is correctly installed.
• Cylinder head and related components
Ignition System
• Throttle
Inspect the ignition transformers for loose connections, moisture, short circuits, and open circuits. Inspect the primary wiring and the secondary electrical connections.
Recommended Repairs
Make sure that the correct transformers and spark plugs are installed. Inspect the extenders for signs or pin holes and arcing. Maintain the spark plug according to Operation and Maintenance Manual, “Ignition System Spark Plugs - Replace”.
Check the Base Timing Verify that the base timing is correct. Refer to Systems Operation/Testing and Adjusting, “Ignition Timing - Adjust”.
Make sure that the load is not excessive. Reduce the load. If necessary, disengage the driven equipment and test the engine. i02085470
Engine Misfires, Runs Rough or Is Unstable Probable Causes • Cold cylinder
• Incorrect valve lash
Note: If the symptom only occurs under certain operating conditions (high idle, full load, engine operating temperature, etc), test the engine under the conditions. Troubleshooting the symptom under other conditions can give misleading results. The Caterpillar Electronic Technician (ET) and the Integrated Temperature Sensing Module (ITSM) can be used to detect a misfiring cylinder. Use the following procedure: 1. Use the “Data Link/Select ECM” option on the Cat ET to select the ITSM. 2. Select “Diagnostics/Diagnostic Tests”. 3. Select the suspect cylinder and click the “Start” button in the lower left corner of the screen.
Excessive Load
SMCS Code: 1000-035
• Exhaust restriction
Cat ET will display a graph of the cylinder’s exhaust gas temperature. The output voltage of the transformer’s secondary circuit, the engine speed, and the desired engine speed are also displayed.
Cold Cylinder Locate the misfiring cylinder. Check the following components for failure: spark plug, extender, ignition transformer, and primary wiring. Inspect the extender for signs of pin holes and/or arcing. Refer to Troubleshooting, “Ignition Transformers Secondary Circuit and Spark Plugs”.
43 Troubleshooting Section
Electrical Connectors or Power Supply There may be an intermittent interruption of power. Check the wiring harnesses and the connectors. Inspect the connectors in the terminal boxes. Inspect the power supply connections and the ground. Inspect the wiring from the power supply to the control modules. Refer to Troubleshooting, “Electrical Power Supply”.
Ignition System Inspect the ignition transformers for the following items: loose connections, moisture, short circuits, and open circuits. Inspect the primary wiring and the secondary electrical connections. Make sure that the correct transformers and spark plugs are installed. Inspect the extenders for signs of pin holes and of arcing. Maintain the spark plug according to the engine’s Operation and Maintenance Manual. Make sure that the ignition timing is correct.
Fuel Supply Make sure that fuel is supplied at a sufficient pressure that is stable. Make sure that the size of the fuel line is sufficient. Inspect the fuel system for leaks. The following conditions can cause the engine to malfunction:
• Low fuel pressure • High fuel pressure • Poor fuel quality Make sure that the fuel pressure is correct. When possible, interview the operator in order to determine if fuel quality is in question. Try to determine if the source of the fuel was changed. Inspect the fuel system components: fuel filter, gas pressure regulator, gas shutoff valve, and fuel metering valve. Verify that the system’s components are operating correctly. Replace the fuel filter, if necessary.
Air/Fuel Ratio An air/fuel mixture that is too rich or too lean will have an adverse effect on engine operation. Verify that the exhaust emissions are correct. Refer to Systems Operation/Testing and Adjusting, “Air/Fuel Ratio Control - Adjust”.
A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis. The fuel supply pressure must be adequate and stable.
Governor Adjustment The governor’s parameters must be programmed with the values that provide stable operation. Refer to Systems Operation/Testing and Adjusting, “Engine Governing - Adjust”.
Compressor Bypass Valve The actuator for the compressor bypass valve must be installed properly in order to provide stable operation. Refer to Disassembly and Assembly, “Actuator Bypass Valve (Variable) - Install”.
Air Inlet Restriction High inlet air restriction adversely affects engine performance. Refer to the applicable Gas Engine Technical Data Sheet for additional information. The maximum allowable air inlet restriction is 3.75 kPa (15 inches of H2O). If the indication is higher than the maximum permissible restriction, clean the filter element or install a new filter element. Check the restriction again. If the restriction remains too high, inspect the air inlet piping for obstructions. For more information, refer to Systems Operation/Testing and Adjusting, “Restriction of Air Inlet and Exhaust”.
Exhaust Restriction Check for restriction in the exhaust system. Refer to Systems Operation/Testing and Adjusting, “Restriction of Air Inlet and Exhaust”.
Check for Binding of the Throttle Actuator Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Move the throttle plate while you feel the motion. If the motion is sticky and/or rough, investigate the cause of the binding. Make the necessary repairs.
Incorrect Valve Lash Check the valve lash. Refer to Systems Operation, Testing And Adjusting, “Valve Lash and Valve Bridge Adjustment”.
44 Troubleshooting Section
Cylinder Head and Related Components
Check the Oil Filter Bypass Valve
Measure the cylinder compression. Refer to the engine’s Operation and Maintenance Manual, “Cylinder Pressure - Measure/Record”.
An oil filter bypass valve that is stuck in the closed position can cause a high reading for differential pressure when the oil is cold. An oil filter bypass valve that is stuck in the open position can cause a low reading for differential pressure when the oil is hot. Check the operation of the oil filter bypass valve. For more information, see Systems Operation/Testing and Adjusting, “Measuring Engine Oil Pressure”.
Inspect the components of the valve train for good condition. Check for signs of damage and/or wear to the valves, cylinder head gasket, etc. Inspect the condition of the camshafts. If a camshaft is replaced, new valve lifters must be installed.
Throttle Make sure that the throttle actuator is operating properly. If the motion of the actuator is sticky and/or rough, service the actuator. i01727473
Engine Oil Filter Differential Pressure SMCS Code: 1308-035
If the oil filter bypass valve is faulty, repair the valve, when possible. Replace the valve, if necessary. i01727510
Engine Oil Pressure (Low) SMCS Code: 1348-035-PX
Probable Causes • Low engine oil level • Incorrect viscosity
Probable Causes
• Contaminated engine oil
• Plugged oil filter or faulty oil filter
• Faulty oil pressure sensors
• Faulty oil pressure sensor and/or circuit
• Improper circulation of the engine oil
• Malfunctioning of the oil filter bypass valve
• Worn components
Recommended Repairs
Recommended Repairs
Check the Oil Filters
Low Engine Oil Level
Check the oil filter differential pressure. Do not allow the differential pressure to exceed 103 kPa (15 psi). If the oil filter differential pressure is too high, change the oil filter elements.
Check the oil level. Add oil, as needed.
Inspect the oil filters for good condition. Replace any suspect oil filter.
Check the Oil Pressure Sensors and/or Circuits Use the Caterpillar Electronic Technician (ET) to compare the readings for the filtered oil pressure and the unfiltered oil pressure while the engine is OFF. Make sure that the sensors are correctly wired. If the readings are not approximately zero for both of the sensors, the sensors are wired improperly. Troubleshoot the sensor circuit(s). Refer to Troubleshooting, “Analog Sensor Signal”.
Contaminated Engine Oil Engine oil that is contaminated with another liquid will cause low engine oil pressure. High engine oil level can be an indication of contamination. Obtain an analysis of the engine oil. Determine the reason for contamination of the engine oil and make the necessary repairs. Change the engine oil and the engine oil filter. For the correct engine oil to use, refer to Operation and Maintenance Manual, “Engine Oil”.
Incorrect Viscosity Make sure that the engine is supplied with the correct engine oil. For the correct engine oil to use, refer to Operation and Maintenance Manual, “Engine Oil”.
45 Troubleshooting Section
Faulty Engine Oil Pressure Sensors Use the Caterpiller Electronic Technician (ET) to compare the readings of the filtered engine oil pressure and the unfiltered engine oil pressure while the engine is OFF. Both readings should be close to zero pressure. If a reading is significantly different from zero, replace the suspect engine oil pressure sensor.
Improper Circulation of the Engine Oil Several factors could cause improper circulation of the engine oil:
• The engine oil filter is clogged. Replace the engine oil filter.
• An engine oil line or a passage for engine oil is disconnected or broken.
• The engine oil cooler is clogged. Thoroughly clean the engine oil cooler.
• There is a problem with a piston cooling jet.
Breakage, a restriction, or incorrect installation of a piston cooling jet will cause seizure of the piston.
• The inlet screen of the suction tube for the engine
oil pump can have a restriction. This restriction will cause cavitation and a loss of engine oil pressure. Check the inlet screen on the suction tube and remove any material that may be restricting engine oil flow.
• The suction tube is drawing in air. Check the joints of the tube for cracks or a damaged O-ring seal.
• There is a problem with the engine oil pump. Check the gears of the engine oil pump for excessive wear. Engine oil pressure is reduced by gears that have too much wear.
i01727521
Engine Oil Temperature (High) SMCS Code: 1348-035
Probable Causes • Faulty oil temperature sensor and/or circuit • Insufficient flow of coolant through the oil cooler • Insufficient flow of oil through the oil cooler
Recommended Repairs Check the Oil Temperature Sensor and/or the Circuit Check the reading of the oil temperature on the Caterpillar Electronic Technician (ET). The temperature should rise steadily as the engine is warmed. Ensure that the temperature is reasonable. If the reading on Cat ET for the oil temperature is not reasonable, troubleshoot the circuit for the oil temperature sensor. Refer to Troubleshooting, “Analog Sensor Signal”.
Check the Flow of Coolant Through the Oil Cooler Oil Coolers that are Cooled with Jacket Water Check for “High Engine Coolant Temperature” events. Refer to Troubleshooting, “Engine coolant Temperature (High)”. Oil Coolers that are Cooled by the Separate Circuit
• The engine oil pump’s pressure regulating valve or
Compare the temperature of the coolant at the inlet of the oil cooler to the regulated temperature. If the inlet temperature is OK, check the temperature of the coolant at the outlet of the oil cooler.
Worn Components
A high temperature difference indicates an insufficient flow rate. Investigate the cause of the obstruction. Make the necessary repairs.
a bypass valve is stuck in the open position. Clean the valve. Replace parts, if necessary.
Excessive clearance at the crankshaft or camshaft bearings will cause low engine oil pressure. Also, inspect the clearance between the rocker arm shafts and the rocker arms. Check the engine components for excessive clearance. Obtain an analysis of the engine oil. Check the analysis for the level of wear metals in the engine oil.
Check the Flow of Oil Through the Oil Cooler Run the engine at normal operating temperature. Determine the pressure differential between the inlet and the outlet of the oil cooler. For comparative data, refer to the Technical Marketing Information for the engine.
46 Troubleshooting Section
If the pressure differential between the inlet and the outlet of the oil cooler exceeds the data that is published for the engine, there is an insufficient flow of oil through the oil cooler. Determine the cause of the obstruction. Make the necessary repairs.
Check the Status of the Relay for the Starting Motor Attempt to start the engine while you observe the status of the relay for the starting motor on Cat ET.
SMCS Code: 1400-035
If the status of the relay for the starting motor indicates that the engine should crank but no cranking occurs, troubleshoot the starting circuit. Refer to Systems Operation/Testing and Adjusting, “Air/Electric Starting System”.
Probable Causes
If the engine should crank and cranking occurs, check the engine rpm.
i01974116
Engine Overcrank
• The gas supply to the engine is insufficient. • A feature for engine protection prevents the engine from starting. • The starting motor circuit is faulty. • There is no engine speed signal to the master Electronic Control Module (ECM).
• The ignition system is not functioning. • The base timing is incorrect. • The quality of the gas does not match the parameter for “Fuel Quality”.
Recommended Repairs Check the Gas Supply to the Engine Check for low gas pressure. If the gas pressure is low, refer to Troubleshooting, “Fuel Pressure”. If the throttle does not open, check for binding of the throttle actuator. Move the throttle plate while you feel the motion. If the motion is sticky and/or rough, investigate the cause of the binding. Make the necessary repairs.
Check for Active Shutdowns Use the Caterpillar Electronic Technician (ET) to check for active diagnostic codes or event codes which may prevent the engine from starting. Correct the cause of the active code. Before the engine can be started, you must recycle the power to the engine. Set the engine control to the OFF/RESET mode. Then set the control to the STOP mode.
Check the Engine Speed The master ECM must detect a minimum of 50 rpm before the gas and the ignition are supplied to the engine. Use Cat ET to monitor the engine speed while you crank the engine. If no engine speed is displayed on Cat ET or if the engine speed is not stable, troubleshoot the speed/timing sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor”.
Check for Diagnostic Codes Check for active diagnostic codes that relate to the ignition system. If there is at least one active diagnostic code that relates to the ignition system, troubleshoot the diagnostic code.
Check the Base Timing Verify that the base timing is correct. Refer to Systems Operation/Testing and Adjusting, “Ignition Timing - Adjust”.
Check the Fuel Quality Compare the Low Heat Value (LHV) of the gas supply to the “Fuel Quality” parameter that is programmed by the customer into the master ECM. The master ECM uses the setting for start-up and for air/fuel ratio control at low loads. If the LHV of the fuel does not match the “Fuel Quality” parameter that is programmed into the master ECM, program the master ECM with the correct setting for the “Fuel Quality” parameter.
47 Troubleshooting Section
i01804844
Engine Overload
• Binding of the throttle actuator
Recommended Repairs
SMCS Code: 1000-035
Check the Trip Point
Probable Causes
Note: Do not program the trip point for engine overspeed higher than the maximum ratings of the driven equipment.
• Excessive inlet manifold air pressure • The Low Heat Value (LHV) of the gas or the
specific gravity of the gas is significantly different from the value that is programmed.
Recommended Repairs
The trip point or engine overspeed may be too low. Verify that the trip point for the engine overspeed is properly programmed. Typically, this parameter is set at 118 percent of rated speed.
Check the Inlet Manifold Air Pressure
This parameter requires a factory password in order to change the trip point. Change the trip point to an acceptable speed.
The calculated engine load increases when the inlet manifold air pressure increases. Measure the inlet manifold air pressure during engine operation with a load. For specific data on the engine, refer to the engine Technical Marketing Information.
Check for Diagnostic Codes that Relate to the Signal from the Signal Driver in the Master ECM
Obtain a Fuel Analysis and Program the Fuel Energy Content Obtain an analysis of the gas in order to determine the LHV. Program the correct LHV for the “Fuel Quality” configuration parameter. If the LHV of the gas does not match the “Fuel Quality” parameter value that is programmed into the ECM, program the master ECM with the correct value for the “Fuel Quality” parameter by selecting the “Change” button in the lower left corner of the screen. Type the correct value and then select “OK”. If the quality of the gas is not consistent, obtain several analyses over a period of time. Program the “Fuel Quality” configuration parameter to the average value of the LHV. i01804850
Engine Overspeed SMCS Code: 1000-035
Probable Causes • Low trip point for engine overspeed • Signal from the signal driver in the master
Electronic Control Module (ECM) for the actuator of the throttle
• Energy of the driven equipment • Slow governor response
Check for diagnostic codes that relate to the actuator of the throttle. Investigate the diagnostic code(s). Make the necessary repairs.
Check the Driven Equipment Determine if the driven equipment has additional inputs of energy that could drive the engine beyond the rated rpm. Make corrections to the installation in order to prevent the overspeed from recurring.
Check for Slow Governor Response Observe the “Speed Governor Adjustment” screen on the Caterpillar Electronic Technician (ET). Look for the engine response to the worst cases for step-loading and unloading.
Check for Binding of the Throttle Actuator Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Move the throttle plate while you feel the motion. If the motion is sticky and/or rough, investigate the cause of the binding. Make the necessary repairs.
48 Troubleshooting Section
i02052150
Engine Shutdown SMCS Code: 1400-035
Probable Causes • The “Emergency Stop” button is pressed.
Inspect the Stop Switches Inspect the stop switches for evidence of damage that has been caused by vibration. Disassemble the switches. Inspect the components for looseness, cracks, and abrasion. Use an ohmmeter and toggle the switches in order to check for proper electrical operation. Replace any faulty components.
• The circuit for the emergency stop is faulty. • The normal stop switch that is installed by the
i01804861
• The circuit for the normal stop switch is faulty.
Engine Shutdown (Unexpected)
• Either switch is activated by excessive vibration.
SMCS Code: 1400-035
Recommended Repairs
Probable Causes
Talk to the operator
• There is a problem with the Gas Shutoff Valve
Ask the operator if the stop was intentional. Make sure that the reason for the stop has been corrected. Reset the control system. Resume normal operation.
• Incorrect input(s) for the mode of operation to the
customer is activated.
If the stop was accidental, reset the control system. Resume normal operation.
Check the Circuit for the Stop Switches Note: The circuit for the normal stop switch and the circuit for the emergency stop switch must remain closed in order for the engine to run. Inspect the wiring between the switches and the connector of the electronic control module. Look for damage and/or corrosion. Refer to Troubleshooting, “Inspecting Electrical Connectors”. For the emergency stop switch, close the switch and check the resistance between terminals 22 and 31 of the P1 connector. For the normal stop switch, close the switch and check the resistance between terminals 23 and 31 of the P1 connector. The correct resistance between the terminals is less than 5 Ohms. If the resistance is greater than 5 Ohms, locate the source of the excessive resistance. Make repairs, as needed.
(GSOV).
master Electronic Control Module (ECM)
• There is a problem with the “Crank Terminate” relay.
• There is a problem with the relay for the starting motor.
• A shutdown has been requested by the driven equipment.
• There is a problem with the “Run” relay. • The “Crank Terminate Speed” is incorrectly programmed.
• The “Cycle Crank Time” is incorrectly programmed. • The “Engine Overcrank Time” is incorrectly programmed.
• The delay time for the driven equipment is excessive.
• There is a problem with the harness code for the slave ECM.
Recommended Repair Check the Circuit for the GSOV Troubleshoot for the following diagnostic codes:
• 17-05 Fuel Shutoff Valve open circuit
49 Troubleshooting Section
• 17-06 Fuel Shutoff Valve short to ground • 17-12 Fuel Shutoff Valve malfunction Refer to Troubleshooting, “ECM Output Circuit (Fuel Control)”. Make repairs, as needed.
Check the Inputs for the Mode of Operation to the Master ECM Troubleshoot for the “336-02 Incorrect ECS Switch inputs” diagnostic code. Refer to Troubleshooting, “Electrical Power Supply”. Make repairs, as needed.
Check the “Crank Terminate” Relay Troubleshoot for the “443-03 Crank Terminate Relay short to +batt” diagnostic code. Refer to Troubleshooting, “ECM Status Indicator Output”. Make repairs, as needed.
Check the “Start” Relay Troubleshoot for the following diagnostic codes:
• 444-05 Start Relay open circuit • 444-06 Start Relay short to ground Refer to Troubleshooting, “ECM Output Circuit (Starting Motor)”. Make repairs, as needed.
Check for a Request for a Shutdown by the Driven Equipment Determine whether a shutdown for the driven equipment has been requested. Refer to Troubleshooting, “Driven Equipment”. Make corrections, as needed.
Check the “Run” Relay Troubleshoot for the “445-03 Run Relay short to +batt” diagnostic code. Refer to Troubleshooting, “ECM Status Indicator Output”. Make repairs, as needed.
Check the “Crank Terminate Speed” The “Crank Terminate Speed” is a parameter that can be configured. The master Electronic Control Module (ECM) disengages the starting motor when the engine exceeds the programmed “Crank Terminate Speed”. The default value of 250 rpm should be sufficient for all applications.
If the “Crank Terminate Speed” is too slow, the engine will shut down. Use the Caterpillar Electronic Technician (ET) to check the programmed “Crank Terminate” speed. Use Cat ET to adjust the “Crank Terminate Speed”, if necessary.
Check the “Cycle Crank Time” The “Cycle Crank Time” is a parameter that can be configured. This parameter determines the time for engagement of the starting motor and the gas shutoff valve during the crank cycle. If the engine does not start within the programmed “Cycle Crank Time”, the attempt to start is suspended for an equal “Rest” cycle. If the “Cycle Crank Time” is insufficient, the “Engine Overcrank Time” can elapse before the engine is able to start. Use Cat ET to check the “Cycle Crank Time”. Use Cat ET to increase the time, if necessary.
Check the “Engine Overcrank Time” The “Engine Overcrank Time” is a parameter that can be configured. This parameter determines the length of time for the crank cycle. If the engine does not start within the programmed “Engine Overcrank time”, the attempt to start is terminated. An “E225 (3) Engine Overcrank” event is generated. If the “Cycle Crank Time” is insufficient, the “Engine Overcrank Time” can elapse before the engine is able to start. Use Cat ET to check the “Engine Overcrank Time”. Use Cat ET to increase the “Engine Overcrank Time”, if necessary.
Check the “Driven Equipment Delay Time” The “Driven Equipment Delay Time” is a parameter that can be configured. The master ECM provides a switch input for the driven equipment in order to delay engine start-up until the driven equipment is ready. The master ECM will not attempt to start the engine until the switch input for the driven equipment closes to ground and the prelubrication (if equipped) is complete. An event code is generated if the “Driven Equipment Delay Time” elapses without closure of the switch input. To disable this feature, program the delay time to zero. If the programmed delay time is too long, the engine may not start. Use Cat ET to check the “Driven Equipment Delay Time”. Use Cat ET to program the delay time to a reasonable amount of time.
50 Troubleshooting Section
Check the Harness Code for the Slave ECM The harness inside the terminal box has a jumper wire (harness code) that connects terminals J3-29 and J3-60. The ECM that is connected to the harness reads the harness code. This allows the ECM to operate as the slave ECM. The jumper wire must remain connected in order for the engine to run. The engine will shut down if the jumper wire becomes disconnected during engine operation. Check the continuity between terminals J3-29 and J3-60. Verify that the jumper wire is in good condition. Make repairs, as needed.
3. Inspect the electronic control modules and the terminal box for proper installation of the connectors. 4. Check the 35 amp circuit breaker on the power distribution box. Check the wiring connections to the 35 amp circuit breaker for proper installation.
Speed/Timing Sensor A loss of supply voltage to the speed/timing sensor will cause a shutdown. Refer to Troubleshooting, “Engine Speed/Timing Sensor”.
Fuel Supply • Check the fuel supply pressure.
i01804877
Engine Shutdown without a Diagnostic Code SMCS Code: 1400-035
Probable Causes • An external shutdown or a customer shutdown was requested.
• The power supply becomes disconnected from the engine control system.
• The master Electronic Control Module (ECM) has
lost the supply voltage for the speed/timing sensor.
• There is a problem with the fuel supply. • A cylinder or cylinders are misfiring.
Recommended Repairs External Shutdown or Customer Shutdown Check the master ECM and the Integrated Temperature Sensing Module (ITSM) for logged codes of events that are shutdowns.
Power Supply to the Engine Control System 1. Refer to Troubleshooting, “Electrical Power Supply”. 2. Inspect the ground strap and the power supply for connections that are loose and/or corroded.
• Inspect the fuel lines for foreign objects and for obstructions that can block the fuel supply.
Misfiring Cylinders For a shutdown that is due to misfiring cylinders, the shutdown is likely to occur only when the engine is operating under a load. The Caterpillar Electronic Technician (ET) and the ITSM can be used to detect a misfiring cylinder. Use the following procedure: 1. Use the “Data Link/Select ECM” screen on Cat ET to select the ITSM. 2. Select “Diagnostics/Diagnostic Tests”. 3. Select the suspect cylinder and click the “Start” button in the lower left corner of the screen. Cat ET will display a graph of the cylinder’s exhaust gas temperature. The transformer’s secondary circuit, the engine speed, and the desired engine speed are also displayed. Locate the misfiring cylinder. Check the following components for failure: spark plug, extender, ignition transformer, and primary wiring. Inspect the extender for signs of pin holes and/or arcing. Refer to Troubleshooting, “Ignition Transformers Secondary Circuit and Spark Plugs”.
51 Troubleshooting Section
i01804883
Engine Starts but Stalls Immediately SMCS Code: 1250-035; 1400-035
Probable Causes
2. Use the Caterpillar Electronic Technician (ET) to check for the 168-02 diagnostic code for “System Voltage intermittent/erratic”. If this diagnostic code is logged, proceed to Troubleshooting, “Electrical Power Supply”.
Engine Speed/Timing Sensor
• Fuel supply
Make sure that the speed/timing sensor is installed correctly. See Troubleshooting, “Engine Speed/Timing Sensor”.
• Electrical connectors or power supply
Make sure that the timing wheel is correctly installed.
• Engine speed/timing sensor • Ignition system • Excessive load
Recommended Repairs Fuel Supply Make sure that fuel is supplied at a sufficient pressure that is stable. Make sure that the size of the fuel line is sufficient. Inspect the fuel system for leaks.
Ignition System Inspect the ignition transformers for the following items: loose connections, moisture, short circuits, and open circuits. Inspect the primary wiring and the secondary electrical connections. Make sure that the correct transformers and spark plugs are installed. Inspect the extenders for signs of pin holes and of arcing. Maintain the spark plug according to the engine’s Operation and Maintenance Manual.
The following conditions can cause the engine to malfunction:
Excessive Load
• Low fuel pressure
Make sure that the load is not excessive. Reduce the load. If necessary, disengage the driven equipment and test the engine.
• High fuel pressure • Poor fuel quality Make sure that the fuel pressure is correct. When possible, interview the operator in order to determine if fuel quality is in question. Try to determine if the source of the fuel was changed.
i01804902
Engine Timing Does Not Match Programmed Timing SMCS Code: 1000-035; 1400-035
Inspect the fuel system components: fuel filter, gas pressure regulator, gas shutoff valve, fuel metering valve, and actuator for the throttle. Verify that the system’s components are operating correctly.
Probable Causes
Replace the fuel filter, if necessary.
• The timing may be retarded due to the selection of
Electrical Connectors or Power Supply 1. Inspect the power supply connections and the ground. Check the wiring harnesses and the connectors from the power supply to the power distribution box. Check the wiring harnesses and the connectors from the power distribution box to the terminal box. Inspect the connectors in the terminal box. Refer to Troubleshooting, “Inspecting Electrical Connectors”.
• The timing may be retarded due to detonation. the map for speed or the map for load.
• The input for the selection of the base timing may be incorrect.
Recommended Repairs Note: If the symptom only occurs under certain operating conditions (high idle, full load, engine operating temperature, etc), test the engine under the conditions. Troubleshooting the symptom under other conditions can give misleading results.
52 Troubleshooting Section
Detonation Use the Caterpillar Electronic Technician (ET) to review the logged codes. Look for codes “E401-1” through “E416-1”. Refer to the topic in Troubleshooting for the particular event code.
Map Use the “Service/Configuration” screen of Cat ET in order to verify the value that is programmed for the timing. Check the “First Desired Timing”, the “Second Desired Timing”, and the “Desired Timing” parameters. Refer to Troubleshooting, “Programming Parameters”.
b. Load test the batteries. Refer to Special Instruction, SEHS9249, “Use of 4C-4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batteries”.
Starting Circuit Check the starting circuit. Refer to the schematic diagram in Troubleshooting, “ECM Output Circuit (Starting Motor)”.
Starting Motor or Flywheel Ring Gear
Timing Selection Verify that the input for the selection of the base timing is correct. An open circuit between terminals J1-20 and J1-31 selects the “First Desired Timing”. A short circuit between terminals J1-20 and J1-31 selects the “Second Desired Timing”. i01822829
Engine Will Not Crank SMCS Code: 1000-035; 1400-035
Probable Causes • Batteries and/or battery cables • Starting circuit • Starter motor pinion or flywheel ring gear • Low air pressure • Static load • Internal mechanical problem • There is a problem with the harness code for the slave Electronic Control Module (ECM).
Recommended Repairs Batteries and/or Battery Cables 1. Inspect the main power switch, battery posts, and battery cables for loose connections and corrosion. If the battery cables are corroded, remove the battery cables and clean the battery cables. Tighten any loose connections. 2. Inspect the batteries.
a. Charge the batteries. Refer to Special Instruction, SEHS7633, “Battery Test Procedure”.
If the pinion engages the flywheel but the flywheel does not turn, there may be a problem with the starting motor. If the starting motor turns but the flywheel does not turn, inspect the gear teeth, the clutch jaws, or other parts. Inspect the pinion and the flywheel ring gear for damage. If the teeth of the pinion and/or of the flywheel ring gear are worn or broken, replace the parts. If the pinion does not engage correctly with the flywheel, the pinion shaft may be stuck. Remove the pinion. Grease the splines of the drive shaft and the pinion. If the pinion does not engage the flywheel, the clutch jaws may be broken. Before you remove the starting motor, turn the crankshaft by hand. Ensure that a mechanical failure inside the engine is not preventing the crankshaft from turning. If the crankshaft will turn by hand, try the starting motor again. If the starting motor does not turn the crankshaft, remove the starting motor. Repair the starting motor or replace the starting motor.
Low Air Pressure Determine the cause of the low air pressure. Inspect the air lines for leaks. Repair any leaks in the air lines.
Static Load Make sure that the driven equipment is not preventing the crankshaft from turning. Try to turn the crankshaft by hand. If necessary, disengage the driven equipment and test the engine.
53 Troubleshooting Section
Internal Mechanical Problem
Recommended Repairs
If the crankshaft will not turn and the driven equipment is disengaged, remove the spark plugs. Check for fluid in the cylinders. If this is not the problem, the engine must be disassembled in order to investigate internal mechanical problems. Possible internal problems include the following conditions:
Check the Inlet Air Temperature
• Bearing seizure
High inlet air temperature can cause detonation. Check the inlet air temperature. Refer to Troubleshooting, “Inlet Air Temperature (High)”.
Inlet Air Restriction
• Piston seizure • Valve and piston contact Check the Harness Code for the Slave ECM The harness inside the terminal box for the slave ECM has a jumper wire (harness code) that connects terminals J3-29 and J3-60. The ECM that is connected to the harness reads the harness code. This allows the ECM to operate as the slave ECM. The jumper wire must be connected in order for the engine to crank. The jumper wire must remain connected in order for the engine to run. Check the continuity between terminals J3-29 and J3-60. Verify that the jumper wire is in good condition. Make repairs, as needed. i02085826
Exhaust Port Temperature (High) SMCS Code: 1059-035
Probable Causes • High inlet air temperature • Inlet air restriction • Air/fuel ratio • Excessive load • Incorrect base timing
High inlet air restriction adversely affects engine performance. Refer to the applicable Gas Engine Technical Data Sheet for additional information. The maximum allowable inlet air restriction is 3.75 kPa (15 inches of H2O). If the indication is higher than the maximum permissible restriction, clean the filter element or install a new filter element. Check the restriction again. If the restriction remains too high, inspect the air inlet piping before the air cleaner for obstructions.
Air/Fuel Ratio An air/fuel mixture that is too rich will increase the exhaust temperature. Verify that the exhaust emissions are correct. Refer to Systems Operation/Testing and Adjusting, “Air/Fuel Ratio Control - Adjust”. A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis. The fuel supply pressure must be adequate and stable.
Excessive Load Make sure that the load is not excessive. Reduce the load. If necessary, disengage the driven equipment and test the engine.
Check the Base Timing Verify that the base timing is correct. Refer to Systems Operation/Testing and Adjusting, “Ignition Timing - Adjust”.
• Exhaust restriction
Measure the Exhaust Restriction
• A buildup of deposits in the cylinder or internal oil
Measure the exhaust restriction during engine operation with a load. For data that is specific to the engine, refer to the Technical Marketing Information.
leaks
Investigate the cause of the exhaust restriction. Perform adjustments and/or make repairs, as needed.
54 Troubleshooting Section
Check for Deposits in the Cylinder and Check for Internal Oil Leaks Use a borescope to inspect the cylinders. Look for the following conditions:
• Deposits on the valve seats • Deposits on the valve faces • Deposits on the cylinder walls that are above the upper limit of the piston stroke
Check for Diagnostic Codes from the Integrated Temperature Sensing Module (ITSM) Use the Caterpillar Electronic Technician (ET) to check for diagnostic codes that relate to the thermocouples for exhaust temperatures. Troubleshoot the code.
Check for Suspect Thermocouples Observe the temperatures from the thermocouples after the engine is shut off.
• Signs of internal oil leaks Other signs of internal oil leaks include high oil consumption and blue smoke. Note: Excessive deposits contribute to guttering of the valves. If excessive deposits and/or signs of internal oil leaks are found, investigate the cause of the condition. Make repairs, as needed. i01727687
Exhaust Port Temperature (Low) SMCS Code: 1059-035
Probable Causes • Operation with a light load • Active diagnostic code from the Integrated Temperature Sensing Module (ITSM)
• A faulty thermocouple
When the engine is operating properly, the temperatures from similar locations are reduced at a similar rate. Also, the temperatures from similar locations are comparable. If any discrepancies are found, switch the suspect thermocouple for another thermocouple. If the temperature problem follows the thermocouple, replace the thermocouple. If the temperature problem stays at the original location of the suspect thermocouple, investigate the cause for the low temperature.
Check for Insufficient Ignition Use Cat ET to check for logged diagnostic codes that relate to the ignition system. Troubleshoot the code. Refer to Troubleshooting, “Ignition Transformers Primary Circuit”. If no logged diagnostic codes are present for the suspect cylinder, inspect the components of the ignition system for the cylinder. Refer to Troubleshooting, “Ignition Transformers Secondary Circuit and Spark Plugs”.
• Insufficient ignition
Check the Cylinder Compression
• Low cylinder compression
Measure the cylinder pressures of the suspect bank in order to check for problems that are related to compression.
Recommended Repairs Check for Misfire Operation with a low load can result in low exhaust temperatures. Operate the engine at low idle or near low idle in order to identify a misfire problem. Troubleshoot the cause of the misfire. Refer to Troubleshooting, “Engine Misfires,Runs Rough or Is Unstable”.
If low compression is found, investigate the cause of the low compression. Make repairs, as needed.
55 Troubleshooting Section
i01804917
Fuel Energy Content
Check the Fuel Metering Valve Shut OFF the fuel supply. Disconnect the fuel lines from the fuel metering valve. Visually inspect the internal mechanism of the valve. Check for binding due to dirt and/or contamination. Check for binding due to wear of internal components.
SMCS Code: 1250-035
Probable Causes • The Low Heat Value (LHV) of the gas or the specific gravity of the gas is significantly different from the value that is programmed into the electronic control module.
Clean the valve, if necessary. If the valve is binding due to wear of internal components, refer to the literature that is provided by the OEM of the valve. i01727704
• Condensation is forming in the gas.
Fuel Pressure
Recommended Repairs
SMCS Code: 1250-035
Obtain a Fuel Analysis and Program the “Fuel Quality” Parameter
Probable Causes
Obtain an analysis of the gas in order to determine the LHV. Program the “Fuel Quality” parameter to the actual value of the LHV.
• Incorrect setting of the gas pressure regulator
If the quality of the gas is not consistent, obtain several analyses over a period of time. Program the “Fuel Quality” parameter to the average value of the LHV.
Recommended Repairs
Check the Dryer for the Gas Check the dryer for the gas for proper operation. Repair the dryer, if necessary. i01804920
Fuel Metering Valve SMCS Code: 1274-035
Probable Causes
• Faulty gas pressure regulator
Check the Gas Pressure Regulator Use the Caterpillar Electronic Technician (ET) to observe the absolute fuel pressure and the fuel differential pressure. The fuel metering valve requires a gas supply that is regulated to a pressure between 10 to 35 kPa (1.5 to 5 psi). If the fuel pressure is not within the acceptable range, adjust the gas pressure regulator in order to achieve the correct pressure. Verify that the emissions are within specifications. If the gas pressure regulator cannot be adjusted to the correct setting, repair the regulator or replace the regulator.
• Low operating voltage for the fuel metering valve i01369481
• Internal binding of the fuel metering valve
Recommended Repairs Check the Operating Voltage for the Fuel Metering Valve Check the operating voltage for the fuel metering valve. Refer to Troubleshooting, “Electrical Power Supply”. Make repairs, as needed.
Gas Fuel Differential Pressure (High) SMCS Code: 1250-035
Probable Causes • Excessive fuel supply pressure • Leaks in the piping after the fuel metering valve
56 Troubleshooting Section
Recommended Repairs
Adjust the gas pressure regulator in order to achieve the correct pressure.
Check the Fuel Supply Pressure
If the gas pressure regulator cannot be adjusted to the correct setting, repair the regulator or replace the regulator.
Check the pressure of the fuel supply to the fuel metering valve for high pressure. The maximum allowable pressure to the fuel metering valve is 35 kPa (5 psi).
Check the Fuel Supply for Obstructions
Adjust the gas pressure regulator in order to achieve the correct pressure.
Check the fuel filter for restriction. Replace the fuel filter, if necessary.
If the gas pressure regulator cannot be adjusted to the correct setting, repair the regulator or replace the regulator.
Inspect the screen inside the inlet of the fuel metering valve for cleanliness. Clean the screen, if necessary.
Check for Leaks Use a gas detector to check for leaks in the piping between the outlet of the fuel metering valve and the turbocharger compressor. Repair the piping, if necessary. i01804929
Gas Fuel Differential Pressure (Low) SMCS Code: 1250-035
Inspect the fuel supply lines to the fuel metering valve for obstructions. Clean the lines and make repairs, as needed. Check the Gas Shutoff Valve (GSOV) for proper operation. Verify that the valve is fully open when the valve is energized. Verify that the GSOV does not stick in a partially open position. Repair the GSOV. Replace the GSOV, if necessary.
Check the Fuel Outlet for Obstructions Inspect the piping for obstructions between the fuel metering valve and the inlet to the turbocharger compressor. Clean the piping and make repairs, as needed.
Probable Causes • Improper installation of the fuel metering valve • Low fuel supply pressure • Obstructed fuel supply • Obstructed fuel outlet
Recommended repairs Check the Installation of the Fuel Metering Valve An “E864 Low Gas Fuel Differential Pressure” event will be generated if the fuel metering valve is installed backward. Ensure that the fuel metering valve is installed properly.
Check the Gas Pressure Regulator The fuel metering valve requires a minimum pressure of 10 kPa (1.5 psi) for the gas supply. Check the outlet pressure from the gas pressure regulator.
i01727721
Gas Fuel Flow Rate (Low) SMCS Code: 1250-035
Probable Causes • High fuel temperature • Faulty gas pressure regulator or low fuel supply pressure
• Obstructions in the fuel supply • Inadequate fuel energy content or moisture in the gas
57 Troubleshooting Section
Recommended Repairs Check the Fuel Temperature Measure the temperature of the gas that is entering the fuel metering valve. Compare the measurement to the reading for the fuel temperature on the Caterpillar Electronic Technician (ET). Check Cat ET for a “E223 High Gas Temperature” event code. If the temperature on Cat ET is different, determine the reason for the faulty signal from the fuel metering valve.
Check Cat ET for a “E230 (1) Fuel Energy Content Setting High” event code. If the code is present, refer to Troubleshooting, “Fuel Energy Content”. Obtain an analysis of the gas in order to determine the LHV. Program the Fuel Energy Content to the actual value of the LHV. If the quality of the gas is not consistent, obtain several analyses over a period of time. Program the Fuel Energy Content to the average value of the LHV.
Check the Dryer for the Gas
If the fuel temperature is high, determine the cause of the high fuel temperature. Check for proper operation of the equipment that treats the gas prior to the engine.
Check the dryer for the gas for proper operation. Repair the dryer, if necessary.
If there is an active “E223 High Gas Temperature” event code, refer to Troubleshooting, “Gas Temperature (High)”.
Gas Temperature (High)
Make repairs, as needed.
Check the Gas Pressure Regulator Check the outlet pressure from the gas pressure regulator. The fuel metering valve requires a minimum pressure of 10 kPa (1.5 psi) for the gas supply. If the pressure of the gas supply is too low, adjust the gas pressure regulator in order to achieve the correct pressure. If the gas pressure regulator cannot be adjusted to the correct setting, repair the regulator or replace the regulator.
Check the Fuel Supply for Obstructions Check the fuel filter for restriction. Replace the fuel filter, if necessary.
i01758553
SMCS Code: 1250-035
Probable Causes • The temperature of the gas is too high. • The fuel metering valve has sent faulty data to the master Electronic Control Module.
Recommended Repairs Investigate the Cause of the High Temperature Check for proper operation of the equipment that treats the gas prior to the engine. If a problem is found for the equipment that treats the gas prior to the engine, repair the equipment, as needed.
Inspect the screen inside the inlet of the fuel metering valve for cleanliness. Clean the screen, if necessary.
Check the Data from the Fuel Metering Valve
Inspect the fuel supply lines to the fuel metering valve for obstructions. Clean the lines and make repairs, as needed.
Measure the temperature of the gas that is entering the fuel metering valve. Compare the measurement to the reading for the temperature on the Caterpillar Electronic Technician (ET).
Check the Gas Shutoff Valve (GSOV) for proper operation. Verify that the valve is fully open when the valve is energized. Verify that the GSOV does not stick in a partially open position. Repair the GSOV. Replace the GSOV, if necessary.
If the measurement for the temperature is significantly different from the reading on Cat ET, determine the reason for the faulty data from the fuel metering valve. Make repairs, as needed.
Obtain a Fuel Analysis If the fuel energy content is too low, the fuel metering valve could demand an excessive supply of fuel.
58 Troubleshooting Section
i02089727
Generator Output Power Readings Do Not Match SMCS Code: 5574-035-PWR The master Electronic Control Module (ECM) monitors the generator’s output power in order to accurately control the air/fuel ratio. The master ECM uses an output from one of the following sources in order to monitor the generator’s output power:
• Electronic Modular Control Panel II+ (EMCP II+) • Programmable Logic Controller (PLC) • Wattmeter The PLC and the wattmeter are also called power sensors.
Probable Causes The following probable causes apply if the generator is equipped with the EMCP II+:
• There is an incorrect calibration value for the AC Transformer Box + (ATB+).
• A potential transformer in the ATB+ is faulty. • A current transformer in the ATB+ is faulty. • The ATB+ is faulty.
• The offset voltage at the input to the master ECM from the power sensor is too high.
• There is an incorrect value for one or more of the “Power Monitoring” parameters.
Read the rest of this procedure before you adjust the “Power Monitoring” parameters.
Recommended Repairs Generators that are Equipped with EMCP II+ Verify that the transformers and the ATB+ are operating correctly. Refer to the appropriate service literature for the EMCP II+. Verify that the values for the “Air/Fuel Ratio Control” configuration parameters are correct. Refer to Troubleshooting, “Electronic Control System Parameters”. Verify that the values for the “Power Monitoring” configuration parameters are correct. Refer to Troubleshooting, “Electronic Control System Parameters”.
Generators that are Equipped with a Power Sensor Verify that the transformers for the power sensor are operating correctly. Refer to the service literature for the power sensor.
• There is an incorrect value for one or more of the
Verify that the power sensor is operating correctly. Refer to the service literature for the power sensor.
• There is an incorrect value for one or more of the
Verify that the values for the “Air/Fuel Ratio Control” configuration parameters are correct. Refer to Troubleshooting, “Electronic Control System Parameters”.
parameters for the fuel.
“Power Monitoring” parameters.
The following probable causes apply if the generator is equipped with a power sensor:
• There is a faulty potential transformer for the power sensor.
• There is a faulty current transformer for the power sensor.
• The power sensor is faulty. • There is a problem with the wiring between the power sensor and the master ECM.
• There is an incorrect value for one or more of the parameters for the fuel.
Check the wiring between the power sensor and the master ECM for corrosion and for pinch points. Refer to Troubleshooting, “Inspecting Electrical Connectors”. The master ECM must receive an accurate voltage from the power sensor. If the voltage is not accurate, the master ECM may not accurately control the air/fuel ratio. When the generator’s output is zero, the voltage from the power sensor must be less than 0.01 VDC. This voltage is called the offset voltage. Use the following procedure in order to determine if the offset voltage is too high. Perform this procedure before you adjust the “Power Monitoring” parameters.
59 Troubleshooting Section
Note: This measurement must be taken at the master ECM P1 connector. The engine must be stopped. 1. If the engine is running, stop the engine. 2. Insert 7X-1710 Multimeter Probes into terminals P1-19 and P1-25. Connect a digital voltmeter to the probes. The polarity of the connections is not important. 3. Verify that the probes are making good contact with the terminals inside the connector. Measure the DC voltage at the terminals. The voltage is acceptable if the voltage is less than ±0.01 VDC. If the voltage is less than ±0.01 VDC, the values for the “Power Monitoring” parameters may be incorrect. Refer to Systems Operation/Testing and Adjusting, “Electronic Control System Parameters”. If the voltage is greater than ±0.01 VDC, the circuit between the power sensor and the master ECM must be calibrated. Refer to Troubleshooting, “Generator Output Power Sensor - Calibration”.
Coolant Temperature Refer to Troubleshooting, “Engine Coolant Temperature (High)”.
Check for High Inlet Air Restriction and/or High Altitude When inlet air pressure is low, the turbocharger works harder in order to achieve the desired inlet manifold pressure. This increases inlet air temperature. Measure the inlet air pressure while the engine is operating under load. For specific data, refer to the Technical Marketing Information for the engine. Inlet Air Restriction Check for plugged air filters. Check for obstructions to the air inlet. Replace the air filters and/or remove the obstruction from the air inlet. High Altitude Make sure that the settings for the engine are correct for the altitude.
i01623042
Inlet Air Temperature (High) SMCS Code: 1087-035
Probable Causes • High ambient air temperature • High coolant temperature • High inlet air restriction and/or high altitude • Faulty inlet air temperature sensor and/or circuit • Insufficient flow of cooling water through the aftercooler
• Insufficient flow of air through the aftercooler
Recommended Repairs High Ambient Air Temperature Determine if the ambient air temperature is within the design specifications for the cooling system. Determine the cause of the high air temperature. Make corrections, when possible.
Check the Temperature Sensor and/or the Circuit Allow the sensor to cool and remove the sensor. Check the reading for the inlet air temperature. If the sensor is OK, the reading and the ambient temperature are approximately equal. If the reading is not correct, switch the sensor with a sensor that is known to be good. Verify that the problem is solved.
Check for Sufficient Flow of Cooling Water Through the Aftercooler Check the inlet temperature of the coolant for the aftercooler. Compare the reading to the regulated temperature. If the temperature is OK, check the outlet temperature of the coolant. A high temperature differential indicates an insufficient flow rate. If there is a high differential between the inlet temperature and the outlet temperature of the coolant for the aftercooler, perform the following procedures:
• Check the water circuit of the aftercooler for obstructions.
• Check the pump for proper operation. • Make repairs, if necessary.
60 Troubleshooting Section
Check for Sufficient Flow of Air Through the Aftercooler Determine the pressure differential of the inlet air across the aftercooler. For specific data, refer to the Technical Marketing Information for the engine. If the pressure differential of the air across the aftercooler does not match the specifications, clean the aftercooler. i01804935
Intermittent Engine Shutdown
3. Inspect the wiring from the power supply to the power distribution box. Inspect the wiring from the power distribution box to the electronic control modules. Check the power and ground connections at each electronic control module. Refer to Troubleshooting, “Electrical Power Supply” for more information.
Circuit Breakers Check the 35 amp circuit breaker on the power distribution box. The circuit breaker may exceed the trip point due to overheating. Reset the circuit breaker if the circuit breaker is tripped.
SMCS Code: 1400-035
Engine Speed/Timing Signal
Note: Use this procedure only if the engine shuts down completely and the engine must be restarted.
Loss of the signal from the speed/timing sensor will cause a shutdown. Use Cat ET to check for logged diagnostic codes. For more information, refer to Troubleshooting, “Engine Speed/Timing Sensor”.
Probable Causes • Active engine shutdown
Fuel Supply
• Electrical connectors
1. Check the fuel lines for the following problems: restrictions, obstructions, collapsed lines, and pinched lines. If problems are found with the fuel lines, repair the lines and/or replace the lines.
• Circuit breaker • Engine speed/timing signal • Fuel supply
2. Check the restriction of the fuel filter. If the fuel pressure is low, replace the fuel filter.
• Spark plug
3. Check the fuel quality.
Recommended Repairs
4. Check the fuel pressure. Refer to Systems Operation/Testing and Adjusting, “Fuel System” for the correct pressure values. If the fuel pressure is still low, check the gas regulator and the fuel metering valve.
Active Engine Shutdown Use the Caterpillar Electronic Technician (ET) to check for any active engine shutdowns and/or logged engine shutdowns. Determine the reason for the shutdown. After correcting the problem, set the engine control to the OFF/RESET mode for at least 15 seconds before you try to restart the engine.
Electrical Connectors
Spark Plug An engine shutdown that is due to a faulty spark plug is likely to occur when the engine is operating under a load. Refer to Troubleshooting, “Ignition Transformers Secondary Circuit and Spark Plugs”. i01368495
1. Check the wiring harnesses and the connectors. Inspect the connectors in the terminal boxes. Inspect the power supply connections and the ground. Refer to Troubleshooting, “Inspecting Electrical Connectors”.
Jacket Water Inlet Pressure (High)
2. Use Cat ET to check for the 168-02 diagnostic code for “System Voltage Intermittent”. If this diagnostic code is logged, proceed to Troubleshooting, “Electrical Power Supply”.
Probable Causes
SMCS Code: 1350-035
• The circuit for the engine coolant pump pressure switch (inlet) is OPEN.
61 Troubleshooting Section
• The pressure at the inlet for the jacket water is
Recommended Repairs
Recommended Repairs
Check the Coolant Level and Inspect the Cooling System for Leaks
excessive.
Check the Circuit for the Engine Coolant Pump Pressure Switch (Inlet)
Check coolant level. If the coolant level is low, inspect the cooling system for leaks.
The circuit for the switch must remain closed in order to avoid an “E224 High Jacket Water Inlet Pressure” event. Check wiring for damage or corrosion. Refer to Troubleshooting, “Inspecting Electrical Connectors”.
If the coolant level is low, fill the cooling system. If leaks are found, make the necessary repairs.
If a problem with the wiring for the circuit is found, repair the wiring, as needed.
Use the Caterpillar Electronic Technician (ET) to observe the pressure at the jacket water outlet with the engine OFF. Then observe the reading during engine operation.
Check the Inlet Pressure of the Jacket Water The engine coolant pump pressure switch (inlet) is designed to open across pin B and pin C at a pressure of 462 ± 41 kPa (67 ± 6 psi). Use a gauge to check the pressure at the inlet for the jacket water. If the pressure is less than 462 ± 41 kPa (67 ± 6 psi) but the event code “E224 High Jacket Water Inlet Pressure” is occurring, replace the pressure switch at the inlet for the jacket water. If a pressure of at least 462 ± 41 kPa (67 ± 6 psi) is measured at the inlet for the jacket water, the high pressure may be caused by a restriction in the jacket water system. Inspect the system for restrictions. Make repairs, as needed. Note: If the outlet pressure of the coolant is greater than approximately 444 kPa (64 psi), a 109-08 diagnostic code will be generated. The “Engine Coolant Outlet Pressure Sensor noisy signal” diagnostic will be generated although there is no malfunction in the electrical circuit. If this code is generated, verify the actual outlet pressure of the coolant with a pressure gauge. If the actual pressure is greater than approximately 444 kPa (64 psi), reduce the pressure. This will prevent a false 109-08 from being logged. i01727750
Check the Flow of Coolant
If the reading is not reasonable or if the reading is not within specifications, install a pressure gauge near the pressure sensor at the jacket water outlet. Compare the gauge reading with the reading from Cat ET. If the readings from the comparative gauge do not agree approximately with Cat ET, troubleshoot the circuit for the pressure sensor at the jacket water outlet. Refer to Troubleshooting, “PWM Sensor”. If the readings from the comparative gauge agree approximately with Cat ET, check the following components:
• Check the water temperature regulators for proper operation.
• Check for plugging of the radiator or the heat exchanger.
• Inspect the jacket water pump for damage to the impeller.
Make the necessary repairs. i01866678
Jacket Water to Engine Oil Differential Temperature (Low)
Jacket Water Pressure (Low)
SMCS Code: 1350-035
SMCS Code: 1350-035
Probable Causes
Probable Causes
• High engine oil temperature or low engine coolant
• Low coolant level • Insufficient flow of coolant
temperature
• Faulty temperature sensor and/or circuit • Faulty water temperature regulators
62 Troubleshooting Section
Recommended Repairs Check for Event Codes for the Engine Oil and for the Engine Coolant Use the Caterpillar Electronic Technician (ET) to check for the following event codes:
• E019 (3) High Engine Oil Temperature (shutdown) • E020 (1) High Engine Oil Temperature (warning) • E038 (1) Low Engine Coolant Temperature (warning)
• E337 (1) Hign Engine Oil to Engine Coolant Diff Temp (warning)
• E337 (3) High Engine Oil to Engine Coolant Diff Temp (shutdown)
If one or more of the codes is active, troubleshoot the code. Refer to Troubleshooting, “Troubleshooting with an Event Code”.
Check the Engine Oil Temperature and the Engine Coolant Temperature Use the Caterpillar Electronic Technician (ET) to check the temperature of the engine oil and the engine coolant. If the engine oil temperature is high, refer to Troubleshooting, “Engine Oil Temperature (High)”. If the temperature of the engine coolant is low, refer to Troubleshooting, “Engine Coolant Temperature (Low)”.
Check the Temperature Sensors and/or Circuits Use a separate device to measure the temperatures of the engine oil and the engine coolant. Compare the measured temperatures to the readings on Cat ET. If one or both of the readings are incorrect, troubleshoot the circuit(s). Refer to Troubleshooting, “Analog Sensor Signal”.
Check the water temperature regulators according to Systems Operation/Testing and Adjusting, “Testing the Cooling System”. Replace the water temperature regulators, if necessary. i01368006
System Voltage SMCS Code: 1400-035
Probable Causes There is a problem with the electrical system.
Recommended Repairs Troubleshoot the electrical system. Refer to Troubleshooting, “Electrical Power Supply”. i02064382
Turbocharger Turbine Temperature (High) SMCS Code: 1052-035
Probable Causes • High inlet manifold temperature • Incorrect base timing • Exhaust restriction • A buildup of deposits in the cylinder or internal oil leaks
Recommended Repairs Check for Event Codes for High Inlet Manifold Air Temperature Use the Caterpillar Electronic Technician (ET) to check for the following event codes:
• E026 (3) High Inlet Air Temperature (shutdown)
Check the Water Temperature Regulators
• E027 (1) High Inlet Air Temperature (warning)
The water temperature regulators should not begin to open until jacket water reaches opening temperature for the regulators. Allow the engine to cool and then start the engine. Check the tube at the outlet for the jacket water. If the tube is warm and normal operating temperature is not achieved yet, a regulator may be stuck open.
If one or more of the codes is active, refer to Troubleshooting, “Inlet Air Temperature (High)”.
63 Troubleshooting Section
Check the Base Timing
• Low cylinder compression
Verify that the base timing is correct. Refer to Systems Operation/Testing and Adjusting, “Ignition Timing - Adjust”.
Recommended Repairs
Measure the Exhaust Restriction Measure the exhaust restriction during engine operation with a load. For data that is specific to the engine, refer to the Technical Marketing Information. Investigate the cause of the exhaust restriction. Perform adjustments and/or make repairs, as needed.
Check for Deposits in the Cylinder and Check for Internal Oil Leaks Use a borescope to inspect the cylinders. Look for the following conditions:
• Deposits on the valve seats
Check for Misfire Operation with a low load can result in low exhaust temperatures. Operate the engine at low idle or near low idle in order to identify a misfire problem. Troubleshoot the cause of the misfire. Refer to Troubleshooting, “Engine Misfires, Runs Rough or Is Unstable”.
Check for Diagnostic Codes from the Integrated Temperature Sensing Module (ITSM) Use the Caterpillar Electronic Technician (ET) to check for diagnostic codes that relate to the thermocouples. Troubleshoot the code.
Check the Temperatures of the Cylinder Exhaust Ports
• Deposits on the valve faces • Deposits on the cylinder walls that are above the
Observe the temperatures for the exhaust ports of the cylinders in the suspect bank.
• Signs of internal oil leaks Other signs of internal oil leaks include high oil consumption and blue smoke.
If any of the temperatures for the exhaust ports are significantly different, determine the reason for the difference in the exhaust port temperatures. Make repairs, as needed.
Note: Excessive deposits contribute to guttering of the valves.
Check for Suspect Thermocouples
If excessive deposits and/or signs of internal oil leaks are found, investigate the cause of the condition. Make repairs, as needed.
Observe the temperatures from the thermocouples for the turbocharger(s) after the engine is shut off.
upper limit of the piston stroke
i01804955
Turbocharger Turbine Temperature (Low) SMCS Code: 1052-035
Probable Causes • Operation with a light load • Diagnostic code from the Integrated Temperature Sensing Module (ITSM)
• Low temperature from the cylinder exhaust ports • A faulty temperature sensor • Faulty ignition
When the engine is operating properly, the temperatures from similar locations are reduced at a similar rate. Also, the temperatures from similar locations are comparable. If any discrepancies are found, switch the suspect thermocouple for another thermocouple. If the temperature problem follows the thermocouple, replace the thermocouple. If the temperature problem stays at the original location of the thermocouple, investigate the cause for the low temperature.
Check for Diagnostic Codes that Relate to Ignition Use Cat ET to check for diagnostic codes that relate to the ignition system. Troubleshoot the code.
64 Troubleshooting Section
Check the Ignition System Inspect the components of the ignition system for the suspect cylinder bank. Refer to Troubleshooting, “Ignition Transformers Secondary Circuit and Spark Plugs”. Make repairs, as needed.
Check the Cylinder Compression Measure the cylinder pressures of the suspect bank in order to check for problems that are related to compression. If low compression is found, investigate the cause of the low compression. Make repairs, as needed.
65 Troubleshooting Section
Troubleshooting with a Diagnostic Code
Table 9
Failure Mode Identifiers FMI i01875210
Diagnostic Codes SMCS Code: 1901-038
Description of Failure
00
“Data valid but above normal operating range”
01
“Data valid but below normal operating range”
02
“Data erratic, intermittent or incorrect”
Diagnostic codes alert the operator that a problem in the electronic system has been detected. Diagnostic codes also indicate the nature of the problem to the service technician. The Caterpillar Electronic Technician (ET) is a software program that is designed to run on a personal computer. Diagnostic codes may be viewed on a personal computer that has Cat ET software. Diagnostic codes consist of the module identifier (MID), the component identifier (CID), and the failure mode identifier (FMI).
03
“Voltage above normal or shorted high”
04
“Voltage below normal or shorted low”
05
“Current below normal or open circuit”
06
“Current above normal or grounded circuit”
07
“Mechanical system not responding properly”
08
“Abnormal frequency, pulse, or period”
Module Identifier (MID) – The MID is a code with two or three digits that indicates the electronic module which generated the diagnostic code. The MID for the master Electronic Control Module (ECM) is 36. The MID for the slave ECM is 33. The MID for the Integrated Temperature Sensing Module (ITSM) is 111. Some electronic displays do not display the MID because the module which generates the code is obvious.
09
“Abnormal update”
10
“Abnormal rate of change”
11
“Failure mode not identifiable”
12
“Bad device or component”
13
“Out of calibration”
14
“Not used”
15
“Not used”
16
“Parameter not available”
17
“Module not responding”
18
“Sensor supply fault”
19
“Condition not met”
20
“Not used”
Component Identifier (CID) – The CID is a number with three or four digits. The CID indicates the component that generated the code. For example, the CID number 0017 identifies the fuel shutoff valve. Failure Mode Identifier (FMI) – The FMI is a two digit code that indicates the type of failure. Table 9 is a list of the failure mode identifiers that are adapted from the “SAE J1587” standard.
The master ECM will generate all of the diagnostic codes that are applicable to G3500 engines that have a single ECM. The diagnostic codes that are generated by the slave ECM are a subset of the diagnostic codes that are generated by the master ECM. All of the diagnostic codes that are pertinent to the slave ECM have the same setting conditions and the same conditions for clearing as the master ECM. Note: Do not confuse diagnostic codes with event codes. For information on event codes, see Troubleshooting, “Troubleshooting with an Event Code”. Illustration 18 represents the operating range of an oil temperature sensor. The diagram is a reference. Do not use the diagram to troubleshoot the oil temperature sensor.
66 Troubleshooting Section
This information is a valuable indicator for troubleshooting intermittent problems. A code is cleared from memory when one of the following conditions occur:
• The service technician manually clears the code. • The code does not recur for 1000 hours. • A new code is logged and there are already ten
codes in memory. In this case, the oldest code is cleared.
Illustration 18
g00791619
Typical operating range of an oil temperature sensor
Some diagnostic codes may be easily triggered. Some diagnostic codes may log occurrences that did not result in complaints. The most likely cause of an intermittent problem is a faulty connection or damaged wiring. The next likely cause is a component failure. The least likely cause is the failure of an electronic module. Diagnostic codes that are logged repeatedly may indicate a problem that needs special investigation.
(1) In these areas, the output voltage of the sensor is too high or too low. The output is outside of the normal range. The electronic problem will generate a diagnostic code. (2) In this area, the oil temperature above 102 °C (216 °F) is higher than the normal range. The output voltage of the sensor will generate an event code for a warning, a derating, or a shutdown for high oil temperature. The sensor does not have an electronic problem. (3) This area represents the normal operating temperature for the engine oil. The normal output voltage of the sensor is between 0.2 and 4.1 volts.
Note: Always clear logged diagnostic codes after investigating and correcting the problem which generated the code.
Active Diagnostic Codes
SMCS Code: 5574-038
An active diagnostic code represents a problem with the electronic control system. Correct the problem as soon as possible.
Conditions Which Generate This Code:
When an active diagnostic code is generated, the “Active Alarm” indicator (“Engine Control Alarm Status” on Cat ET) is activated in order to alert the operator. If the condition that generated the code is momentary, the message disappears from the list of active diagnostic codes. The diagnostic code becomes logged.
Logged Diagnostic Codes When an ECM generates a diagnostic code, the ECM logs the code in permanent memory. Each ECM has an internal diagnostic clock. Each ECM will record the following information when a code is generated:
• The hour of the first occurrence of the code • The hour of the last occurrence of the code • The number of occurrences of the code
i01775013
MID 033 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt
The voltage supply from the slave Electronic Control Module (ECM) to the detonation sensors on the right side of the engine has exceeded the normal range. System Response: Default values are assumed for the inputs to the slave ECM from all of the detonation sensors on the right side of the engine. All of the diagnostic codes for the detonation sensors on the right side of the engine are disabled while this code is active. The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: Since the engine protection is disabled, the engine is shut down.
67 Troubleshooting Section
• The power supply voltage is less than 6 VDC for
Troubleshooting: Perform the following diagnostic procedure: “+8V Sensor Voltage Supply”
a minimum of 0.060 seconds. The power supply voltage returns to the normal range within 0.015 seconds.
• There are three voltage readings of less than 6
Results:
VDC within 7 seconds.
• OK – STOP.
System Response: i01775014
MID 033 - CID 0041 - FMI 04 8 Volt DC Supply short to ground SMCS Code: 5574-038
The alarm output is activated. The code is logged. Note: If power supply voltage is lost and the voltage does not return, the slave ECM will not log this diagnostic code. The engine will shut down. Possible Performance Effect:
Conditions Which Generate This Code: The voltage supply from the slave Electronic Control Module (ECM) to the detonation sensors on the right side of the engine is below the normal range. System Response: Default values are assumed for the inputs to the slave ECM from all of the detonation sensors on the right side of the engine. All of the diagnostic codes for the detonation sensors on the right side of the engine are disabled while this code is active. The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: Since the engine protection is disabled, the engine is shut down. Troubleshooting:
The intermittent problem may not affect engine operation. However, the engine may experience speed burps, intermittent shutdowns, and/or complete shutdowns. Perform the following diagnostic procedure: “Electrical Power Supply” Results:
• OK – STOP. i01769134
MID 033 - CID 0301 - FMI 05 Ignition Transformer Primary #1 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code:
Perform the following diagnostic procedure: “+8V Sensor Voltage Supply” Results:
The primary circuit of the transformer is diagnosed with an open circuit. System Response:
• OK – STOP.
The alarm output is activated. The code is logged. i01935325
MID 033 - CID 0168 FMI 02 System Voltage intermittent/erratic
Possible Performance Effect: The cylinder will misfire. Troubleshooting:
SMCS Code: 1408-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code:
• A broken circuit driver’s wire for the transformer
The slave Electronic Control Module (ECM) has been powered for at least 5 seconds. The engine has been running. Either of the following conditions occur:
• A broken return wire for the transformer
68 Troubleshooting Section
• An open circuit within the primary winding of the transformer
i01758839
• An internal failure of the slave electronic control module (ECM)
MID 033 - CID 0303 - FMI 05 Ignition Transformer Primary #3 open circuit
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
SMCS Code: 1561-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The primary circuit of the transformer is diagnosed with an open circuit. i01758737
MID 033 - CID 0301 - FMI 06 Ignition Transformer Primary #1 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect:
System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
The cylinder will misfire.
• An internal failure of the slave ECM
Troubleshooting:
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer
Results:
• OK – STOP.
• A short circuit within the primary winding of the transformer
• An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:
• OK – STOP.
i01758841
MID 033 - CID 0303 - FMI 06 Ignition Transformer Primary #3 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged.
69 Troubleshooting Section
Possible Performance Effect:
Results:
The cylinder will misfire.
• OK – STOP.
Troubleshooting:
i01758849
One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer
• A short circuit within the primary winding of the transformer
MID 033 - CID 0305 - FMI 06 Ignition Transformer Primary #5 short SMCS Code: 1561-038 Conditions Which Generate This Code:
• An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:
The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged.
• OK – STOP.
Possible Performance Effect: i01758846
MID 033 - CID 0305 - FMI 05 Ignition Transformer Primary #5 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response:
The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer
• A short circuit within the primary winding of the transformer
• An internal failure of the slave ECM
The alarm output is activated. The code is logged.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Possible Performance Effect:
Results:
The cylinder will misfire.
• OK – STOP.
Troubleshooting: One of the following conditions is the source of the diagnostic code:
• An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer
i01758852
MID 033 - CID 0307 - FMI 05 Ignition Transformer Primary #7 open circuit SMCS Code: 1561-038
• An open circuit within the primary winding of the
Conditions Which Generate This Code:
• An internal failure of the slave ECM
The primary circuit of the transformer is diagnosed with an open circuit.
transformer
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
70 Troubleshooting Section
• A short circuit within the primary winding of the
System Response: The alarm output is activated. The code is logged. Possible Performance Effect:
transformer
• An internal failure of the slave ECM
The cylinder will misfire.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Troubleshooting:
Results:
One of the following conditions is the source of the diagnostic code:
• OK – STOP.
• An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
i01758859
MID 033 - CID 0309 - FMI 05 Ignition Transformer Primary #9 open circuit SMCS Code: 1561-038
• An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:
Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response:
• OK – STOP.
The alarm output is activated. The code is logged. i01758853
MID 033 - CID 0307 - FMI 06 Ignition Transformer Primary #7 short
Possible Performance Effect:
SMCS Code: 1561-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect:
The cylinder will misfire. Troubleshooting:
• An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
• An internal failure of the slave ECM
The cylinder will misfire.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Troubleshooting:
Results:
One of the following conditions is the source of the diagnostic code:
• OK – STOP.
• A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer
71 Troubleshooting Section
i01758861
MID 033 - CID 0309 - FMI 06 Ignition Transformer Primary #9 short
Possible Performance Effect: The cylinder will misfire. Troubleshooting:
SMCS Code: 1561-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code:
• An open circuit in the wiring from the slave
The path for the circuit driver of the transformer is diagnosed with a short circuit.
Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the
System Response:
transformer
The alarm output is activated. The code is logged.
• An internal failure of the slave ECM
Possible Performance Effect:
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
The cylinder will misfire.
Results:
Troubleshooting: One of the following conditions is the source of the diagnostic code:
• OK – STOP. i01758875
• A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
MID 033 - CID 0311 - FMI 06 Ignition Transformer Primary #11 short SMCS Code: 1561-038
• An internal failure of the slave ECM
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:
The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response:
• OK – STOP.
The alarm output is activated. The code is logged. i01758872
MID 033 - CID 0311 - FMI 05 Ignition Transformer Primary #11 open circuit
Possible Performance Effect: The cylinder will misfire. Troubleshooting:
SMCS Code: 1561-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code:
• A short circuit in the wiring between the slave
The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged.
Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
72 Troubleshooting Section
• An internal failure of the slave ECM
i01758889
Results:
MID 033 - CID 0313 - FMI 06 Ignition Transformer Primary #13 short
• OK – STOP.
SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Conditions Which Generate This Code: i01758886
MID 033 - CID 0313 - FMI 05 Ignition Transformer Primary #13 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting:
The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
One of the following conditions is the source of the diagnostic code:
• An internal failure of the slave ECM
• An open circuit in the wiring from the slave
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
Results:
• OK – STOP.
• An internal failure of the slave ECM
i01758898
Results:
MID 033 - CID 0315 - FMI 05 Ignition Transformer Primary #15 open circuit
• OK – STOP.
SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged.
73 Troubleshooting Section
Possible Performance Effect:
• An internal failure of the slave ECM
The cylinder will misfire.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Troubleshooting: One of the following conditions is the source of the diagnostic code:
Results:
• OK – STOP.
• An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer
i01775725
• An open circuit within the primary winding of the
MID 033 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt
• An internal failure of the slave ECM
SMCS Code: 1912-038
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Conditions Which Generate This Code:
Results:
To activate this code, all of the following conditions must occur:
transformer
• OK – STOP. i01758902
MID 033 - CID 0315 - FMI 06 Ignition Transformer Primary #15 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged.
The slave Electronic Control Module (ECM) has been powered for at least one second. The pattern of the timing reference gear is lost for more than one second. The engine speed is greater than 150 rpm. Neither of the following diagnostic codes are active:
• 145 - 03 12 Volt DC Power Supply short to +batt • 145 - 04 12 Volt DC Power Supply short to ground Note: The 0320 - 03 code is set after the pattern of the timing reference gear is lost for more than one second. However, the logic hesitates for 1.5 seconds before the code is activated. If a 145 - 03 or 145 - 04 is activated during the 1.5 seconds, then the 0320 03 code is deactivated. System Response:
Possible Performance Effect:
If the engine is running, the ignition signals stop. The shutdown output is activated. The code is logged.
The cylinder will misfire.
Possible Performance Effect:
Troubleshooting:
If the engine is running, the engine will be shut down. If the engine is not running, the engine will not start.
One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results:
• OK – STOP.
74 Troubleshooting Section
i01775729
MID 033 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal
Possible Performance Effect: The cylinder will misfire. Troubleshooting:
SMCS Code: 1912-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code:
• A problem with the transformer’s ground
The slave Electronic Control Module (ECM) must be powered for at least one second. The engine speed is greater than 150 rpm. One of the following two conditions occurs:
• An open circuit within the secondary winding of
• An invalid pattern for the timing reference gear is detected. For example, reverse rotation is detected.
the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
• The pattern for the timing reference gear is lost for
• The spark plug gap is too wide.
System Response:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
If the engine is running, the ignition signals stop. The shutdown output is activated. The code is logged.
Results:
less than one second.
• OK – STOP.
Possible Performance Effect: If the engine is running, the engine will be shut down. If the engine is not running, the engine will not start. Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results:
i01864793
MID 033 - CID 0401 - FMI 06 Ignition Transformer Secondary #1 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code:
• OK – STOP.
The transformer’s secondary circuit is diagnosed with a short circuit. i01864730
MID 033 - CID 0401 - FMI 05 Ignition Transformer Secondary #1 open circuit
System Response:
SMCS Code: 1561-038
Possible Performance Effect:
Conditions Which Generate This Code:
The cylinder will misfire.
The transformer’s secondary circuit is diagnosed with an open circuit.
Troubleshooting:
System Response:
One of the following conditions is the source of the diagnostic code:
The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged.
• A short circuit within the secondary winding of the transformer
75 Troubleshooting Section
• The spark plug is fouled.
i01864797
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
MID 033 - CID 0403 - FMI 06 Ignition Transformer Secondary #3 short to ground
Results:
SMCS Code: 1561-038
• OK – STOP.
Conditions Which Generate This Code:
• The spark plug gap is closed.
i01864795
MID 033 - CID 0403 - FMI 05 Ignition Transformer Secondary #3 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit within the secondary winding of the transformer
Possible Performance Effect:
• The spark plug is fouled.
The cylinder will misfire.
• The spark plug gap is closed.
Troubleshooting:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
One of the following conditions is the source of the diagnostic code:
• A problem with the transformer’s ground
Results:
• OK – STOP.
• An open circuit within the secondary winding of the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
• The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
• OK – STOP.
i01864798
MID 033 - CID 0405 - FMI 05 Ignition Transformer Secondary #5 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
76 Troubleshooting Section
Possible Performance Effect:
• A short circuit within the secondary winding of the
Generation of the diagnostic code does not affect engine performance. However, the engine will probably misfire. This will cause the engine to run rough. The engine may shut down.
• The spark plug is fouled.
Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A problem with the transformer’s ground
transformer
• The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
• OK – STOP.
• An open circuit within the secondary winding of the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
i01864802
MID 033 - CID 0407 - FMI 05 Ignition Transformer Secondary #7 open circuit SMCS Code: 1561-038
• The spark plug gap is too wide.
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
The transformer’s secondary circuit is diagnosed with an open circuit. System Response:
• OK – STOP. i01864800
MID 033 - CID 0405 - FMI 06 Ignition Transformer Secondary #5 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect:
The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
The cylinder will misfire.
• The spark plug gap is too wide.
Troubleshooting:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
One of the following conditions is the source of the diagnostic code:
77 Troubleshooting Section
Results:
System Response:
• OK – STOP.
The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
i01864806
MID 033 - CID 0407 - FMI 06 Ignition Transformer Secondary #7 short to ground SMCS Code: 1561-038
Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit.
• A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer
System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged.
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
Possible Performance Effect: The cylinder will misfire.
• The spark plug gap is too wide.
Troubleshooting:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
One of the following conditions is the source of the diagnostic code:
Results:
• A short circuit within the secondary winding of the
• OK – STOP.
transformer
i01864812
• The spark plug is fouled. • The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
MID 033 - CID 0409 - FMI 06 Ignition Transformer Secondary #9 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code:
• OK – STOP. i01864809
MID 033 - CID 0409 - FMI 05 Ignition Transformer Secondary #9 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.
The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.
78 Troubleshooting Section
Troubleshooting:
• The spark plug gap is too wide.
One of the following conditions is the source of the diagnostic code:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
• A short circuit within the secondary winding of the
Results:
transformer
• OK – STOP.
• The spark plug is fouled.
i01864821
• The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
MID 033 - CID 0411 - FMI 06 Ignition Transformer Secondary #11 short to ground SMCS Code: 1561-038
• OK – STOP.
Conditions Which Generate This Code: i01864818
MID 033 - CID 0411 - FMI 05 Ignition Transformer Secondary #11 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.
The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.
System Response:
Troubleshooting:
The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
One of the following conditions is the source of the diagnostic code:
Possible Performance Effect:
• A short circuit within the secondary winding of the transformer
The cylinder will misfire.
• The spark plug is fouled.
Troubleshooting:
• The spark plug gap is closed.
One of the following conditions is the source of the diagnostic code:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
• A problem with the transformer’s ground
Results:
• An open circuit within the secondary winding of
• OK – STOP.
the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
79 Troubleshooting Section
i01864822
MID 033 - CID 0413 - FMI 05 Ignition Transformer Secondary #13 open circuit
System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect:
SMCS Code: 1561-038
The cylinder will misfire.
Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit within the secondary winding of the transformer
• The spark plug is fouled.
Possible Performance Effect:
• The spark plug gap is closed.
The cylinder will misfire.
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
Troubleshooting: One of the following conditions is the source of the diagnostic code:
Results:
• OK – STOP.
• A problem with the transformer’s ground
i01864826
• An open circuit within the secondary winding of the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
MID 033 - CID 0415 - FMI 05 Ignition Transformer Secondary #15 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code:
• The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
• OK – STOP. i01864824
MID 033 - CID 0413 - FMI 06 Ignition Transformer Secondary #13 short to ground
Possible Performance Effect: The cylinder will misfire. Troubleshooting:
SMCS Code: 1561-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code:
• A problem with the transformer’s ground
The transformer’s secondary circuit is diagnosed with a short circuit.
• An open circuit within the secondary winding of the transformer
80 Troubleshooting Section
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit. • The spark plug gap is too wide.
i01796190
MID 033 - CID 0590 - FMI 09 Unable to communicate with Engine ECM SMCS Code: 1901-038
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
• OK – STOP. i01864829
MID 033 - CID 0415 - FMI 06 Ignition Transformer Secondary #15 short to ground
Conditions Which Generate This Code: The master Electronic Control Module (ECM) has sent ten consecutive messages to the slave ECM via the Cat data link. None of the messages have been received by the slave ECM. Alternatively, the master ECM has sent messages to the slave ECM over a period of time, and two-thirds of the messages have not been received by the slave ECM. Neither ECM is being flashed.
SMCS Code: 1561-038
Note: Although there is a failure to communicate with the slave ECM, the master ECM may still be able to communicate with the Caterpillar Electronic Technician (ET).
Conditions Which Generate This Code:
System Response:
The transformer’s secondary circuit is diagnosed with a short circuit.
The alarm output is activated.
System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged.
The code is logged by the slave ECM. Engine ignition is terminated. Note: If Cat ET cannot communicate with the master ECM, the values will display “Unavailable”.
Possible Performance Effect:
Possible Performance Effect:
The cylinder will misfire.
The engine is shut down.
Troubleshooting:
Perform the following diagnostic procedure: “Cat Data Link”
One of the following conditions is the source of the diagnostic code:
• A short circuit within the secondary winding of the transformer
• The spark plug is fouled. • The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
• OK – STOP.
Results:
• OK – STOP.
81 Troubleshooting Section
i01761131
MID 033 - CID 1501 - FMI 03 Cylinder #1 Detonation Sensor open/short to +batt
System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 1 and 3 to the slave Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds.
Perform the following diagnostic procedure: “Detonation Sensors” Results:
• OK – STOP.
Neither of the following diagnostic codes are active: i01761195
• 0041 - 03 8 Volt DC Supply short to +batt
System Response:
MID 033 - CID 1505 - FMI 03 Cylinder #5 Detonation Sensor open/short to +batt
The shutdown output is activated. The code is logged.
SMCS Code: 1559-038
Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut down.
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 5 and 7 to the slave Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds.
• 0041 - 04 8 Volt DC Supply short to ground
Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors”
Neither of the following diagnostic codes are active:
Results:
• 0041 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 0041 - 04 8 Volt DC Supply short to ground i01761136
MID 033 - CID 1501 - FMI 04 Cylinder #1 Detonation Sensor short to ground SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 1 and 3 to the slave Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds. Neither of the following diagnostic codes are active:
• 0041 - 03 8 Volt DC Supply short to +batt • 0041 - 04 8 Volt DC Supply short to ground
System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results:
• OK – STOP.
82 Troubleshooting Section
i01761200
MID 033 - CID 1505 - FMI 04 Cylinder #5 Detonation Sensor short to ground
Possible Performance Effect:
Troubleshooting:
Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 5 and 7 to the slave Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds. Neither of the following diagnostic codes are active:
• 0041 - 03 8 Volt DC Supply short to +batt
Perform the following diagnostic procedure: “Detonation Sensors” Results:
• OK – STOP. i01761215
MID 033 - CID 1509 - FMI 04 Cylinder #9 Detonation Sensor short to ground
• 0041 - 04 8 Volt DC Supply short to ground System Response: The shutdown output is activated. The code is logged. Possible Performance Effect:
SMCS Code: 1559-038 Conditions Which Generate This Code:
The engine is shut down.
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 9 and 11 to the slave Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds.
Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors”
Neither of the following diagnostic codes are active:
Results:
• 0041 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 0041 - 04 8 Volt DC Supply short to ground i01761212
MID 033 - CID 1509 - FMI 03 Cylinder #9 Detonation Sensor open/short to +batt SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 9 and 11 to the slave Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds. Neither of the following diagnostic codes are active:
• 0041 - 04 8 Volt DC Supply short to ground
The shutdown output is activated. The code is logged.
The engine is shut down.
SMCS Code: 1559-038
• 0041 - 03 8 Volt DC Supply short to +batt
System Response:
System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results:
• OK – STOP.
83 Troubleshooting Section
i01761230
MID 033 - CID 1513 - FMI 03 Cylinder #13 Detonation Sensor open/short to +batt
System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 13 and 15 to the slave Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds.
Perform the following diagnostic procedure: “Detonation Sensors” Results:
• OK – STOP.
Neither of the following diagnostic codes are active: i01761242
• 0041 - 03 8 Volt DC Supply short to +batt
System Response:
MID 033 - CID 1517 - FMI 03 Cylinder #17 Detonation Sensor open/short to +batt
The shutdown output is activated. The code is logged.
SMCS Code: 1559-038
Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut down.
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 17 and 19 to the slave Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds.
• 0041 - 04 8 Volt DC Supply short to ground
Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors”
Neither of the following diagnostic codes are active:
Results:
• 0041 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 0041 - 04 8 Volt DC Supply short to ground i01761234
MID 033 - CID 1513 - FMI 04 Cylinder #13 Detonation Sensor short to ground SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 13 and 15 to the slave Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds. Neither of the following diagnostic codes are active:
• 0041 - 03 8 Volt DC Supply short to +batt • 0041 - 04 8 Volt DC Supply short to ground
System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results:
• OK – STOP.
84 Troubleshooting Section
i01761245
MID 033 - CID 1517 - FMI 04 Cylinder #17 Detonation Sensor short to ground
Possible Performance Effect: The cylinder will misfire. Troubleshooting:
SMCS Code: 1559-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code:
• A problem with the transformer’s ground
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 17 and 19 to the slave Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds.
• An open circuit within the secondary winding of
Neither of the following diagnostic codes are active:
the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open
• 0041 - 03 8 Volt DC Supply short to +batt
circuit.
• 0041 - 04 8 Volt DC Supply short to ground
• The spark plug gap is too wide.
System Response:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
The shutdown output is activated. The code is logged.
Results:
Possible Performance Effect:
• OK – STOP.
The engine is shut down. Troubleshooting:
i01760914
MID 033 - CID 1748 - FMI 06 Ignition Transformer Secondary #17 short to ground
Perform the following diagnostic procedure: “Detonation Sensors” Results:
SMCS Code: 1561-038
• OK – STOP.
Conditions Which Generate This Code: i01760803
MID 033 - CID 1748 - FMI 05 Ignition Transformer Secondary #17 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.
The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.
System Response:
Troubleshooting:
The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
One of the following conditions is the source of the diagnostic code:
• A short circuit within the secondary winding of the transformer
85 Troubleshooting Section
• The spark plug is fouled.
i01760949
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
MID 033 - CID 1750 - FMI 06 Ignition Transformer Secondary #19 short to ground
Results:
SMCS Code: 1561-038
• OK – STOP.
Conditions Which Generate This Code:
• The spark plug gap is closed.
i01760805
MID 033 - CID 1750 - FMI 05 Ignition Transformer Secondary #19 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit within the secondary winding of the transformer
Possible Performance Effect:
• The spark plug is fouled.
The cylinder will misfire.
• The spark plug gap is closed.
Troubleshooting:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
One of the following conditions is the source of the diagnostic code:
• A problem with the transformer’s ground
Results:
• OK – STOP.
• An open circuit within the secondary winding of the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
• The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
• OK – STOP.
i01760301
MID 033 - CID 1752 - FMI 05 Ignition Transformer Primary #17 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged.
86 Troubleshooting Section
Possible Performance Effect:
• An internal failure of the slave ECM
The cylinder will misfire.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Troubleshooting: One of the following conditions is the source of the diagnostic code:
Results:
• OK – STOP.
• An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer
i01760309
• An open circuit within the primary winding of the
MID 033 - CID 1754 - FMI 05 Ignition Transformer Primary #19 open circuit
• An internal failure of the slave ECM
SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Conditions Which Generate This Code:
Results:
The primary circuit of the transformer is diagnosed with an open circuit.
• OK – STOP.
System Response:
transformer
i01760305
MID 033 - CID 1752 - FMI 06 Ignition Transformer Primary #17 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
Possible Performance Effect:
• An internal failure of the slave ECM
The cylinder will misfire.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
Results:
• OK – STOP.
87 Troubleshooting Section
i01760311
MID 033 - CID 1754 - FMI 06 Ignition Transformer Primary #19 short to ground
• There is a short circuit to the +Battery in the wiring for the fuel control relay.
SMCS Code: 1561-038
Note: This code cannot be detected by the master ECM when the output for the fuel control relay is ON. The output is normally ON when the engine control is in the START mode and the engine RPM is greater than zero.
Conditions Which Generate This Code:
System Response:
The path for the circuit driver of the transformer is diagnosed with a short circuit.
No fuel is provided to the engine. The alarm output is activated. The code is logged.
System Response:
Possible Performance Effect:
The alarm output is activated. The code is logged.
The engine will not start due to the lack of fuel.
Possible Performance Effect:
Troubleshooting:
The cylinder will misfire.
The most likely cause is one of the following conditions:
Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
• An open circuit in the harness or in the fuel control relay
• A short circuit to the +Battery in the harness or in the fuel control relay
Perform the following diagnostic procedure: “ECM Output Circuit (Fuel Control)” Results:
• An internal failure of the slave ECM
• OK – STOP.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short to ground
Results:
• OK – STOP. i02088213
MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open circuit SMCS Code: 1259-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has detected a positive voltage source on the output for the fuel shutoff valve. The most likely cause is one of the following conditions:
• The wiring harness has an open circuit. • The fuel control relay has an open coil.
i01805813
SMCS Code: 1259-038 Conditions Which Generate This Code:
• The output for the fuel control relay is ON. • The master Electronic Control Module (ECM)
detects excessive current on the output for the fuel control relay.
Note: This condition cannot be detected by the master ECM when the output for the fuel control relay is OFF. The output is normally OFF when the engine control is in the STOP mode.
88 Troubleshooting Section
System Response:
i01914066
The master ECM will continue attempting to energize the relay. The engine may shut down due to a lack of fuel. The alarm output is activated. The code is logged.
MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt SMCS Code: 5574-038
Possible Performance Effect:
Conditions Which Generate This Code:
The engine will not start due to the lack of fuel.
The voltage supply from the master Electronic Control Module (ECM) for the 8 volt sensors has exceeded the normal range.
Troubleshooting: The condition is probably caused by a short circuit in the harness or by an internal short circuit in the fuel control relay. Perform the following diagnostic procedure: “ECM Output Circuit (Fuel Control)” Results:
System Response: Default values are assumed for the inputs to the master ECM from all of the 8 volt sensors. All of the diagnostic codes for the 8 volt sensors to the ECM are disabled while this code is active. The fuel is shut off. The shutdown output is activated. The code is logged.
• OK – STOP.
Possible Performance Effect: i01758598
MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve malfunction SMCS Code: 1259-038 Conditions Which Generate This Code: The driver in the master Electronic Control Module (ECM) for the gas shutoff valve is OFF but the engine still runs.
Since the engine protection is disabled, the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “+8V Sensor Voltage Supply” Results:
• OK – STOP.
System Response: The master ECM will disable the ignition system and the gas shutoff valve in order to shut down the engine. The shutdown output is activated. The code is logged.
i01914068
MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short to ground SMCS Code: 5574-038
Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut down.
The voltage supply from the master Electronic Control Module (ECM) for the 8 volt sensors is below the normal range.
Troubleshooting: Perform the following diagnostic procedure: “ECM Output Circuit (Fuel Control)” Results:
• OK – STOP.
System Response: Default values are assumed for the inputs to the master ECM from all of the 8 volt sensors. All of the diagnostic codes for the 8 volt sensors to the ECM are disabled while this code is active. The fuel is shut off. The shutdown output is activated. The code is logged.
89 Troubleshooting Section
Possible Performance Effect:
Results:
Since the engine protection is disabled, the engine is shut down.
• OK – STOP. i01758623
Troubleshooting: Perform the following diagnostic procedure: “+8V Sensor Voltage Supply” Results:
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure short to ground SMCS Code: 1924-038
• OK – STOP.
Conditions Which Generate This Code: i01758614
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure open/short to +batt SMCS Code: 1924-038 Conditions Which Generate This Code: The signal from the filtered oil pressure sensor to the master Electronic Control Module (ECM) is greater than 4.8 VDC for at least five seconds. Additionally, neither of the following diagnostic codes are active:
• 262 - 03 5 Volt Sensor DC Power Supply short to +batt
The signal from the filtered oil pressure sensor to the master Electronic Control Module (ECM) is less than 0.2 VDC for at least five seconds. Additionally, neither of the following diagnostic codes are active:
• 262 - 03 5 Volt Sensor DC Power Supply short to +batt
• 262 - 04 5 Volt Sensor DC Power Supply short to ground
System Response: The master ECM assumes the last valid value for the engine oil pressure. The monitoring of the oil pressure is disabled. This disables the engine protection for low oil pressure and for excessive oil pressure.
• 262 - 04 5 Volt Sensor DC Power Supply short to
The fuel is shut off. The shutdown output is activated. The code is logged.
System Response:
Possible Performance Effect:
The master ECM assumes the last valid value for the engine oil pressure. The monitoring of the oil pressure is disabled. This disables the engine protection for low oil pressure and for excessive oil pressure.
Since the engine protection is disabled, the engine is shut down.
The fuel is shut off. The shutdown output is activated. The code is logged.
Perform the following diagnostic procedure: “Analog Sensor Signal”
Possible Performance Effect:
Results:
Since the engine protection is disabled, the engine is shut down.
• OK – STOP.
ground
Troubleshooting: This condition indicates an open circuit or a short circuit to a positive voltage source. Perform the following diagnostic procedure: “Analog Sensor Signal”
Troubleshooting:
90 Troubleshooting Section
i01780399
MID 036 - CID 0106 - FMI 03 Air Inlet Pressure Sensor short to +batt
• 41 - 04 8 Volt DC Supply short to ground System Response: The fuel is shut off. The shutdown output is activated. The code is logged.
SMCS Code: 5574-038-PX
Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut down.
The duty cycle for the inlet manifold pressure sensor is greater than the maximum value.
Troubleshooting:
Additionally, neither of the following diagnostic codes are active:
Perform the following diagnostic procedure: “PWM Sensor” Results:
• 41 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 41 - 04 8 Volt DC Supply short to ground System Response:
i01793903
Possible Performance Effect:
MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure open/short to +batt
The engine is shut down.
SMCS Code: 5574-038-PX
Troubleshooting:
Conditions Which Generate This Code:
This condition indicates a possible open circuit or a possible short circuit.
The duty cycle of the pressure sensor for the outlet of the engine coolant is greater than the maximum limit.
Perform the following diagnostic procedure: “PWM Sensor”
Additionally, neither of the following diagnostic codes are active:
Results:
• 41 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 41 - 04 8 Volt DC Supply short to ground
The fuel is shut off. The shutdown output is activated. The code is logged.
System Response: i01636377
MID 036 - CID 0106 - FMI 08 Air Inlet Pressure Sensor noisy signal
The alarm output is activated. The code is logged.
SMCS Code: 5574-038-PX
Troubleshooting:
Conditions Which Generate This Code:
The condition indicates a possible open circuit or a short circuit.
The duty cycle or the frequency for the inlet manifold pressure sensor is out of range. Additionally, neither of the following diagnostic codes are active:
• 41 - 03 8 Volt DC Supply short to +batt
Possible Performance Effect: The engine performance is not affected.
Perform the following diagnostic procedure: “PWM Sensor” Results:
• OK – STOP.
91 Troubleshooting Section
i01691110
MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal SMCS Code: 5574-038-PX
The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: Since the engine protection is disabled, the engine is shut down. Troubleshooting:
Conditions Which Generate This Code: The duty cycle or the frequency of the signal from the pressure sensor for the outlet of the engine coolant is out of range. Additionally, neither of the following diagnostic codes are active:
• 41 - 03 8 Volt DC Supply short to +batt
This condition indicates a possible open circuit or a possible short circuit. Perform the following diagnostic procedure: “Analog Sensor Signal” Results:
• OK – STOP.
• 41 - 04 8 Volt DC Supply short to ground
i01758638
System Response:
Possible Performance Effect:
MID 036 - CID 0110 - FMI 04 Engine Coolant Temperature short to ground
The engine performance is not affected.
SMCS Code: 1906-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “PWM Sensor”
The signal from the engine coolant temperature sensor to the master Electronic Control Module (ECM) is less than 0.2 VDC for at least five seconds.
The alarm output is activated. The code is logged.
Results:
System Response:
• OK – STOP. i01758632
MID 036 - CID 0110 - FMI 03 Engine Coolant Temperature open/short to +batt
The master ECM assumes the last valid value for the engine coolant temperature. The monitoring of the coolant temperature is disabled. This disables the engine protection for low coolant temperature and for high coolant temperature. The fuel is shut off. The shutdown output is activated. The code is logged.
SMCS Code: 1906-038
Possible Performance Effect:
Conditions Which Generate This Code:
Since the engine protection is disabled, the engine is shut down.
The signal from the engine coolant temperature sensor to the master Electronic Control Module (ECM) is greater than 4.8 VDC for at least five seconds. System Response: The master ECM assumes the last valid value for engine coolant temperature. The monitoring of the coolant temperature is disabled. This disables the engine protection for low coolant temperature and for high coolant temperature.
Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results:
• OK – STOP.
92 Troubleshooting Section
i01866770
MID 036 - CID 0145 - FMI 03 12 Volt DC Power Supply short to +batt SMCS Code: 5574-038
Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results:
• OK – STOP.
Conditions Which Generate This Code: i01921808
The master Electronic Control Module (ECM) has been powered for at least five seconds. The 12 volt sensor supply voltage becomes greater than 14.2 V for at least one second. System Response:
MID 036 - CID 0168 FMI 02 System Voltage intermittent/erratic SMCS Code: 1408-038
If the engine is running, the fuel is shut off. The shutdown output is activated. The code is logged.
Conditions Which Generate This Code:
The engine is shut down or the engine will not start.
The master Electronic Control Module (ECM) has been powered for at least 5 seconds. The engine is running. Either of the two following conditions occur:
Troubleshooting:
• The power supply voltage is less than 6 VDC for a
Possible Performance Effect:
Perform the following diagnostic procedure: “Engine Speed/Timing Sensor”
minimum of 0.060 seconds. The voltage returns to the normal range within 0.015 seconds.
• There are three voltage readings of less than 6 VDC within 7 seconds.
Results:
System Response:
• OK – STOP.
The alarm output is activated. The code is logged. i01866808
MID 036 - CID 0145 - FMI 04 12 Volt DC Power Supply short to ground
Note: If power supply voltage is lost and the voltage does not return, the master ECM will not log this diagnostic code. The engine will shut down.
SMCS Code: 5574-038
The intermittent problem may not affect engine operation. However, the engine may experience speed burps, intermittent shutdowns, and/or complete shutdowns.
Conditions Which Generate This Code: The master Electronic Control Module (ECM) has been powered for at least five seconds. The 12 volt sensor supply voltage becomes less than 11 VDC for at least one second. System Response: If the engine is running, the fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down or the engine will not start.
Possible Performance Effect:
Troubleshooting: Perform the following diagnostic procedure: “Electrical Power Supply” Results:
• OK – STOP.
93 Troubleshooting Section
i01875963
i01758674
MID 036 - CID 0172 - FMI 03 Intake Manifold Air Temp open/short to +batt
MID 036 - CID 0172 - FMI 04 Intake Manifold Air Temp short to ground
SMCS Code: 5574-038-TA
SMCS Code: 5574-038-TA
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The master Electronic Control Module (ECM) has been powered for at least five seconds. The signal from the inlet manifold temperature sensor to the master ECM is greater than 4.8 VDC for at least five seconds. Additionally, neither of the following diagnostic codes are active:
The signal from the inlet manifold temperature sensor to the master Electronic Control Module (ECM) is less than 0.2 VDC for at least five seconds.
• 262 - 03 5 Volt Sensor DC Power Supply short to
• 262 - 03 5 Volt Sensor DC Power Supply short to
• 262 - 04 5 Volt Sensor DC Power Supply short to
• 262 - 04 5 Volt Sensor DC Power Supply short to
System Response:
System Response:
The master ECM assumes the last valid value for the inlet manifold air temperature. The monitoring of the inlet manifold air temperature is disabled. This disables the engine protection for high inlet manifold air temperature. The air/fuel ratio control cannot compensate for the inlet air temperature.
The master ECM assumes the last valid value for the inlet manifold air temperature. The monitoring of the inlet manifold air temperature is disabled. This disables the engine protection for high inlet manifold air temperature. The air/fuel ratio control cannot compensate for the inlet air temperature.
The fuel is shut off. The shutdown output is activated. The code is logged.
The fuel is shut off. The shutdown output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine is shut down.
The engine is shut down.
Troubleshooting:
Troubleshooting:
The condition indicates a possible open circuit or a short circuit to a positive voltage source.
Perform the following diagnostic procedure: “Analog Sensor Signal”
Perform the following diagnostic procedure: “Analog Sensor Signal”
Results:
+batt
ground
Results:
• OK – STOP.
Additionally, neither of the following diagnostic codes are active: +batt
ground
• OK – STOP. i01758680
MID 036 - CID 0175 - FMI 03 Engine Oil Temperature open/short to +batt SMCS Code: 5574-038-TA Conditions Which Generate This Code: The signal from the engine oil temperature sensor to the master Electronic Control Module (ECM) is greater than 4.8 VDC for at least five seconds.
94 Troubleshooting Section
Additionally, neither of the following diagnostic codes are active:
• 262 - 03 5 Volt Sensor DC Power Supply short to +batt
• 262 - 04 5 Volt Sensor DC Power Supply short to ground
System Response: The master ECM assumes the last valid value for the engine oil temperature. The monitoring of the engine oil temperature is disabled. Also, monitoring for a high difference in temperature between the engine oil and the engine coolant is disabled. This disables the engine protection for both parameters.
System Response:
The shutdown output is activated. The code is logged.
The master ECM assumes the last valid value for the engine oil temperature. The monitoring of the engine oil temperature is disabled. Also, the monitoring for a high difference in temperature between the engine oil and the engine coolant is disabled. This disables the engine protection for both parameters.
Possible Performance Effect:
The shutdown output is activated. The code is logged.
Perform the following diagnostic procedure: “Analog Sensor Signal”
Possible Performance Effect: Since engine protection is disabled, the engine is shut down.
Since engine protection is disabled, the engine is shut down. Troubleshooting:
Results:
• OK – STOP.
Troubleshooting:
i01636386
The condition indicates a possible open circuit or a short circuit to a positive voltage source. Perform the following diagnostic procedure: “Analog Sensor Signal”
MID 036 - CID 0261 - FMI 13 Engine Timing calibration required SMCS Code: 1905-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The timing calibration has not been performed. i01758708
MID 036 - CID 0175 - FMI 04 Engine Oil Temperature short to ground
System Response:
SMCS Code: 5574-038-TA
The timing will be advanced or the timing will be retarded. Either condition will result in reduced engine performance. If the condition is not corrected, engine damage will result.
Conditions Which Generate This Code: The signal from the engine oil temperature sensor to the master Electronic Control Module (ECM) is less than 0.2 VDC for at least five seconds. Additionally, neither of the following diagnostic codes are active:
• 262 - 03 5 Volt Sensor DC Power Supply short to +batt
• 262 - 04 5 Volt Sensor DC Power Supply short to ground
The alarm output is activated. The code is logged. Possible Performance Effect:
Troubleshooting: Calibrate the engine speed/timing sensor. Perform the following diagnostic procedure: “Engine Speed/Timing Sensor - Calibrate” Results:
• OK – STOP.
95 Troubleshooting Section
i01805835
i01805855
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power Supply short to +batt
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power Supply short to ground
SMCS Code: 5574-038
SMCS Code: 5574-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The supply voltage from the master Electronic Control Module (ECM) to the sensors for the following parameters is exceeding the normal level:
The supply voltage from the master Electronic Control Module (ECM) to the sensors for the following parameters is less than the normal level:
• Inlet air temperature
• Inlet air temperature
• Engine oil temperature
• Engine oil temperature
• Unfiltered engine oil pressure
• Unfiltered engine oil pressure
• Filtered engine oil pressure
• Filtered engine oil pressure
If the engine is equipped with a desired speed potentiometer, a short circuit in the signal wire for the desired speed potentiometer can generate this code.
If the engine is equipped with a desired speed potentiometer, a short circuit in the signal wire for the desired speed potentiometer can generate this code.
System Response:
System Response:
All of the inputs to the master ECM for the 5 volt sensors assume default values. All other diagnostic codes for the 5 volt sensors are disabled while this diagnostic code is active. The “Status” screen of Caterpillar Electronic Technician (ET) indicates a “Sensor Supply Fault” for each sensor. This indicates that the sensors are not operating due to an active diagnostic code.
All of the inputs to the master ECM for the 5 volt sensors assume default values. All other diagnostic codes for the 5 volt sensors are disabled while this diagnostic code is active. The “Status” screen of the Caterpillar Electronic Technician (ET) indicates a “Sensor Supply Fault” for each sensor. This indicates that the sensors are not operating due to an active diagnostic code.
The shutdown indicator is activated. The code is logged.
The shutdown output is activated. The code is logged.
Possible Performance Effect: Since engine protection is disabled, the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “+5V Sensor Voltage Supply” Results:
• OK – STOP.
Possible Performance Effect: Since engine protection is disabled, the engine is shut down. Troubleshooting: The condition indicates a possible short circuit to ground or a short circuit between the sensor supply and the return. Perform the following diagnostic procedure: “+5V Sensor Voltage Supply” Results:
• OK – STOP.
96 Troubleshooting Section
i01758830
MID 036 - CID 0302 - FMI 05 Ignition Transformer Primary #2 open circuit
Possible Performance Effect: The cylinder will misfire. Troubleshooting:
SMCS Code: 1561-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code:
• A short circuit in the wiring between the master
The primary circuit of the transformer is diagnosed with an open circuit.
Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the
System Response:
transformer
The alarm output is activated. The code is logged.
• An internal failure of the master ECM
Possible Performance Effect:
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
The cylinder will misfire.
Results:
Troubleshooting: One of the following conditions is the source of the diagnostic code:
• OK – STOP. i01758842
• An open circuit in the wiring from the master
Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
MID 036 - CID 0304 - FMI 05 Ignition Transformer Primary #4 open circuit
• An internal failure of the master ECM
SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Conditions Which Generate This Code:
Results:
The primary circuit of the transformer is diagnosed with an open circuit. System Response:
• OK – STOP.
The alarm output is activated. The code is logged. i01758836
MID 036 - CID 0302 - FMI 06 Ignition Transformer Primary #2 short
Possible Performance Effect:
SMCS Code: 1561-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged.
The cylinder will misfire. Troubleshooting:
• An open circuit in the wiring from the master
Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
97 Troubleshooting Section
• An internal failure of the master ECM
i01758850
Results:
MID 036 - CID 0306 - FMI 05 Ignition Transformer Primary #6 open circuit
• OK – STOP.
SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Conditions Which Generate This Code: i01758843
MID 036 - CID 0304 - FMI 06 Ignition Transformer Primary #4 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the
The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• An open circuit in the wiring from the master
Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
• An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:
• OK – STOP.
transformer
• An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:
• OK – STOP.
i01758851
MID 036 - CID 0306 - FMI 06 Ignition Transformer Primary #6 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire.
98 Troubleshooting Section
Troubleshooting:
Results:
One of the following conditions is the source of the diagnostic code:
• OK – STOP.
• A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
i01758856
MID 036 - CID 0308 - FMI 06 Ignition Transformer Primary #8 short SMCS Code: 1561-038
• An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:
Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response:
• OK – STOP.
The alarm output is activated. The code is logged. i01758855
MID 036 - CID 0308 - FMI 05 Ignition Transformer Primary #8 open circuit
Possible Performance Effect:
SMCS Code: 1561-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect:
The cylinder will misfire. Troubleshooting:
• A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
• An internal failure of the master ECM
The cylinder will misfire.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Troubleshooting:
Results:
One of the following conditions is the source of the diagnostic code:
• OK – STOP.
• An open circuit in the wiring from the master
i01758862
• An open circuit within the primary winding of the
MID 036 - CID 0310 - FMI 05 Ignition Transformer Primary #10 open circuit
• An internal failure of the master ECM
SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Conditions Which Generate This Code:
Electronic Control Module (ECM) to the transformer transformer
The primary circuit of the transformer is diagnosed with an open circuit.
99 Troubleshooting Section
System Response:
• An internal failure of the master ECM
The alarm output is activated. The code is logged.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Possible Performance Effect:
Results:
The cylinder will misfire.
• OK – STOP.
Troubleshooting: One of the following conditions is the source of the diagnostic code:
i01758879
• An open circuit in the wiring from the master
MID 036 - CID 0312 - FMI 05 Ignition Transformer Primary #12 open circuit
• An open circuit within the primary winding of the
SMCS Code: 1561-038
Electronic Control Module (ECM) to the transformer transformer
Conditions Which Generate This Code:
• An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
The primary circuit of the transformer is diagnosed with an open circuit. System Response:
Results:
The alarm output is activated. The code is logged.
• OK – STOP.
Possible Performance Effect: i01758867
MID 036 - CID 0310 - FMI 06 Ignition Transformer Primary #10 short SMCS Code: 1561-038 Conditions Which Generate This Code:
The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• An open circuit in the wiring from the master
Electronic Control Module (ECM) to the transformer
The path for the circuit driver of the transformer is diagnosed with a short circuit.
• An open circuit within the primary winding of the
System Response:
• An internal failure of the master ECM
The alarm output is activated. The code is logged.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
transformer
Results:
• OK – STOP.
100 Troubleshooting Section
i01758881
MID 036 - CID 0312 - FMI 06 Ignition Transformer Primary #12 short
Possible Performance Effect: The cylinder will misfire. Troubleshooting:
SMCS Code: 1561-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code:
• An open circuit in the wiring from the master
The path for the circuit driver of the transformer is diagnosed with a short circuit.
Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
System Response: The alarm output is activated. The code is logged.
• An internal failure of the master ECM
Possible Performance Effect:
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
The cylinder will misfire.
Results:
Troubleshooting:
• OK – STOP.
One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
i01758894
MID 036 - CID 0314 - FMI 06 Ignition Transformer Primary #14 short SMCS Code: 1561-038
• An internal failure of the master ECM
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
The path for the circuit driver of the transformer is diagnosed with a short circuit.
Results:
System Response:
• OK – STOP.
The alarm output is activated. The code is logged. Possible Performance Effect: i01758891
MID 036 - CID 0314 - FMI 05 Ignition Transformer Primary #14 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged.
The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
101 Troubleshooting Section
• An internal failure of the master ECM
i01758913
Results:
MID 036 - CID 0316 - FMI 06 Ignition Transformer Primary #16 short
• OK – STOP.
SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Conditions Which Generate This Code: i01758906
MID 036 - CID 0316 - FMI 05 Ignition Transformer Primary #16 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting:
The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
One of the following conditions is the source of the diagnostic code:
• An internal failure of the master ECM
• An open circuit in the wiring from the master
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
Results:
• OK – STOP.
• An internal failure of the master ECM i01760423
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:
• OK – STOP.
MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt SMCS Code: 1912-038 Conditions Which Generate This Code: To activate this code, all of the following conditions must occur: The master Electronic Control Module (ECM) has been powered for at least one second. The pattern of the timing reference gear is lost for more than one second. The engine speed is greater than 150 rpm. Neither of the following diagnostic codes are active:
102 Troubleshooting Section
• 145 - 03 12 Volt DC Power Supply short to +batt
Possible Performance Effect:
• 145 - 04 12 Volt DC Power Supply short to ground
If the engine is running, the engine will be shut down. If the engine is not running, the engine will not start.
Note: The 0320 - 03 code is set after the pattern of the timing reference gear is lost for more than one second. However, the logic hesitates for 1.5 seconds before the code is activated. If a 145 - 03 or 145 - 04 is activated during the 1.5 seconds, then the 0320 03 code is deactivated. System Response: If the engine is running, the ignition signals stop. The shutdown output is activated. The code is logged. Possible Performance Effect: If the engine is running, the engine will be shut down. If the engine is not running, the engine will not start. Troubleshooting:
Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results:
• OK – STOP. i01760427
MID 036 - CID 0323 - FMI 03 Shutdown Lamp short to +batt SMCS Code: 7400-038-IND Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results:
The master Electronic Control Module (ECM) detects excessive current for the shutdown output. Note: This diagnostic condition cannot be detected when the shutdown output is OFF.
• OK – STOP. i01760426
MID 036 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal SMCS Code: 1912-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) must be powered for at least one second. The engine speed is greater than 150 rpm. One of the following two conditions occurs:
• An invalid pattern for the timing reference gear
System Response: The master ECM limits the current for the shutdown output to 0.3 amperes. The code is logged. Possible Performance Effect: The engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “ECM Status Indicator Output” Results:
• OK – STOP.
is detected. For example, reverse rotation is detected.
i01760430
• The pattern for the timing reference gear is lost for
MID 036 - CID 0324 - FMI 03 Warning Lamp short to +batt
System Response:
SMCS Code: 7400-038-IND
If the engine is running, the ignition signals stop. The shutdown output is activated. The code is logged.
Conditions Which Generate This Code:
less than one second.
The master Electronic Control Module (ECM) detects excessive current for the alarm output.
103 Troubleshooting Section
Note: This diagnostic condition cannot be detected when the alarm output is OFF. System Response: The master ECM limits the current for the alarm output to 0.3 amperes. The code is logged. Possible Performance Effect:
i01864831
MID 036 - CID 0402 - FMI 05 Ignition Transformer Secondary #2 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code:
The engine operation is not affected.
The transformer’s secondary circuit is diagnosed with an open circuit.
Troubleshooting: Perform the following diagnostic procedure: “ECM Status Indicator Output” Results:
• OK – STOP.
System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect:
i01760434
MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch inputs
The cylinder will misfire. Troubleshooting:
SMCS Code: 7332-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code:
• A problem with the transformer’s ground
The master Electronic Control Module (ECM) detects an invalid combination on these inputs from the Engine Control Switch (ECS): “Switched +Battery”, “Start”, “Stop”, and “Auto”.
• An open circuit within the secondary winding of
System Response: The shutdown output is activated. The code is logged.
the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
Possible Performance Effect:
• The spark plug gap is too wide.
If the engine is running, the engine will be shut down.
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
Troubleshooting: Perform the following diagnostic procedure: “Electrical Power Supply”
Results:
• OK – STOP.
Results:
• OK – STOP.
i01864834
MID 036 - CID 0402 - FMI 06 Ignition Transformer Secondary #2 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit.
104 Troubleshooting Section
System Response:
• An open circuit within the secondary winding of
The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged.
• A problem with the connection to the spark plug’s
Possible Performance Effect:
• The spark plug has internal damage or an open
the transformer terminal post circuit.
The cylinder will misfire.
• The spark plug gap is too wide.
Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit within the secondary winding of the transformer
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
• OK – STOP.
• The spark plug is fouled.
i01864836
• The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
MID 036 - CID 0404 - FMI 06 Ignition Transformer Secondary #4 short to ground
Results:
SMCS Code: 1561-038
• OK – STOP.
Conditions Which Generate This Code: i01864835
MID 036 - CID 0404 - FMI 05 Ignition Transformer Secondary #4 open circuit
The transformer’s secondary circuit is diagnosed with a short circuit. System Response:
SMCS Code: 1561-038
The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged.
Conditions Which Generate This Code:
Possible Performance Effect:
The transformer’s secondary circuit is diagnosed with an open circuit.
The cylinder will misfire.
System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A problem with the transformer’s ground
Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit within the secondary winding of the transformer
• The spark plug is fouled. • The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
• OK – STOP.
105 Troubleshooting Section
i01864837
MID 036 - CID 0406 - FMI 05 Ignition Transformer Secondary #6 open circuit
System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect:
SMCS Code: 1561-038
The cylinder will misfire.
Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit within the secondary winding of the transformer
• The spark plug is fouled.
Possible Performance Effect:
• The spark plug gap is closed.
The cylinder will misfire.
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
Troubleshooting: One of the following conditions is the source of the diagnostic code:
Results:
• OK – STOP.
• A problem with the transformer’s ground
i01864848
• An open circuit within the secondary winding of the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
MID 036 - CID 0408 - FMI 05 Ignition Transformer Secondary #8 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code:
• The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
• OK – STOP. i01864842
MID 036 - CID 0406 - FMI 06 Ignition Transformer Secondary #6 short to ground
Possible Performance Effect: The cylinder will misfire. Troubleshooting:
SMCS Code: 1561-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code:
• A problem with the transformer’s ground
The transformer’s secondary circuit is diagnosed with a short circuit.
• An open circuit within the secondary winding of the transformer
106 Troubleshooting Section
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit. • The spark plug gap is too wide.
i01864850
MID 036 - CID 0410 - FMI 05 Ignition Transformer Secondary #10 open circuit SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
Conditions Which Generate This Code:
Results:
The transformer’s secondary circuit is diagnosed with an open circuit.
• OK – STOP.
System Response: i01864849
MID 036 - CID 0408 - FMI 06 Ignition Transformer Secondary #8 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.
The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
Troubleshooting:
• The spark plug gap is too wide.
One of the following conditions is the source of the diagnostic code:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
• A short circuit within the secondary winding of the
Results:
transformer
• The spark plug is fouled. • The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
• OK – STOP.
• OK – STOP.
107 Troubleshooting Section
i01864851
MID 036 - CID 0410 - FMI 06 Ignition Transformer Secondary #10 short to ground
Possible Performance Effect: The cylinder will misfire. Troubleshooting:
SMCS Code: 1561-038
One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code:
• A problem with the transformer’s ground
The transformer’s secondary circuit is diagnosed with a short circuit.
• An open circuit within the secondary winding of
System Response:
• A problem with the connection to the spark plug’s
the transformer terminal post
The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged.
• The spark plug has internal damage or an open
Possible Performance Effect:
• The spark plug gap is too wide.
The cylinder will misfire.
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
Troubleshooting: One of the following conditions is the source of the diagnostic code:
circuit.
Results:
• OK – STOP.
• A short circuit within the secondary winding of the transformer
i01864861
MID 036 - CID 0412 - FMI 06 Ignition Transformer Secondary #12 short to ground
• The spark plug is fouled. • The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
SMCS Code: 1561-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The transformer’s secondary circuit is diagnosed with a short circuit. i01864860
MID 036 - CID 0412 - FMI 05 Ignition Transformer Secondary #12 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit within the secondary winding of the transformer
• The spark plug is fouled.
108 Troubleshooting Section
• The spark plug gap is closed.
i01864863
Results:
MID 036 - CID 0414 - FMI 06 Ignition Transformer Secondary #14 short to ground
• OK – STOP.
SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
Conditions Which Generate This Code: i01864862
MID 036 - CID 0414 - FMI 05 Ignition Transformer Secondary #14 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.
The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.
System Response:
Troubleshooting:
The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
One of the following conditions is the source of the diagnostic code:
Possible Performance Effect:
• A short circuit within the secondary winding of the transformer
The cylinder will misfire.
• The spark plug is fouled.
Troubleshooting:
• The spark plug gap is closed.
One of the following conditions is the source of the diagnostic code:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
• A problem with the transformer’s ground
Results:
• An open circuit within the secondary winding of
• OK – STOP.
the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
• The spark plug gap is too wide.
i01864864
MID 036 - CID 0416 - FMI 05 Ignition Transformer Secondary #16 open circuit SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
Conditions Which Generate This Code:
Results:
The transformer’s secondary circuit is diagnosed with an open circuit.
• OK – STOP.
109 Troubleshooting Section
System Response:
Troubleshooting:
The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
One of the following conditions is the source of the diagnostic code:
• A short circuit within the secondary winding of the transformer
Possible Performance Effect: The cylinder will misfire.
• The spark plug is fouled.
Troubleshooting:
• The spark plug gap is closed.
One of the following conditions is the source of the diagnostic code:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
• A problem with the transformer’s ground
Results:
• An open circuit within the secondary winding of
• OK – STOP.
the transformer
• A problem with the connection to the spark plug’s
i01866568
• The spark plug has internal damage or an open
MID 036 - CID 0443 - FMI 03 Crank Terminate Relay short to +batt
• The spark plug gap is too wide.
SMCS Code: 4493-038
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
Conditions Which Generate This Code:
Results:
The master Electronic Control Module (ECM) detects excessive current for the crank terminate relay.
terminal post circuit.
• OK – STOP. i01864865
MID 036 - CID 0416 - FMI 06 Ignition Transformer Secondary #16 short to ground
Note: This diagnostic condition cannot be detected when the output for the crank terminate relay is OFF. The output is normally OFF when the engine control is in the STOP mode. System Response:
SMCS Code: 1561-038
The master ECM will limit the current for the crank terminate relay to 0.3 amperes. The alarm output is activated. The code is logged.
Conditions Which Generate This Code:
Troubleshooting:
The transformer’s secondary circuit is diagnosed with a short circuit.
Perform the following diagnostic procedure: “ECM Status Indicator Output”
System Response:
Results:
The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged.
• OK – STOP.
Possible Performance Effect: The cylinder will misfire.
110 Troubleshooting Section
i01866572
MID 036 - CID 0444 - FMI 05 Start Relay open circuit SMCS Code: 1426-038
System Response: The master ECM will continue to attempt to energize the relay. The alarm output is activated. The code is logged. Possible Performance Effect:
Conditions Which Generate This Code:
The engine will probably be unable to crank.
The output from the master Electronic Control Module (ECM) for the starting motor relay is OFF. An open circuit or a short circuit to the +Battery is detected. Note: This diagnostic condition can only be detected by the master ECM when the output for the starting motor relay is OFF. The output is normally OFF when the engine control is in the STOP mode or when the crank terminate relay is energized. System Response:
Troubleshooting: This condition indicates an short circuit in the harness or the relay. Perform the following diagnostic procedure: “ECM Output Circuit (Starting Motor)” Results:
• OK – STOP.
An internal resistor rises to the +Battery side when no electrical load is present. The alarm output is activated. The code is logged. Possible Performance Effect: The engine will be unable to crank.
i01866579
MID 036 - CID 0445 - FMI 03 Run Relay short to +batt SMCS Code: 4493-038
Troubleshooting:
Conditions Which Generate This Code:
The harness or the relay probably has an open circuit. Perform the following diagnostic procedure: “ECM Output Circuit (Starting Motor)” Results:
• OK – STOP.
The master Electronic Control Module (ECM) detects excessive current for the run relay. Note: This diagnostic condition cannot be detected when the output for the “Run” relay is OFF. The output is normally OFF when the engine control is in the STOP mode. System Response:
i01866577
MID 036 - CID 0444 - FMI 06 Start Relay short to ground SMCS Code: 1426-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) detects excessive current for the output of the starting motor relay. Note: This diagnostic condition can only be detected by the master ECM when the output for the starting motor relay is ON. The output is normally ON when the engine control is changed from the STOP mode to the START mode. The output is ON until the crank terminate relay is energized.
The master ECM will limit the current to 0.3 amperes. The “Status” screen of the Caterpillar Electronic Technician (ET) will display “Relay Fault”. The code is logged. Troubleshooting: Perform the following diagnostic procedure: “ECM Status Indicator Output” Results:
• OK – STOP.
111 Troubleshooting Section
i01761091
MID 036 - CID 0524 - FMI 03 Desired Engine Speed Sensor short to +batt
System Response: When the “Idle/Rated” switch is in the “Rated” position, the master ECM assumes a default value for the desired engine speed. The alarm output is activated. The code is logged.
SMCS Code: 5574-038
Possible Performance Effect:
Conditions Which Generate This Code: The master Electronic Control Module (ECM) has been powered up for at least five seconds. The current to the master ECM for the desired speed input is greater than 22 mA for more than five seconds.
The default value for the desired engine speed is equal to the “Minimum Engine High Idle Speed” that is programmed on the “Service/Configuration” screen of the Caterpillar Electronic Technician (ET). Troubleshooting:
System Response:
The diagnostic code is generated by one of the following conditions:
When the “Idle/Rated” switch is in the “Rated” position, the master ECM assumes a default value for the desired engine speed.
• An open circuit or a short circuit to ground
The alarm output is activated. The code is logged.
• An open circuit or a short circuit to the +Battery
Possible Performance Effect:
Perform the following diagnostic procedure: “Desired Speed Input (4 - 20 mA)”
The default value for the desired engine speed is equal to the “Minimum Engine High Idle Speed” that is programmed on the “Service/Configuration” screen of the Caterpillar Electronic Technician (ET).
Results:
• OK – STOP.
Troubleshooting: i01761094
The diagnostic code is generated by one of the following conditions:
• A short circuit to the +Battery side • A short circuit to ground
MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil Pressure open/short to +batt SMCS Code: 1924-038
Perform the following diagnostic procedure: “Desired Speed Input (4 - 20 mA)”
Conditions Which Generate This Code: The signal to the master Electronic Control Module (ECM) from the sensor for unfiltered engine oil pressure is greater than 4.8 VDC for at least five seconds. Also, neither of the following diagnostic codes are active:
Results:
• OK – STOP. i01761093
MID 036 - CID 0524 - FMI 04 Desired Engine Speed Sensor short to ground
• 262 - 03 5 Volt Sensor DC Power Supply short to
SMCS Code: 5574-038
System Response:
Conditions Which Generate This Code:
The master ECM assumes the last valid value for unfiltered engine oil pressure. Monitoring for restriction of the oil filters is disabled.
The master Electronic Control Module (ECM) has been powered up for at least five seconds. The current to the master ECM for the desired speed input is less than 2 mA for more than five seconds.
+batt
• 262 - 04 5 Volt Sensor DC Power Supply short to ground
The alarm output is activated. The code is logged.
112 Troubleshooting Section
Possible Performance Effect:
i01946568
MID 036 - CID 1042 - FMI 09 Unable to communicate with ITSM
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal”
SMCS Code: 1901-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The master Electronic Control Module (ECM) has been powered up for at least five seconds. The Integrated Temperature Sensing Module (ITSM) has sent ten consecutive messages to the master ECM via the CAT Data Link. None of the messages have been received by the master ECM.
i01761095
MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil Pressure short to ground SMCS Code: 1924-038 Conditions Which Generate This Code: The signal to the master Electronic Control Module (ECM) from the sensor for unfiltered engine oil pressure is less than 0.2 VDC for at least five seconds. Also, neither of the following diagnostic codes are active:
• 262 - 03 5 Volt Sensor DC Power Supply short to +batt
• 262 - 04 5 Volt Sensor DC Power Supply short to ground
System Response: The master ECM assumes the last valid value for unfiltered engine oil pressure. Monitoring for restriction of the oil filters is disabled.
Note: This diagnostic code is logged by the master ECM only. This code is not activated or logged by the ITSM. Although there is a failure to communicate with the master ECM, the ITSM may still be able to communicate with the Caterpillar Electronic Technician (ET). System Response: The alarm output is activated. The code is logged. Note: If Cat ET cannot communicate with the ITSM, the values for the ITSM “Status Parameter” will display “Unavailable”. Possible Performance Effect: If the engine is not running, the engine will not start. If the engine is running, the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “CAT Data Link”
The alarm output is activated. The code is logged.
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Analog Sensor Signal” Results:
• OK – STOP.
113 Troubleshooting Section
i01830219
MID 036 - CID 1440 - FMI 09 Unable to communicate with Throttle Actuator Drv SMCS Code: 1716-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has been powered for at least five seconds. Messages on the CAN data link between the master ECM and the throttle actuator have been lost for 0.48 seconds, indicating a short circuit or an open circuit on one of the wires or both of the wires for the CAN data link. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect:
Table 10
X = 3.0 V − [ ( G · 1.75 V ) ÷ 300 CFM ] G is the flow of the fuel in CFM.
System Response: The “Status Parameter” for “Fuel Valve Position” will display “0 %” on the Caterpillar Electronic Technician (ET). The alarm output is activated. The code is logged. Possible Performance Effect: Engine performance is affected. Troubleshooting: Perform the following diagnostic procedure: “Fuel Metering Valve” Results:
• OK – STOP.
If the engine is not running, the engine will not start. If the engine is running, the engine is shut down.
i01761115
Perform the following diagnostic procedure: “Throttle Actuator”
MID 036 - CID 1446 - FMI 09 Unable to communicate with Fuel Metering Module
Results:
SMCS Code: 1741-038
• OK – STOP.
Conditions Which Generate This Code:
Troubleshooting:
i01884041
MID 036 - CID 1446 - FMI 05 Fuel Metering Module open circuit
The master Electronic Control Module (ECM) has been powered up for more than 5 seconds. Ten consecutive messages have been sent from the fuel metering valve to the master ECM via the CAN Data Link. None of the messages have been received by the master ECM.
SMCS Code: 1741-038
System Response:
Conditions Which Generate This Code:
The “Alarm Status” is activated. The “Status Parameter” for “Fuel Valve Position”, “Fuel Pressure (abs)”, “Fuel Valve Differential Pressure”, and “Fuel Temperature” are frozen on the Caterpillar Electronic Technician (ET). The alarm output is activated. The code is logged.
To generate this diagnostic code, all of the following conditions must occur:
• The master Electronic Control Module (ECM) has been powered up for more than 5 seconds.
Possible Performance Effect:
• The battery voltage is greater than 20 VDC.
Engine performance is affected.
• The flow rate of the fuel is less than 8497 L/min
Troubleshooting:
• The voltage of the signal is less than “X” for 5
Perform the following diagnostic procedure: “Fuel Metering Valve”
(300 CFM).
seconds. The calculation for “X” is given in Table 10.
114 Troubleshooting Section
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Fuel Metering Valve” i01761117
MID 036 - CID 1446 - FMI 12 Fuel Metering Module malfunction
Results:
• OK – STOP. i01761123
SMCS Code: 1741-038 Conditions Which Generate This Code: The fuel metering valve sends a signal to the master Electronic Control Module (ECM) via the CAN data link. The signal indicates that there is a problem with the fuel metering valve.
MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor Module malfunction SMCS Code: 1741-038 Conditions Which Generate This Code:
System Response: The code is logged. The shutdown output is activated. Possible Performance Effect: The engine is shut down.
The fuel metering valve sends a signal to the master Electronic Control Module (ECM) via the CAN data link. The signal indicates that there is a problem with the fuel metering valve’s sensor module. System Response:
Troubleshooting:
The code is logged. The shutdown output is activated.
Perform the following diagnostic procedure: “Fuel Metering Valve”
Possible Performance Effect: The engine is shut down.
Results:
Troubleshooting:
• OK – STOP. i01619975
MID 036 - CID 1446 - FMI 13 Fuel Metering Module calibration required SMCS Code: 1741-038 Conditions Which Generate This Code: The “Gas Fuel Properties” have not been programmed for the fuel metering valve. System Response: The code is logged. The alarm output is activated. Possible Performance Effect: The fuel metering valve is shutdown. This prevents the engine from running.
Perform the following diagnostic procedure: “Fuel Metering Valve” Results:
• OK – STOP. i01761169
MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation Sensor open/short to +batt SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 2 and 4 to the master Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds. Neither of the following diagnostic codes are active:
115 Troubleshooting Section
• 0041 - 03 8 Volt DC Supply short to +batt
i01761203
MID 036 - CID 1506 - FMI 03 Cylinder #6 Detonation Sensor open/short to +batt
• 0041 - 04 8 Volt DC Supply short to ground System Response: The shutdown output is activated. The code is logged. Possible Performance Effect:
SMCS Code: 1559-038 Conditions Which Generate This Code:
The engine is shut down.
Perform the following diagnostic procedure: “Detonation Sensors”
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 6 and 8 to the master Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds.
Results:
Neither of the following diagnostic codes are active:
• OK – STOP.
• 0041 - 03 8 Volt DC Supply short to +batt
Troubleshooting:
i01761191
• 0041 - 04 8 Volt DC Supply short to ground
MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation Sensor short to ground
System Response:
SMCS Code: 1559-038
The engine is shut down.
Conditions Which Generate This Code:
Troubleshooting:
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 2 and 4 to the master Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds.
Perform the following diagnostic procedure: “Detonation Sensors”
Neither of the following diagnostic codes are active:
• OK – STOP.
The shutdown output is activated. The code is logged. Possible Performance Effect:
Results:
• 0041 - 03 8 Volt DC Supply short to +batt i01761210
• 0041 - 04 8 Volt DC Supply short to ground
The shutdown output is activated. The code is logged.
MID 036 - CID 1506 - FMI 04 Cylinder #6 Detonation Sensor short to ground
Possible Performance Effect:
SMCS Code: 1559-038
The engine is shut down.
Conditions Which Generate This Code:
Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors”
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 6 and 8 to the master Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds.
Results:
Neither of the following diagnostic codes are active:
• OK – STOP.
• 0041 - 03 8 Volt DC Supply short to +batt
System Response:
• 0041 - 04 8 Volt DC Supply short to ground
116 Troubleshooting Section
System Response:
i01761225
The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation Sensor short to ground SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Detonation Sensors”
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 10 and 12 to the master Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds.
Results:
• OK – STOP.
Neither of the following diagnostic codes are active: i01761217
MID 036 - CID 1510 - FMI 03 Cylinder #10 Detonation Sensor open/short to +batt SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 10 and 12 to the master Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds.
• 0041 - 03 8 Volt DC Supply short to +batt • 0041 - 04 8 Volt DC Supply short to ground System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors”
Neither of the following diagnostic codes are active:
Results:
• 0041 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 0041 - 04 8 Volt DC Supply short to ground i01761236
System Response:
Possible Performance Effect:
MID 036 - CID 1514 - FMI 03 Cylinder #14 Detonation Sensor open/short to +batt
The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Detonation Sensors”
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 14 and 16 to the master Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds.
The shutdown output is activated. The code is logged.
Results:
• OK – STOP.
Neither of the following diagnostic codes are active:
• 0041 - 03 8 Volt DC Supply short to +batt • 0041 - 04 8 Volt DC Supply short to ground
117 Troubleshooting Section
System Response:
i01761250
The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
MID 036 - CID 1518 - FMI 03 Cylinder #18 Detonation Sensor open/short to +batt SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Detonation Sensors”
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 18 and 20 to the master Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds.
Results:
• OK – STOP.
Neither of the following diagnostic codes are active: i01761239
MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation Sensor short to ground
• 0041 - 03 8 Volt DC Supply short to +batt
SMCS Code: 1559-038
The shutdown output is activated. The code is logged.
Conditions Which Generate This Code:
Possible Performance Effect:
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 14 and 16 to the master Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds.
The engine is shut down.
• 0041 - 04 8 Volt DC Supply short to ground System Response:
Troubleshooting:
Neither of the following diagnostic codes are active:
Perform the following diagnostic procedure: “Detonation Sensors”
• 0041 - 03 8 Volt DC Supply short to +batt
Results:
• 0041 - 04 8 Volt DC Supply short to ground
• OK – STOP.
System Response: i01761252
The shutdown output is activated. The code is logged.
The engine is shut down.
MID 036 - CID 1518 - FMI 04 Cylinder #18 Detonation Sensor short to ground
Troubleshooting:
SMCS Code: 1559-038
Perform the following diagnostic procedure: “Detonation Sensors”
Conditions Which Generate This Code:
Possible Performance Effect:
Results:
• OK – STOP.
The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 18 and 20 to the master Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds. Neither of the following diagnostic codes are active:
• 0041 - 03 8 Volt DC Supply short to +batt • 0041 - 04 8 Volt DC Supply short to ground
118 Troubleshooting Section
System Response:
i02088242
The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
MID 036 - CID 1719 - FMI 03 Generator Output Power Sensor open/short to +batt SMCS Code: 5574-038-PWR
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Detonation Sensors”
One of the following conditions has occurred:
Results:
• The load signal from the Electronic Modular Control Panel II+ (EMCP II+) is missing.
• OK – STOP.
• The load signal from the power sensor to the i01796209
MID 036 - CID 1636 - FMI 09 Loss of Communication with Engine #2 (Slave) SMCS Code: 1901-038 Conditions Which Generate This Code: The slave Electronic Control Module (ECM) has sent ten consecutive messages to the master ECM via the Cat data link. None of the messages have been received by the master ECM. Note: Although there is a failure to communicate with the master ECM, the slave ECM may still be able to communicate with the Caterpillar Electronic Technician (ET).
master Electronic Control Module (ECM) is missing.
• The load signal from the power sensor to the master ECM is greater than 4.8 VDC.
System Response: The diagnostic code is logged and the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Generator Output Power Sensor” Results:
• OK – STOP. i02088252
System Response:
The code is logged by the master ECM.
MID 036 - CID 1719 - FMI 04 Generator Output Power Sensor short to ground
Engine ignition is terminated.
SMCS Code: 5574-038-PWR
Note: If Cat ET cannot communicate with the slave ECM, the values will display “Unavailable”.
Conditions Which Generate This Code:
The alarm output is activated.
Possible Performance Effect: The engine is shut down.
This diagnostic code is not applicable to generators that are equipped with the Electronic Modular Control Panel II+ (EMCP II+). Both of the following conditions occur:
Perform the following diagnostic procedure: “Cat Data Link”
• The engine load is greater than 20 percent.
Results:
• The signal from the power sensor to the master
• OK – STOP.
Electronic Control Module (ECM) is less than 0.2 VDC.
119 Troubleshooting Section
System Response:
System Response:
The diagnostic code is logged and the engine is shut down.
The fuel is shut off. The shutdown output is activated. The code is logged.
Troubleshooting:
Possible Performance Effect:
Perform the following diagnostic procedure: “Generator Output Power Sensor”
If the engine is not running, the engine will not start. If the engine is running, the engine is shut down.
Results:
Perform the following diagnostic procedure: “Bypass Valve”
• OK – STOP.
Results: i02088262
MID 036 - CID 1719 - FMI 12 Generator Output Power Sensor malfunction SMCS Code: 5574-038-PWR Conditions Which Generate This Code: This diagnostic code is applicable to generators that are equipped with the Electronic Modular Control Panel II+ (EMCP II+) only. The master Electronic Control Module (ECM) has determined that the load signal from the EMCP II+ may be invalid. System Response: The diagnostic code is logged and the engine is shut down. Troubleshooting:
• OK – STOP. i01760808
MID 036 - CID 1749 - FMI 05 Ignition Transformer Secondary #18 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.
Perform the following diagnostic procedure: “Generator Output Power Sensor”
Troubleshooting:
Results:
One of the following conditions is the source of the diagnostic code:
• OK – STOP.
• A problem with the transformer’s ground i01904169
MID 036 - CID 1720 - FMI 09 Turbocharger Compressor Bypass Valve Actuator not communicating on link SMCS Code: 1052-038-BV Conditions Which Generate This Code: The master Electronic Control Module (ECM) cannot communicate with the actuator for the bypass valve.
• An open circuit within the secondary winding of the transformer
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
• The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
120 Troubleshooting Section
Results:
System Response:
• OK – STOP.
The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged.
i01760946
MID 036 - CID 1749 - FMI 06 Ignition Transformer Secondary #18 short to ground SMCS Code: 1561-038
Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit.
• A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer
System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged.
• A problem with the connection to the spark plug’s terminal post
• The spark plug has internal damage or an open circuit.
Possible Performance Effect: The cylinder will misfire.
• The spark plug gap is too wide.
Troubleshooting:
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”
One of the following conditions is the source of the diagnostic code:
Results:
• A short circuit within the secondary winding of the
• OK – STOP.
transformer
i01760951
• The spark plug is fouled. • The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
MID 036 - CID 1751 - FMI 06 Ignition Transformer Secondary #20 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code:
• OK – STOP. i01760821
MID 036 - CID 1751 - FMI 05 Ignition Transformer Secondary #20 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.
The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.
121 Troubleshooting Section
Troubleshooting:
i01760307
One of the following conditions is the source of the diagnostic code:
• A short circuit within the secondary winding of the transformer
MID 036 - CID 1753 - FMI 06 Ignition Transformer Primary #18 short to ground SMCS Code: 1561-038
• The spark plug is fouled.
Conditions Which Generate This Code:
• The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:
The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged.
• OK – STOP.
Possible Performance Effect: i01760306
MID 036 - CID 1753 - FMI 05 Ignition Transformer Primary #18 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code:
The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer
The primary circuit of the transformer is diagnosed with an open circuit.
• A short circuit within the primary winding of the
System Response:
• An internal failure of the master ECM
The alarm output is activated. The code is logged.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• An open circuit in the wiring from the master
Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
transformer
Results:
• OK – STOP. i01760312
MID 036 - CID 1755 - FMI 05 Ignition Transformer Primary #20 open circuit SMCS Code: 1561-038
• An internal failure of the master ECM
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
The primary circuit of the transformer is diagnosed with an open circuit.
Results:
System Response:
• OK – STOP.
The alarm output is activated. The code is logged.
122 Troubleshooting Section
Possible Performance Effect:
• An internal failure of the master ECM
The cylinder will misfire.
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Troubleshooting: One of the following conditions is the source of the diagnostic code:
Results:
• OK – STOP.
• An open circuit in the wiring from the master
Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the transformer
• An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:
i01636449
MID 111 - CID 0591 - FMI 12 EEPROM checksum fault or ECM not programmed SMCS Code: 1901-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a problem within the EPROM circuit.
• OK – STOP.
System Response: i01760313
MID 036 - CID 1755 - FMI 06 Ignition Transformer Primary #20 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
• A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer
• A short circuit within the primary winding of the transformer
Monitoring of the exhaust temperature is lost. Also, protection against high exhaust temperatures is lost. The alarm output is activated. The code is logged. Troubleshooting: There is a problem with the ITSM. Replace the ITSM. Follow the instructions in Troubleshooting, “Replacing the ITSM”. Results:
• OK – STOP. i01728761
MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out Temp Sens short to +batt SMCS Code: 5574-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the turbocharger.
123 Troubleshooting Section
System Response:
Results:
Monitoring of the temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine.
• OK – STOP.
This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds.
i01728782
MID 111 - CID 1489 - FMI 05 Left Turbo Turbine Out Temp Sens open circuit SMCS Code: 5574-038
Possible Performance Effect:
Conditions Which Generate This Code:
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01728777
MID 111 - CID 1489 - FMI 04 Left Turbo Turbine Out Temp Sens short to ground SMCS Code: 5574-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the turbocharger:
The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger. System Response: Monitoring of the exhaust temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP.
• A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
i01728785
MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out Temp Sens short to +batt SMCS Code: 5574-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the turbocharger. System Response: Monitoring of the temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine.
124 Troubleshooting Section
This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.
i01728794
MID 111 - CID 1490 - FMI 05 Rt Turbo Turbine Out Temp Sens open circuit SMCS Code: 5574-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger.
• OK – STOP.
System Response: i01728791
MID 111 - CID 1490 - FMI 04 Rt Turbo Turbine Out Temp Sens short to ground
Monitoring of the exhaust temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. Possible Performance Effect:
SMCS Code: 5574-038
Engine operation is not affected.
Conditions Which Generate This Code:
Troubleshooting:
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the turbocharger:
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
• A short circuit to the −Battery side • A short circuit to the ground
Results:
• OK – STOP.
System Response: Monitoring of the temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine. Possible Performance Effect: Engine operation is not affected.
i01728795
MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In Temp Sens short to +batt SMCS Code: 5574-038 Conditions Which Generate This Code:
Troubleshooting:
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the turbocharger.
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
System Response:
Results:
• OK – STOP.
Monitoring of the temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine.
125 Troubleshooting Section
This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.
i01728800
MID 111 - CID 1491 - FMI 05 Rt Turbo Turbine In Temp Sens open circuit SMCS Code: 5574-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger.
• OK – STOP.
System Response: i01728797
MID 111 - CID 1491 - FMI 04 Rt Turbo Turbine In Temp Sens short to ground
Monitoring of the exhaust temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. Possible Performance Effect:
SMCS Code: 5574-038
Engine operation is not affected.
Conditions Which Generate This Code:
Troubleshooting:
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the turbocharger:
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
• A short circuit to the −Battery side • A short circuit to the ground
Results:
• OK – STOP.
System Response: Monitoring of the temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine. Possible Performance Effect: Engine operation is not affected.
i01728804
MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In Temp Sens short to +batt SMCS Code: 5574-038 Conditions Which Generate This Code:
Troubleshooting:
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the turbocharger.
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
System Response:
Results:
• OK – STOP.
Monitoring of the temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds.
126 Troubleshooting Section
Possible Performance Effect:
i01728813
MID 111 - CID 1492 - FMI 05 Left Turbo Turbine In Temp Sens open circuit
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
SMCS Code: 5574-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger. i01728806
MID 111 - CID 1492 - FMI 04 Left Turbo Turbine In Temp Sens short to ground
System Response:
SMCS Code: 5574-038
Monitoring of the exhaust temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine.
Conditions Which Generate This Code:
Possible Performance Effect:
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the turbocharger:
Engine operation is not affected.
• A short circuit to the −Battery side
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
• A short circuit to the ground System Response: Monitoring of the temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
Troubleshooting:
Results:
• OK – STOP. i01728819
MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code:
Results:
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
• OK – STOP.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine.
127 Troubleshooting Section
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting:
Results:
• OK – STOP. i01728828
MID 111 - CID 1531 - FMI 05 Cyl #1 Exhaust Port Temp Sensor open circuit SMCS Code: 1919
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code:
Results:
The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
• OK – STOP.
System Response: i01728826
MID 111 - CID 1531 - FMI 04 Cyl #1 Exhaust Port Temp Sensor short to ground
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
SMCS Code: 1919
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.
Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
• A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
The thermocouple is removed from the calculation for the average temperature of the engine.
The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01728833
MID 111 - CID 1532 - FMI 03 Cyl #2 Exhaust Port Temp Sensor short to +batt
Possible Performance Effect:
SMCS Code: 1919
Engine operation is not affected.
Conditions Which Generate This Code:
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
128 Troubleshooting Section
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect:
The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01728837
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
MID 111 - CID 1532 - FMI 05 Cyl #2 Exhaust Port Temp Sensor open circuit SMCS Code: 1919
Results:
Conditions Which Generate This Code:
• OK – STOP. i01728835
MID 111 - CID 1532 - FMI 04 Cyl #2 Exhaust Port Temp Sensor short to ground SMCS Code: 1919
The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Conditions Which Generate This Code:
The thermocouple is removed from the calculation for the average temperature of the engine.
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.
• A short circuit to the −Battery side
The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
• A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Possible Performance Effect: Engine operation is not affected. Troubleshooting:
The thermocouple is removed from the calculation for the average temperature of the engine.
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.
Results:
• OK – STOP.
129 Troubleshooting Section
i01728852
MID 111 - CID 1533 - FMI 03 Cyl #3 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
System Response:
Possible Performance Effect:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Engine operation is not affected.
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01728915
Possible Performance Effect:
MID 111 - CID 1533 - FMI 05 Cyl #3 Exhaust Port Temp Sensor open circuit
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
• OK – STOP. i01728912
MID 111 - CID 1533 - FMI 04 Cyl #3 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
• A short circuit to the −Battery side
Possible Performance Effect:
• A short circuit to the ground
Engine operation is not affected.
130 Troubleshooting Section
Troubleshooting:
i01728923
Results:
MID 111 - CID 1534 - FMI 04 Cyl #4 Exhaust Port Temp Sensor short to ground
• OK – STOP.
SMCS Code: 1919
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code: i01728917
MID 111 - CID 1534 - FMI 03 Cyl #4 Exhaust Port Temp Sensor short to +batt
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
SMCS Code: 1919
• A short circuit to the ground
Conditions Which Generate This Code:
System Response:
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
System Response:
The thermocouple is removed from the calculation for the average temperature of the engine.
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
• A short circuit to the −Battery side
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01728928
Results:
• OK – STOP.
MID 111 - CID 1534 - FMI 05 Cyl #4 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
131 Troubleshooting Section
System Response:
Troubleshooting:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
The thermocouple is removed from the calculation for the average temperature of the engine.
Results:
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect:
• OK – STOP. i01728940
MID 111 - CID 1535 - FMI 04 Cyl #5 Exhaust Port Temp Sensor short to ground SMCS Code: 1919
Engine operation is not affected.
Conditions Which Generate This Code:
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
• A short circuit to the −Battery side
• OK – STOP.
• A short circuit to the ground i01728934
MID 111 - CID 1535 - FMI 03 Cyl #5 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
System Response:
Possible Performance Effect:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Engine operation is not affected.
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP.
132 Troubleshooting Section
i01728953
MID 111 - CID 1535 - FMI 05 Cyl #5 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
System Response:
Possible Performance Effect:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Engine operation is not affected.
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01728968
Possible Performance Effect:
MID 111 - CID 1536 - FMI 04 Cyl #6 Exhaust Port Temp Sensor short to ground
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
• OK – STOP. i01728959
MID 111 - CID 1536 - FMI 03 Cyl #6 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
• A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.
133 Troubleshooting Section
The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
i01728993
Engine operation is not affected.
MID 111 - CID 1537 - FMI 03 Cyl #7 Exhaust Port Temp Sensor short to +batt
Troubleshooting:
SMCS Code: 1919
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code:
Possible Performance Effect:
Results:
• OK – STOP.
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response:
i01728976
MID 111 - CID 1536 - FMI 05 Cyl #6 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect:
System Response:
Engine operation is not affected.
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Troubleshooting:
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01728999
Engine operation is not affected.
MID 111 - CID 1537 - FMI 04 Cyl #7 Exhaust Port Temp Sensor short to ground
Troubleshooting:
SMCS Code: 1919
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code:
Possible Performance Effect:
Results:
• OK – STOP.
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
• A short circuit to the −Battery side • A short circuit to the ground
134 Troubleshooting Section
System Response:
Possible Performance Effect:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Engine operation is not affected.
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01729015
MID 111 - CID 1538 - FMI 03 Cyl #8 Exhaust Port Temp Sensor short to +batt
Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
• OK – STOP. i01729006
MID 111 - CID 1537 - FMI 05 Cyl #7 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
System Response:
Possible Performance Effect:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Engine operation is not affected.
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP.
135 Troubleshooting Section
i01729019
MID 111 - CID 1538 - FMI 04 Cyl #8 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
• A short circuit to the −Battery side
Possible Performance Effect:
• A short circuit to the ground
Engine operation is not affected.
System Response:
Troubleshooting:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
The thermocouple is removed from the calculation for the average temperature of the engine.
Results:
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.
• OK – STOP. i01729257
Possible Performance Effect:
MID 111 - CID 1539 - FMI 03 Cyl #9 Exhaust Port Temp Sensor short to +batt
Engine operation is not affected.
SMCS Code: 1919
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Results:
System Response:
• OK – STOP.
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. i01729025
MID 111 - CID 1538 - FMI 05 Cyl #8 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.
136 Troubleshooting Section
Troubleshooting:
i01729264
Results:
MID 111 - CID 1539 - FMI 05 Cyl #9 Exhaust Port Temp Sensor open circuit
• OK – STOP.
SMCS Code: 1919
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code: i01761374
MID 111 - CID 1539 - FMI 04 Cyl #9 Exhaust Port Temp Sensor short to ground
The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
SMCS Code: 1919
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
• A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
System Response:
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP.
Possible Performance Effect: Engine operation is not affected. Troubleshooting:
i01729267
MID 111 - CID 1540 - FMI 03 Cyl #10 Exhaust Port Temp Sensor short to +batt
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
SMCS Code: 1919
Results:
Conditions Which Generate This Code:
• OK – STOP.
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
137 Troubleshooting Section
System Response:
Possible Performance Effect:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Engine operation is not affected.
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01729271
MID 111 - CID 1540 - FMI 05 Cyl #10 Exhaust Port Temp Sensor open circuit
Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
• OK – STOP. i01729270
MID 111 - CID 1540 - FMI 04 Cyl #10 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
• A short circuit to the −Battery side
Possible Performance Effect:
• A short circuit to the ground
Engine operation is not affected.
System Response:
Troubleshooting:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
The thermocouple is removed from the calculation for the average temperature of the engine.
Results:
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
• OK – STOP.
138 Troubleshooting Section
i01729273
MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
System Response:
Possible Performance Effect:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Engine operation is not affected.
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01729277
Possible Performance Effect:
MID 111 - CID 1541 - FMI 05 Cyl #11 Exhaust Port Temp Sensor open circuit
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
i01729275
MID 111 - CID 1541 - FMI 04 Cyl #11 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
• A short circuit to the ground
Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
• OK – STOP.
• A short circuit to the −Battery side
SMCS Code: 1919
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
139 Troubleshooting Section
Possible Performance Effect:
i01729281
MID 111 - CID 1542 - FMI 04 Cyl #12 Exhaust Port Temp Sensor short to ground
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
SMCS Code: 1919
Results:
Conditions Which Generate This Code:
• OK – STOP.
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. i01729278
MID 111 - CID 1542 - FMI 03 Cyl #12 Exhaust Port Temp Sensor short to +batt
• A short circuit to the −Battery side
SMCS Code: 1919
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
• A short circuit to the ground System Response:
The thermocouple is removed from the calculation for the average temperature of the engine.
System Response:
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
The thermocouple is removed from the calculation for the average temperature of the engine.
Possible Performance Effect:
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP.
Troubleshooting:
i01729284
Results:
MID 111 - CID 1542 - FMI 05 Cyl #12 Exhaust Port Temp Sensor open circuit
• OK – STOP.
SMCS Code: 1919
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
140 Troubleshooting Section
System Response:
Possible Performance Effect:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Engine operation is not affected.
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01729291
MID 111 - CID 1543 - FMI 04 Cyl #13 Exhaust Port Temp Sensor short to ground
Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
• OK – STOP. i01729287
MID 111 - CID 1543 - FMI 03 Cyl #13 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
• A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP.
141 Troubleshooting Section
i01729294
MID 111 - CID 1543 - FMI 05 Cyl #13 Exhaust Port Temp Sensor open circuit SMCS Code: 1919
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
Possible Performance Effect: Engine operation is not affected. Troubleshooting:
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect:
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01729303
MID 111 - CID 1544 - FMI 04 Cyl #14 Exhaust Port Temp Sensor short to ground SMCS Code: 1919
Engine operation is not affected.
Conditions Which Generate This Code:
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
Results:
• A short circuit to the −Battery side
• OK – STOP.
• A short circuit to the ground System Response: i01729297
MID 111 - CID 1544 - FMI 03 Cyl #14 Exhaust Port Temp Sensor short to +batt
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
SMCS Code: 1919
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.
Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
The thermocouple is removed from the calculation for the average temperature of the engine.
The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.
142 Troubleshooting Section
Troubleshooting:
i01729307
Results:
MID 111 - CID 1545 - FMI 03 Cyl #15 Exhaust Port Temp Sensor short to +batt
• OK – STOP.
SMCS Code: 1919
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code: i01729306
MID 111 - CID 1544 - FMI 05 Cyl #14 Exhaust Port Temp Sensor open circuit
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
SMCS Code: 1919
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
System Response:
The thermocouple is removed from the calculation for the average temperature of the engine.
System Response:
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
The thermocouple is removed from the calculation for the average temperature of the engine.
Possible Performance Effect:
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP.
Troubleshooting:
i01729310
Results:
MID 111 - CID 1545 - FMI 04 Cyl #15 Exhaust Port Temp Sensor short to ground
• OK – STOP.
SMCS Code: 1919
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
• A short circuit to the −Battery side • A short circuit to the ground
143 Troubleshooting Section
System Response:
Troubleshooting:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
The thermocouple is removed from the calculation for the average temperature of the engine.
Results:
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect:
• OK – STOP. i01729314
MID 111 - CID 1546 - FMI 03 Cyl #16 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919
Engine operation is not affected.
Conditions Which Generate This Code:
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response:
• OK – STOP.
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. i01729312
MID 111 - CID 1545 - FMI 05 Cyl #15 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code:
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
Possible Performance Effect:
System Response:
Troubleshooting:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
The thermocouple is removed from the calculation for the average temperature of the engine.
Results:
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.
Engine operation is not affected.
• OK – STOP.
144 Troubleshooting Section
i01729316
MID 111 - CID 1546 - FMI 04 Cyl #16 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
• A short circuit to the −Battery side
Possible Performance Effect:
• A short circuit to the ground
Engine operation is not affected.
System Response:
Troubleshooting:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
The thermocouple is removed from the calculation for the average temperature of the engine.
Results:
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.
• OK – STOP. i01761434
Possible Performance Effect:
MID 111 - CID 1547 - FMI 03 Cyl #17 Exhaust Port Temp Sensor short to +batt
Engine operation is not affected.
SMCS Code: 1919-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Results:
System Response:
• OK – STOP.
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. i01729319
MID 111 - CID 1546 - FMI 05 Cyl #16 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
145 Troubleshooting Section
Possible Performance Effect:
i01761455
MID 111 - CID 1547 - FMI 05 Cyl #17 Exhaust Port Temp Sensor open circuit
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
SMCS Code: 1919-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. i01761445
MID 111 - CID 1547 - FMI 04 Cyl #17 Exhaust Port Temp Sensor short to ground SMCS Code: 1919-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
• A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01761436
The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
MID 111 - CID 1548 - FMI 03 Cyl #18 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919-038 Conditions Which Generate This Code:
Results:
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
• OK – STOP.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
146 Troubleshooting Section
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Results:
• OK – STOP.
MID 111 - CID 1548 - FMI 05 Cyl #18 Exhaust Port Temp Sensor open circuit
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
SMCS Code: 1919-038 Conditions Which Generate This Code:
Results:
The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
• OK – STOP. i01761446
MID 111 - CID 1548 - FMI 04 Cyl #18 Exhaust Port Temp Sensor short to ground SMCS Code: 1919-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
• A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Engine operation is not affected.
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
i01761457
Possible Performance Effect:
Possible Performance Effect:
Troubleshooting:
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP.
147 Troubleshooting Section
i01761437
MID 111 - CID 1549 - FMI 03 Cyl #19 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
System Response:
Possible Performance Effect:
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
Engine operation is not affected.
The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01761460
Possible Performance Effect:
MID 111 - CID 1549 - FMI 05 Cyl #19 Exhaust Port Temp Sensor open circuit
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
SMCS Code: 1919-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
• OK – STOP. i01761447
MID 111 - CID 1549 - FMI 04 Cyl #19 Exhaust Port Temp Sensor short to ground SMCS Code: 1919-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.
• A short circuit to the −Battery side
Possible Performance Effect:
• A short circuit to the ground
Engine operation is not affected.
148 Troubleshooting Section
Troubleshooting:
i01761449
Results:
MID 111 - CID 1550 - FMI 04 Cyl #20 Exhaust Port Temp Sensor short to ground
• OK – STOP.
SMCS Code: 1919-038
Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code: i01761438
MID 111 - CID 1550 - FMI 03 Cyl #20 Exhaust Port Temp Sensor short to +batt
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
SMCS Code: 1919-038
• A short circuit to the ground
Conditions Which Generate This Code:
System Response:
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost.
System Response:
The thermocouple is removed from the calculation for the average temperature of the engine.
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)”
• A short circuit to the −Battery side
The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP. i01761461
Results:
• OK – STOP.
MID 111 - CID 1550 - FMI 05 Cyl #20 Exhaust Port Temp Sensor open circuit SMCS Code: 1919-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
149 Troubleshooting Section
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results:
• OK – STOP.
150 Troubleshooting Section
Troubleshooting with an Event Code i02088275
Event Codes SMCS Code: 1901-038 Use this section for the troubleshooting of problems that have generated event codes but do not have active diagnostic codes. When the event code is generated, the event is active. Any generated code becomes logged in the permanent memory of the Electronic Control Module (ECM) that detected the event. Both the master ECM and the slave ECM can indicate active events. The master ECM will diagnose all of the events that are applicable to G3500 engines that have a single ECM. The events that are diagnosed by the slave ECM are a subset of the events that are diagnosed by the master ECM. All of the events that are pertinent to the slave ECM have the same setting conditions and the same conditions for clearing as the master ECM. Event codes alert the operator that an abnormal engine operating condition such as low oil pressure or high coolant temperature has been detected. Events do not indicate problems with the electronic system. Event codes also indicate the nature of the problem. The Caterpillar Electronic Technician (ET) is designed to run on a personal computer. Event codes may be viewed on a personal computer that has the Cat ET software. Illustration 19 represents the operating range of an oil temperature sensor. The diagram is a reference. Do not use the diagram to troubleshoot the oil temperature sensor.
Illustration 19
g00791619
Typical operating range of an oil temperature sensor (1) In these areas, the output voltage of the sensor is too high or too low. The output is outside of the normal range. The electronic problem will generate a diagnostic code. (2) In this area, the oil temperature above 102 °C (216 °F) is higher than normal. The output voltage of the sensor will generate an event code for a warning or a shutdown for high oil temperature. The sensor does not have an electronic problem. (3) This area represents the normal operating temperature for the engine oil. The normal output voltage of the sensor is between 0.2 and 4.1 volts.
The following format is used for event codes:
• “EXXX (X) Description of the code” The “E” means that the code is an event code. The “XXX” represents a numeric identifier for the event code. The fourth “(X)” represents a numeric identifier for the severity of the code. This is followed by a description of the code. Refer to the following example:
• “E004 (3) Engine Overspeed Shutdown” The numbers that indicate the severity of the event code are defined below: Warning (1) – This condition represents a serious problem with engine operation. However, this condition does not require a shutdown. Shutdown (3) – For this condition, the engine is shut down in order to help prevent possible engine damage.
151 Troubleshooting Section
These responses to certain events may be programmed into the ECM. If the responses are programmed, Cat ET can display the event. If the responses are not programmed, the display will not appear. However, the occurrence of any event will cause the event code to be logged in the ECM that detected the event.
Be sure to check the connectors. This is specially true for problems that are intermittent. See Troubleshooting, “Inspecting Electrical Connectors”.
Note: Do not confuse event codes with diagnostic codes. For information on diagnostic codes, see Troubleshooting, “Troubleshooting with a Diagnostic Code”.
Operator Information
Perform the following tasks before you troubleshoot the event code:
• Gather enough information about the complaint in order to describe the symptom(s) adequately.
• Verify that the complaint is not due to normal engine operation.
• Repair all active diagnostic codes. See
Troubleshooting, “Troubleshooting With A Diagnostic Code”.
Troubleshooting For basic troubleshooting of the engine, perform the following steps first in order to diagnose a malfunction.
Narrow the probable cause. Consider the operator information, the conditions of operation, and the history of the engine.
Obtain the following information from the operator:
• The occurrence and the time of the occurrence • Determine the conditions for the occurrence. The
conditions will include the engine rpm and the load.
• Determine if there are any systems that were
installed by the dealer or the customer that could cause the symptom.
• Determine whether any other occurrences happened in addition to the symptom.
Diagnostic Codes and Event Codes Examine the following information regarding any codes:
• The probable cause of the symptom is correlated to the code.
1. Gather information about the complaint from the operator.
• The code was generated when the symptom
2. Verify that the complaint is not due to normal engine operation. Verify that the complaint is not due to error of the operator.
• Codes that are repeatedly logged
3. Perform a visual inspection. Inspect the following items:
• Fuel supply
occurred.
• The complaint is not due to normal engine operation.
Other Symptoms
• Oil level
If other occurrences happened in addition to the symptom, investigate the following conditions:
• Oil supply
• The other occurrences are related to the symptom.
• Wiring
• The symptoms have a probable cause that is
• Connectors 4. Check the diagnostic codes and event codes. Repair any active codes. If these inspections do not reveal any problems, identify the probable causes with the procedures in this manual that best describe the symptoms. Check each probable cause according to the tests that are recommended.
common.
Active Event Codes An active event code represents a problem with engine operation. Correct the problem as soon as possible.
152 Troubleshooting Section
Both the master ECM and the slave ECM can indicate active events. When an event code is active, the “Active Alarm” indicator (“Engine Control Alarm Status” on Cat ET) is activated in order to alert the operator. If the condition that generated the code is momentary, the message disappears. The event code will be logged in the memory of the ECM that detected the event. Active event codes are listed in ascending numerical order on Cat ET. The code with the lowest number is listed first.
Logged Event Codes The master ECM and the slave ECM can log events. When an ECM generates an event code the ECM logs the code in permanent memory. Each ECM has an internal diagnostic clock. Each ECM will record the following information when a code is generated:
• The hour of the first occurrence of the code • The hour of the last occurrence of the code • The number of occurrences of the code This information can be helpful for troubleshooting intermittent problems. Logged codes can also be used to review the performance of the engine.
i01761523
E004 Engine Overspeed Shutdown SMCS Code: 1348-038 Conditions Which Generate This Code: The engine rpm has exceeded the trip point that is programmed into the master Electronic Control Module (ECM) and the delay time has expired. The master ECM has determined that the detected speed is accurate. System Response: The gas shutoff valve and the ignition are shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, “Engine Overspeed”. Results:
• OK – STOP.
A code is cleared from memory when one of the following conditions occur:
i01633543
• The code does not recur for 1000 hours.
E016 High Engine Coolant Temperature Shutdown
• A new code is logged and there are already ten
SMCS Code: 1395-038
• The service technician manually clears the code.
codes in memory. In this case, the oldest code is cleared.
Logged events are listed in chronological order. The most recent event code is listed first. Note: Always clear logged event codes after investigating and correcting the problem which generated the code.
Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine coolant temperature has exceeded the trip point and the delay time has expired. No other codes for the engine coolant are active. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, “Engine Coolant Temperature (High)”.
153 Troubleshooting Section
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Engine Oil Temperature (High)”. i01633545
E017 High Engine Coolant Temperature Warning
Results:
• OK – STOP. i01633605
SMCS Code: 1395-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine coolant temperature has exceeded the trip point and the delay time has expired. No other codes for the engine coolant are active. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the coolant temperature continues to rise, the engine will be shut down. Troubleshooting:
E020 High Engine Oil Temperature Warning SMCS Code: 1348-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine oil temperature has exceeded the trip point and the delay time has expired. No other codes for the engine oil temperature are active. System Response: The alarm output is activated. The code is logged. Possible Performance Effect:
Refer to Troubleshooting, “Engine Coolant Temperature (High)”.
The engine operation is not immediately affected. However, if the engine oil temperature continues to rise, the engine can be shut down.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Engine Oil Temperature (High)”. i01633603
E019 High Engine Oil Temperature Shutdown SMCS Code: 1348-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine oil temperature has exceeded the trip point and the delay time has expired. No other codes for the engine oil temperature are active. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut off.
Results:
• OK – STOP. i01633755
E026 High Inlet Air Temperature Shutdown SMCS Code: 1050-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The inlet air temperature has exceeded the trip point and the delay time has expired. No other codes for the inlet air temperature are active.
154 Troubleshooting Section
System Response:
i01633757
The fuel is shut off. The shutdown output is activated. The code is logged.
E038 Low Engine Coolant Temperature Warning
Possible Performance Effect:
SMCS Code: 1395-038
The engine is shut down.
Conditions Which Generate This Code:
Troubleshooting:
The crank terminate relay is set and the engine has been running for at least 30 seconds. The temperature of the engine coolant is less than the trip point and the delay time has expired. No other codes for the coolant temperature are active.
Refer to Troubleshooting, “Inlet Air Temperature (High)”. Results:
System Response:
• OK – STOP.
The alarm output is activated. The code is logged. i01633756
E027 High Inlet Air Temperature Warning SMCS Code: 1050-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The inlet air temperature has exceeded the trip point and the delay time has expired. No other codes for the inlet air temperature are active.
Possible Performance Effect: The engine operation is not immediately affected. Troubleshooting: Refer to Troubleshooting, “Engine Coolant Temperature (Low)”. Results:
• OK – STOP. i01633762
System Response: The alarm output is activated. The code is logged.
E040 Low Engine Oil Pressure Shutdown
Possible Performance Effect:
SMCS Code: 1348-038-PX
The engine operation is not immediately affected. However, if the inlet air temperature continues to rise, the engine may be shut down.
Conditions Which Generate This Code:
Troubleshooting: Refer to Troubleshooting, “Inlet Air Temperature (High)”. Results:
• OK – STOP.
The crank terminate relay is set and the engine has been running for at least 10 seconds. The engine oil pressure is less than the trip point and the delay time has expired. No codes for the engine oil pressure sensor are active. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, “Engine Oil Pressure (Low)”.
155 Troubleshooting Section
Results:
Results:
• OK – STOP.
• OK – STOP. i01633763
i01877738
E042 Low System Voltage Shutdown
E050 High System Voltage Warning
SMCS Code: 1400-038
SMCS Code: 1400-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The voltage is less than the trip point and the delay time has expired. No other codes for the system voltage are present.
The voltage is greater than the trip point and the delay time has expired. No other codes for the system voltage are present.
System Response:
System Response:
The shutdown output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine is shut down. Troubleshooting:
The engine operation is not immediately affected. However, engine components could be damaged if the system voltage continues to increase.
Refer to Troubleshooting, “System Voltage”.
Troubleshooting:
Results:
Refer to Troubleshooting, “System Voltage”.
• OK – STOP.
Results: i01633765
E043 Low System Voltage Warning
• OK – STOP. i01637578
SMCS Code: 1400-038
E053 Low Fuel Pressure Warning
Conditions Which Generate This Code:
SMCS Code: 1250-038
The voltage is less than the trip point and the delay time has expired. No other codes for the system voltage are present.
Conditions Which Generate This Code:
System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the system voltage continues to be reduced, the engine will be shut down.
The fuel pressure is less than the trip point and the delay time has expired. System Response: The alarm output is activated. The code is logged. Possible Performance Effect:
Troubleshooting:
The engine operation is not immediately affected. However, if the fuel pressure continues to be reduced, the supply may become inadequate for the fuel metering valve.
Refer to Troubleshooting, “System Voltage”.
Troubleshooting: Refer to Troubleshooting, “Fuel Pressure”.
156 Troubleshooting Section
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Engine Oil Pressure (Low)”. i01637590
E096 High Fuel Pressure
Results:
• OK – STOP.
SMCS Code: 1250-038 i01633790
Conditions Which Generate This Code: The fuel pressure is higher than the trip point and the delay time has expired.
E127 Engine Oil Filter Diff Pressure Low Warning
System Response:
SMCS Code: 1308-038
The alarm output is activated. The code is logged.
Conditions Which Generate This Code:
Possible Performance Effect: The engine operation is not immediately affected. However, if the fuel pressure continues to increase, the supply may exceed the maximum limit for the fuel metering valve. Troubleshooting:
The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine oil filter differential pressure is less than the trip point and the delay time has expired. There are no active codes for the oil pressure sensors. System Response: The alarm output is activated. The code is logged.
Refer to Troubleshooting, “Fuel Pressure”.
Possible Performance Effect:
Results:
The engine operation is not immediately affected. However, if the engine oil filter differential pressure continues to be reduced, the engine may be shut down.
• OK – STOP. i01633787
E100 Low Engine Oil Pressure Warning SMCS Code: 1348-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least ten seconds. The engine oil pressure is less than the trip point and the delay time has expired. There are no active codes for the engine oil pressure sensor. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the oil pressure continues to be reduced, the engine may be shut down.
Troubleshooting: Refer to Troubleshooting, “Engine Oil Filter Differential Pressure”. Results:
• OK – STOP. i01633814
E128 Engine Oil Filter Diff Pressure Low Shutdown SMCS Code: 1308-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The oil filter differential pressure is less than the trip point and the delay time has expired. There are no active codes for the oil pressure sensors.
157 Troubleshooting Section
System Response:
i01633832
The fuel is shut off. The shutdown output is activated. The code is logged.
E130 Engine Oil Filter Diff Pressure High Shutdown
Possible Performance Effect:
SMCS Code: 1308-038
The engine is shut down.
Conditions Which Generate This Code:
Troubleshooting:
The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine oil filter differential pressure is greater than the trip point and the delay time has expired. There are no active codes for the oil pressure sensors.
Refer to Troubleshooting, “Engine Oil Filter Differential Pressure”. Results:
System Response:
• OK – STOP. i01633828
The fuel is shut off. The shutdown output is activated. The code is logged.
E129 Engine Oil Filter Diff Pressure High Warning
Possible Performance Effect:
SMCS Code: 1308-038
Troubleshooting:
Conditions Which Generate This Code:
Refer to Troubleshooting, “Engine Oil Filter Differential Pressure”.
The crank terminate relay is set and the engine has been running for at least 30 seconds. The oil filter differential pressure is greater than the trip point and the delay time has expired. There are no active codes for the oil pressure sensors.
The engine is shut down.
Results:
• OK – STOP.
System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the oil filter differential pressure continues to increase, the engine may be shut down.
i01633833
E135 Low Jacket Water Pressure Shutdown SMCS Code: 1350-038 Conditions Which Generate This Code:
Refer to Troubleshooting, “Engine Oil Filter Differential Pressure”.
The crank terminate relay is set and the engine has been running for at least ten seconds. The pressure of the jacket water is less than the trip point and the delay time has expired. There are no active codes for the pressure sensor at the outlet for the jacket water.
Results:
System Response:
• OK – STOP.
The fuel is shut off. The shutdown output is activated. The code is logged.
Troubleshooting:
Possible Performance Effect: The engine is shut off. Troubleshooting: Refer to Troubleshooting, “Jacket Water Pressure (Low)”.
158 Troubleshooting Section
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Jacket Water Inlet Pressure (High)”. i01633954
E223 High Gas Temperature
Results:
• OK – STOP.
SMCS Code: 1250-038 i01633959
Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The temperature of the gas has exceeded the trip point and the delay timer has expired. There are no active codes for the fuel temperature sensor.
E225 Engine Overcrank SMCS Code: 1400-038 Conditions Which Generate This Code:
System Response:
The engine did not start within the programmed parameters for starting.
The alarm output is activated. The code is logged.
System Response:
Possible Performance Effect:
The fuel is shut off. Engine cranking is prevented. The code is logged.
The engine operation is not immediately affected. However, if the fuel temperature continues to increase, the air/fuel ratio and the inlet manifold air temperature can be affected.
Possible Performance Effect: The engine will not start.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Gas Temperature (High)”.
Refer to Troubleshooting, “Engine Overcrank”.
Results:
Results:
• OK – STOP.
• OK – STOP. i01633956
i01761561
E224 High Jacket Water Inlet Pressure
E226 Driven Equipment Not Ready
SMCS Code: 1350-038
SMCS Code: 1404-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The crank terminate relay is set and the engine has been running for at least 10 seconds. The trip point for high pressure at the inlet for the jacket water has been exceeded and the delay time has expired.
The engine is ready to start. However, the master Electronic Control Module (ECM) has received a signal which indicates that the driven equipment is not ready for the engine to start.
System Response:
System Response:
The fuel is shut off. The shutdown output is activated. The code is logged.
The shutdown output is activated. Engine cranking is prevented. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine is shut down.
The engine will not start.
159 Troubleshooting Section
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Driven Equipment”.
Refer to Troubleshooting, “Fuel Energy Content”.
Results:
Results:
• OK – STOP.
• OK – STOP. i01633972
i01746483
E229 Fuel Energy Content Setting Low
E231 Fuel Quality Out of Range
SMCS Code: 1250-038
Conditions Which Generate This Code:
SMCS Code: 1250-038
Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The fuel correction factor is less than the trip point for 20 seconds.
The crank terminate relay is set and the engine has been running for at least 30 seconds. The Low Heat Value (LHV) of the fuel is less than the trip point OR the LHV of the fuel is greater than the trip point for 20 seconds. System Response:
System Response: The alarm output is activated. The code is logged.
The fuel is shut off. The shutdown output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be erratic.
The engine is shut off.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Fuel Energy Content”. Results:
Refer to Troubleshooting, “Fuel Energy Content”. Results:
• OK – STOP.
• OK – STOP. i01633976
E230 Fuel Energy Content Setting High SMCS Code: 1250-038
i01634015
E243 High Left Turbo Turbine Outlet Temperature SMCS Code: 1052-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The crank terminate relay is set and the engine has been running for at least 30 seconds. The fuel correction factor is greater than the trip point for 20 seconds.
The temperature at the outlet for the left turbocharger turbine has exceeded the trip point and the delay time has expired.
System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance may be erratic.
System Response: The following event codes are logged according to the trip points for the temperature:
• E243 (1) High Left Turbo Turbine Outlet Temperature (warning)
• E243 (3) High Left Turbo Turbine Outlet Temperature (shutdown)
160 Troubleshooting Section
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
Troubleshooting: Refer to Troubleshooting, “Turbocharger Turbine Temperature (High)”. Results:
• OK – STOP. i01634041
E245 High Right Turbo Turbine Inlet Temperature SMCS Code: 1052-038
Refer to Troubleshooting, “Turbocharger Turbine Temperature (High)”.
Conditions Which Generate This Code: The temperature at the inlet for the right turbocharger turbine has exceeded the trip point and the delay time has expired.
Results:
• OK – STOP. i01634039
E244 High Right Turbo Turbine Outlet Temperature SMCS Code: 1052-038
System Response: The following event codes are logged according to the trip points for the temperature:
• E245 (1) High Right Turbo Turbine Inlet Temperature (warning)
Conditions Which Generate This Code:
• E245 (3) High Right Turbo Turbine Inlet
The temperature at the outlet for the right turbocharger turbine has exceeded the trip point and the delay time has expired.
If a warning is generated, the alarm output is activated.
System Response: The following event codes are logged according to the trip points for the temperature:
Temperature (shutdown)
If a shutdown is generated, the shutdown output is activated. Possible Performance Effect:
• E244 (1) High Right Turbo Turbine Outlet
If a warning is generated, the engine performance is not immediately affected.
• E244 (3) High Right Turbo Turbine Outlet
The engine will be shut down if the trip point for the shutdown is exceeded.
If a warning is generated, the alarm output is activated.
Troubleshooting:
Temperature (warning)
Temperature (shutdown)
If a shutdown is generated, the shutdown output is activated. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
Refer to Troubleshooting, “Turbocharger Turbine Temperature (High)”. Results:
• OK – STOP.
161 Troubleshooting Section
i01634043
E246 High Left Turbo Turbine Inlet Temperature SMCS Code: 1052-038
System Response: The gas shutoff valve (GSOV) and the ignition are shut off. The shutdown output is activated. The code is logged. Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut off.
The temperature at the inlet for the left turbocharger turbine has exceeded the trip point and the delay time has expired. System Response:
Troubleshooting: Refer to Troubleshooting, “Engine Shutdown”. Results:
The following event codes are logged according to the trip points for the temperature:
• OK – STOP.
• E246 (1) High Left Turbo Turbine Inlet Temperature (warning)
• E246 (3) High Left Turbo Turbine Inlet Temperature (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
i01634063
E268 Unexpected Engine Shutdown SMCS Code: 1400-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine is running. The engine rpm is less than the programmed speed of the postlube cycle for 200 ms. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
Refer to Troubleshooting, “Turbocharger Turbine Temperature (High)”.
Troubleshooting:
Results:
Refer to Troubleshooting, “Engine Shutdown (Unexpected)”.
• OK – STOP.
Results: i01634059
E264 Emergency Stop Activated SMCS Code: 1400-038 Conditions Which Generate This Code: The input for the emergency stop is activated.
• OK – STOP. i01634093
E269 Customer Shutdown Requested SMCS Code: 1400-038 Conditions Which Generate This Code: The engine is either cranking or running. The input for the stop is set for 200 ms.
162 Troubleshooting Section
System Response:
i01864896
The fuel is shut off. The shutdown output is activated. The code is logged.
E337 High Engine Oil to Engine Coolant Diff Temp
Possible Performance Effect:
SMCS Code: 1350-038
The engine is shut off.
Conditions Which Generate This Code:
Troubleshooting:
The crank terminate relay is set and the engine has been running for at least 30 seconds. The differential between the temperature of the engine oil and the temperature of the engine coolant has exceeded the trip point. Also, the delay time has expired. There are no active codes for the sensors for the engine oil temperature and the engine coolant.
Refer to Troubleshooting, “Engine Shutdown”. Results:
• OK – STOP. i01634097
E270 Driven Equipment Shutdown Requested SMCS Code: 1400-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine is running. The input requests a shutdown for 200 ms. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
System Response: The following event codes are logged according to the trip points for the temperature differential:
• E337 (1) High Engine Oil to Engine Coolant Diff Temp (warning)
• E337 (3) High Engine Oil to Engine Coolant Diff Temp (shutdown)
If a warning is activated, the alarm output is activated. If a shutdown is activated, the shutdown output is activated. Possible Performance Effect: If a warning is generated, the engine operation is not immediately affected.
Troubleshooting:
The engine will be shut down if the trip point for the shutdown is exceeded.
Refer to Troubleshooting, “Driven Equipment”.
Troubleshooting:
Results:
Refer to Troubleshooting, “Jacket Water to Engine Oil Differential Temperature (Low)”.
• OK – STOP.
Results:
• OK – STOP.
163 Troubleshooting Section
i01637607
i01637627
E401 Cylinder #1 Detonation
E403 Cylinder #3 Detonation
SMCS Code: 1000-038
SMCS Code: 1000-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Refer to Troubleshooting, “Detonation”.
Results:
Results:
• OK – STOP.
• OK – STOP. i01637623
i01637634
E402 Cylinder #2 Detonation
E404 Cylinder #4 Detonation
SMCS Code: 1000-038
SMCS Code: 1000-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Refer to Troubleshooting, “Detonation”.
Results:
Results:
• OK – STOP.
• OK – STOP.
164 Troubleshooting Section
i01637642
i01637648
E405 Cylinder #5 Detonation
E407 Cylinder #7 Detonation
SMCS Code: 1000-038
SMCS Code: 1000-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Refer to Troubleshooting, “Detonation”.
Results:
Results:
• OK – STOP.
• OK – STOP. i01637646
i01637651
E406 Cylinder #6 Detonation
E408 Cylinder #8 Detonation
SMCS Code: 1000-038
SMCS Code: 1000-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Refer to Troubleshooting, “Detonation”.
Results:
Results:
• OK – STOP.
• OK – STOP.
165 Troubleshooting Section
i01637653
i01637663
E409 Cylinder #9 Detonation
E411 Cylinder #11 Detonation
SMCS Code: 1000-038
SMCS Code: 1000-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Refer to Troubleshooting, “Detonation”.
Results:
Results:
• OK – STOP.
• OK – STOP. i01637657
i01637665
E410 Cylinder #10 Detonation
E412 Cylinder #12 Detonation
SMCS Code: 1000-038
SMCS Code: 1000-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Refer to Troubleshooting, “Detonation”.
Results:
Results:
• OK – STOP.
• OK – STOP.
166 Troubleshooting Section
i01637696
i01637702
E413 Cylinder #13 Detonation
E415 Cylinder #15 Detonation
SMCS Code: 1000-038
SMCS Code: 1000-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Refer to Troubleshooting, “Detonation”.
Results:
Results:
• OK – STOP.
• OK – STOP. i01637699
i01637706
E414 Cylinder #14 Detonation
E416 Cylinder #16 Detonation
SMCS Code: 1000-038
SMCS Code: 1000-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Refer to Troubleshooting, “Detonation”.
Results:
Results:
• OK – STOP.
• OK – STOP.
167 Troubleshooting Section
i01762523
i01762525
E417 Cylinder #17 Detonation
E419 Cylinder #19 Detonation
SMCS Code: 1000-038
SMCS Code: 1000-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Refer to Troubleshooting, “Detonation”.
Results:
Results:
• OK – STOP.
• OK – STOP. i01762524
i01762527
E418 Cylinder #18 Detonation
E420 Cylinder #20 Detonation
SMCS Code: 1000-038
SMCS Code: 1000-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
The engine performance may be affected by an adjustment of the timing in order to reduce detonation.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Refer to Troubleshooting, “Detonation”.
Results:
Results:
• OK – STOP.
• OK – STOP.
168 Troubleshooting Section
i01634664
E421 Cylinder #1 Detonation Shutdown
Results:
• OK – STOP. i01634838
SMCS Code: 1000-038
E423 Cylinder #3 Detonation Shutdown
Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor.
SMCS Code: 1000-038 Conditions Which Generate This Code:
The fuel is shut off. The shutdown output is activated. The code is logged.
The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor.
Possible Performance Effect:
System Response:
The engine is shut down.
The fuel is shut off. The shutdown output is activated. The code is logged.
System Response:
Troubleshooting:
Possible Performance Effect:
Refer to Troubleshooting, “Detonation”.
The engine is shut down.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Detonation”. i01634746
E422 Cylinder #2 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor.
Results:
• OK – STOP. i01635415
E424 Cylinder #4 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code:
The fuel is shut off. The shutdown output is activated. The code is logged.
The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor.
Possible Performance Effect:
System Response:
The engine is shut down.
The fuel is shut off. The shutdown output is activated. The code is logged.
System Response:
Troubleshooting: Refer to Troubleshooting, “Detonation”.
Possible Performance Effect: The engine is shut down.
169 Troubleshooting Section
Troubleshooting:
Possible Performance Effect:
Refer to Troubleshooting, “Detonation”.
The engine is shut down.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Detonation”. i01635416
Results:
E425 Cylinder #5 Detonation Shutdown
• OK – STOP.
SMCS Code: 1000-038
E427 Cylinder #7 Detonation Shutdown
Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect:
i01635420
SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor. System Response:
The engine is shut down.
The fuel is shut off. The shutdown output is activated. The code is logged.
Troubleshooting:
Possible Performance Effect:
Refer to Troubleshooting, “Detonation”.
The engine is shut down.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Detonation”. i01635417
Results:
E426 Cylinder #6 Detonation Shutdown
• OK – STOP.
SMCS Code: 1000-038
E428 Cylinder #8 Detonation Shutdown
Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged.
i01635421
SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor.
170 Troubleshooting Section
System Response:
i01635424
The fuel is shut off. The shutdown output is activated. The code is logged.
E430 Cylinder #10 Detonation Shutdown
Possible Performance Effect:
SMCS Code: 1000-038
The engine is shut down.
Conditions Which Generate This Code:
Troubleshooting:
Results:
The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor.
• OK – STOP.
System Response:
Refer to Troubleshooting, “Detonation”.
i01635423
E429 Cylinder #9 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor.
The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, “Detonation”. Results:
• OK – STOP.
System Response:
i01635428
The fuel is shut off. The shutdown output is activated. The code is logged.
E431 Cylinder #11 Detonation Shutdown
Possible Performance Effect:
SMCS Code: 1000-038
The engine is shut down.
Conditions Which Generate This Code:
Troubleshooting:
Results:
The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor.
• OK – STOP.
System Response:
Refer to Troubleshooting, “Detonation”.
The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, “Detonation”.
171 Troubleshooting Section
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Detonation”. i01635429
Results:
E432 Cylinder #12 Detonation Shutdown
• OK – STOP.
SMCS Code: 1000-038
E434 Cylinder #14 Detonation Shutdown
Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect:
i01635433
SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor. System Response:
The engine is shut down.
The fuel is shut off. The shutdown output is activated. The code is logged.
Troubleshooting:
Possible Performance Effect:
Refer to Troubleshooting, “Detonation”.
The engine is shut down.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Detonation”. i01635431
Results:
E433 Cylinder #13 Detonation Shutdown
• OK – STOP.
SMCS Code: 1000-038
E435 Cylinder #15 Detonation Shutdown
Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
i01635435
SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged.
172 Troubleshooting Section
Possible Performance Effect:
System Response:
The engine is shut down.
The fuel is shut off. The shutdown output is activated. The code is logged.
Troubleshooting:
Possible Performance Effect:
Refer to Troubleshooting, “Detonation”.
The engine is shut down.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Detonation”. i01635436
E436 Cylinder #16 Detonation Shutdown
Results:
• OK – STOP. i01762529
SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor.
E438 Cylinder #18 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code:
The fuel is shut off. The shutdown output is activated. The code is logged.
The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor.
Possible Performance Effect:
System Response:
The engine is shut down.
The fuel is shut off. The shutdown output is activated. The code is logged.
System Response:
Troubleshooting:
Possible Performance Effect:
Refer to Troubleshooting, “Detonation”.
The engine is shut down.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Detonation”. i01762528
E437 Cylinder #17 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor.
Results:
• OK – STOP.
173 Troubleshooting Section
i01762530
E439 Cylinder #19 Detonation Shutdown
Results:
• OK – STOP. i01635494
SMCS Code: 1000-038
E801 Cylinder #1 High Exhaust Port Temp
Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged.
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. System Response:
Possible Performance Effect:
The following event codes are logged according to the trip points for the temperature:
The engine is shut down.
• E801 (1) Cylinder #1 High Exhaust Port Temp (warning)
Troubleshooting:
• E801 (3) Cylinder #1 High Exhaust Port Temp (shutdown)
Refer to Troubleshooting, “Detonation”.
If a warning is generated, the alarm output is activated.
Results:
• OK – STOP.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. i01762532
E440 Cylinder #20 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor. System Response:
Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
The fuel is shut off. The shutdown output is activated. The code is logged.
i01635500
The engine is shut down.
E802 Cylinder #2 High Exhaust Port Temp
Troubleshooting:
SMCS Code: 1059-038
Refer to Troubleshooting, “Detonation”.
Conditions Which Generate This Code:
Possible Performance Effect:
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
174 Troubleshooting Section
System Response: The following event codes are logged according to the trip points for the temperature:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
• E802 (1) Cylinder #2 High Exhaust Port Temp
If a warning is generated, the engine performance is not immediately affected.
• E802 (3) Cylinder #2 High Exhaust Port Temp
The engine will be shut down if the trip point for the shutdown is exceeded.
If a warning is generated, the alarm output is activated.
Troubleshooting:
(warning)
(shutdown)
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP. i01635505
E804 Cylinder #4 High Exhaust Port Temp SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
• OK – STOP.
System Response: i01635503
E803 Cylinder #3 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code:
The following event codes are logged according to the trip points for the temperature:
• E804 (1) Cylinder #4 High Exhaust Port Temp (warning)
• E804 (3) Cylinder #4 High Exhaust Port Temp (shutdown)
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
If a warning is generated, the alarm output is activated.
System Response:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
The following event codes are logged according to the trip points for the temperature:
Possible Performance Effect:
• E803 (1) Cylinder #3 High Exhaust Port Temp
If a warning is generated, the engine performance is not immediately affected.
• E803 (3) Cylinder #3 High Exhaust Port Temp
The engine will be shut down if the trip point for the shutdown is exceeded.
(warning)
(shutdown)
If a warning is generated, the alarm output is activated.
175 Troubleshooting Section
Troubleshooting:
i01635511
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
E806 Cylinder #6 High Exhaust Port Temp
Results:
SMCS Code: 1059-038
• OK – STOP.
Conditions Which Generate This Code: i01635508
E805 Cylinder #5 High Exhaust Port Temp
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. System Response:
SMCS Code: 1059-038
The following event codes are logged according to the trip points for the temperature:
Conditions Which Generate This Code:
• E806 (1) Cylinder #6 High Exhaust Port Temp
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E805 (1) Cylinder #5 High Exhaust Port Temp (warning)
• E805 (3) Cylinder #5 High Exhaust Port Temp (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
(warning)
• E806 (3) Cylinder #6 High Exhaust Port Temp (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
Troubleshooting:
i01635512
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
E807 Cylinder #7 High Exhaust Port Temp
Results:
SMCS Code: 1059-038
• OK – STOP.
Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
176 Troubleshooting Section
• E807 (1) Cylinder #7 High Exhaust Port Temp
Possible Performance Effect:
• E807 (3) Cylinder #7 High Exhaust Port Temp
If a warning is generated, the engine performance is not immediately affected.
(warning)
(shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP. i01635546
E809 Cylinder #9 High Exhaust Port Temp SMCS Code: 1059-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. i01635513
E808 Cylinder #8 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
System Response: The following event codes are logged according to the trip points for the temperature:
• E809 (1) Cylinder #9 High Exhaust Port Temp (warning)
• E809 (3) Cylinder #9 High Exhaust Port Temp (shutdown)
System Response:
If a warning is generated, the alarm output is activated.
The following event codes are logged according to the trip points for the temperature:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
• E808 (1) Cylinder #8 High Exhaust Port Temp
Possible Performance Effect:
• E808 (3) Cylinder #8 High Exhaust Port Temp
If a warning is generated, the engine performance is not immediately affected.
(warning)
(shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
177 Troubleshooting Section
Results:
System Response:
• OK – STOP.
The following event codes are logged according to the trip points for the temperature: i01635549
E810 Cylinder #10 High Exhaust Port Temp
• E811 (1) Cylinder #11 High Exhaust Port Temp (warning)
• E811 (3) Cylinder #11 High Exhaust Port Temp (shutdown)
SMCS Code: 1059-038 Conditions Which Generate This Code:
If a warning is generated, the alarm output is activated.
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
System Response:
Possible Performance Effect:
The following event codes are logged according to the trip points for the temperature:
If a warning is generated, the engine performance is not immediately affected.
• E810 (1) Cylinder #10 High Exhaust Port Temp
The engine will be shut down if the trip point for the shutdown is exceeded.
• E810 (3) Cylinder #10 High Exhaust Port Temp
Troubleshooting:
(warning)
(shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
Possible Performance Effect:
i01635568
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
E812 Cylinder #12 High Exhaust Port Temp SMCS Code: 1059-038
Troubleshooting:
Conditions Which Generate This Code:
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
Results:
System Response:
• OK – STOP.
The following event codes are logged according to the trip points for the temperature: i01635556
E811 Cylinder #11 High Exhaust Port Temp SMCS Code: 1059-038
• E812 (1) Cylinder #12 High Exhaust Port Temp (warning)
• E812 (3) Cylinder #12 High Exhaust Port Temp (shutdown)
Conditions Which Generate This Code:
If a warning is generated, the alarm output is activated.
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
178 Troubleshooting Section
Possible Performance Effect:
Results:
If a warning is generated, the engine performance is not immediately affected.
• OK – STOP.
The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
i01635577
E814 Cylinder #14 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
• OK – STOP. i01635570
E813 Cylinder #13 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E813 (1) Cylinder #13 High Exhaust Port Temp (warning)
• E813 (3) Cylinder #13 High Exhaust Port Temp (shutdown)
If a warning is generated, the alarm output is activated.
System Response: The following event codes are logged according to the trip points for the temperature:
• E814 (1) Cylinder #14 High Exhaust Port Temp (warning)
• E814 (3) Cylinder #14 High Exhaust Port Temp (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
Possible Performance Effect:
Results:
If a warning is generated, the engine performance is not immediately affected.
• OK – STOP.
The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
179 Troubleshooting Section
i01635578
• E816 (1) Cylinder #16 High Exhaust Port Temp (warning)
E815 Cylinder #15 High Exhaust Port Temp
• E816 (3) Cylinder #16 High Exhaust Port Temp (shutdown)
SMCS Code: 1059-038 Conditions Which Generate This Code:
If a warning is generated, the alarm output is activated.
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
System Response:
Possible Performance Effect:
The following event codes are logged according to the trip points for the temperature:
If a warning is generated, the engine performance is not immediately affected.
• E815 (1) Cylinder #15 High Exhaust Port Temp
The engine will be shut down if the trip point for the shutdown is exceeded.
• E815 (3) Cylinder #15 High Exhaust Port Temp
Troubleshooting:
(warning)
(shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
Possible Performance Effect:
i01762533
If a warning is generated, the engine performance is not immediately affected.
E817 Cylinder #17 High Exhaust Port Temp
The engine will be shut down if the trip point for the shutdown is exceeded.
SMCS Code: 1059-038
Troubleshooting:
Conditions Which Generate This Code:
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
Results:
System Response:
• OK – STOP.
The following event codes are logged according to the trip points for the temperature: i01635584
E816 Cylinder #16 High Exhaust Port Temp SMCS Code: 1059-038
• E817 (1) Cylinder #17 High Exhaust Port Temp (warning)
• E817 (3) Cylinder #17 High Exhaust Port Temp (shutdown)
Conditions Which Generate This Code:
If a warning is generated, the alarm output is activated.
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
System Response:
Possible Performance Effect:
The following event codes are logged according to the trip points for the temperature:
If a warning is generated, the engine performance is not immediately affected.
180 Troubleshooting Section
The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
i01762535
E819 Cylinder #19 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
• OK – STOP. i01762534
E818 Cylinder #18 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E818 (1) Cylinder #18 High Exhaust Port Temp (warning)
• E818 (3) Cylinder #18 High Exhaust Port Temp (shutdown)
If a warning is generated, the alarm output is activated.
System Response: The following event codes are logged according to the trip points for the temperature:
• E819 (1) Cylinder #19 High Exhaust Port Temp (warning)
• E819 (3) Cylinder #19 High Exhaust Port Temp (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
Possible Performance Effect:
Results:
If a warning is generated, the engine performance is not immediately affected.
• OK – STOP.
The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
i01762536
E820 Cylinder #20 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
181 Troubleshooting Section
System Response: The following event codes are logged according to the trip points for the temperature:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
• E820 (1) Cylinder #20 High Exhaust Port Temp
If a warning is generated, the engine performance is not immediately affected.
• E820 (3) Cylinder #20 High Exhaust Port Temp
The engine will be shut down if the trip point for the shutdown is exceeded.
If a warning is generated, the alarm output is activated.
Troubleshooting:
(warning)
(shutdown)
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP. i01635593
E822 Cyl #2 Exhaust Port Temp Deviating High SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Results:
• OK – STOP. i01635587
E821 Cyl #1 Exhaust Port Temp Deviating High SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
System Response: The following event codes are logged according to the trip points for the temperature:
• E822 (1) Cyl #2 Exhaust Port Temp Deviating High (warning)
• E822 (3) Cyl #2 Exhaust Port Temp Deviating High (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
• E821 (1) Cyl #1 Exhaust Port Temp Deviating High
If a warning is generated, the engine performance is not immediately affected.
• E821 (3) Cyl #1 Exhaust Port Temp Deviating High
The engine will be shut down if the trip point for the shutdown is exceeded.
(warning)
(shutdown)
If a warning is generated, the alarm output is activated.
182 Troubleshooting Section
Troubleshooting:
i01635604
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
E824 Cyl #4 Exhaust Port Temp Deviating High
Results:
SMCS Code: 1059-038
• OK – STOP.
Conditions Which Generate This Code: i01635600
E823 Cyl #3 Exhaust Port Temp Deviating High SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E823 (1) Cyl #3 Exhaust Port Temp Deviating High (warning)
• E823 (3) Cyl #3 Exhaust Port Temp Deviating High (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E824 (1) Cyl #4 Exhaust Port Temp Deviating High (warning)
• E824 (3) Cyl #4 Exhaust Port Temp Deviating High (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
183 Troubleshooting Section
i01635605
System Response:
E825 Cyl #5 Exhaust Port Temp Deviating High
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E826 (1) Cyl #6 Exhaust Port Temp Deviating High (warning)
Conditions Which Generate This Code:
• E826 (3) Cyl #6 Exhaust Port Temp Deviating High
The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
(shutdown)
If a warning is generated, the alarm output is activated.
System Response:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
The following event codes are logged according to the trip points for the temperature:
Possible Performance Effect:
• E825 (1) Cyl #5 Exhaust Port Temp Deviating High
If a warning is generated, the engine performance is not immediately affected.
• E825 (3) Cyl #5 Exhaust Port Temp Deviating High
The engine will be shut down if the trip point for the shutdown is exceeded.
If a warning is generated, the alarm output is activated.
Troubleshooting:
(warning)
(shutdown)
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
i01635614
E827 Cyl #7 Exhaust Port Temp Deviating High SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Results:
• OK – STOP. i01635612
System Response:
E826 Cyl #6 Exhaust Port Temp Deviating High
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E827 (1) Cyl #7 Exhaust Port Temp Deviating High
Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
(warning)
• E827 (3) Cyl #7 Exhaust Port Temp Deviating High (shutdown)
If a warning is generated, the alarm output is activated.
184 Troubleshooting Section
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP. i01635618
E829 Cyl #9 Exhaust Port Temp Deviating High SMCS Code: 1059-038 Conditions Which Generate This Code:
• OK – STOP. i01635616
E828 Cyl #8 Exhaust Port Temp Deviating High SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E828 (1) Cyl #8 Exhaust Port Temp Deviating High (warning)
The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E829 (1) Cyl #9 Exhaust Port Temp Deviating High (warning)
• E829 (3) Cyl #9 Exhaust Port Temp Deviating High (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
• E828 (3) Cyl #8 Exhaust Port Temp Deviating High
If a warning is generated, the engine performance is not immediately affected.
If a warning is generated, the alarm output is activated.
The engine will be shut down if the trip point for the shutdown is exceeded.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
Troubleshooting:
(shutdown)
Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
185 Troubleshooting Section
i01635634
System Response:
E830 Cyl #10 Exhaust Port Temp Deviating High
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E831 (1) Cyl #11 Exhaust Port Temp Deviating High (warning)
Conditions Which Generate This Code:
• E831 (3) Cyl #11 Exhaust Port Temp Deviating
The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
High (shutdown)
If a warning is generated, the alarm output is activated.
System Response:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
The following event codes are logged according to the trip points for the temperature:
Possible Performance Effect:
• E830 (1) Cyl #10 Exhaust Port Temp Deviating
If a warning is generated, the engine performance is not immediately affected.
• E830 (3) Cyl #10 Exhaust Port Temp Deviating
The engine will be shut down if the trip point for the shutdown is exceeded.
If a warning is generated, the alarm output is activated.
Troubleshooting:
High (warning)
High (shutdown)
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
i01635645
E832 Cyl #12 Exhaust Port Temp Deviating High SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Results:
• OK – STOP. i01635641
System Response:
E831 Cyl #11 Exhaust Port Temp Deviating High
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E832 (1) Cyl #12 Exhaust Port Temp Deviating
Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
High (warning)
• E832 (3) Cyl #12 Exhaust Port Temp Deviating High (shutdown)
If a warning is generated, the alarm output is activated.
186 Troubleshooting Section
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP. i01635656
E834 Cyl #14 Exhaust Port Temp Deviating High SMCS Code: 1059-038 Conditions Which Generate This Code:
• OK – STOP. i01635653
E833 Cyl #13 Exhaust Port Temp Deviating High SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E833 (1) Cyl #13 Exhaust Port Temp Deviating High (warning)
The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E834 (1) Cyl #14 Exhaust Port Temp Deviating High (warning)
• E834 (3) Cyl #14 Exhaust Port Temp Deviating High (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
• E833 (3) Cyl #13 Exhaust Port Temp Deviating
If a warning is generated, the engine performance is not immediately affected.
If a warning is generated, the alarm output is activated.
The engine will be shut down if the trip point for the shutdown is exceeded.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
Troubleshooting:
High (shutdown)
Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
187 Troubleshooting Section
i01635658
System Response:
E835 Cyl #15 Exhaust Port Temp Deviating High
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E836 (1) Cyl #16 Exhaust Port Temp Deviating High (warning)
Conditions Which Generate This Code:
• E836 (3) Cyl #16 Exhaust Port Temp Deviating
The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
High (shutdown)
If a warning is generated, the alarm output is activated.
System Response:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
The following event codes are logged according to the trip points for the temperature:
Possible Performance Effect:
• E835 (1) Cyl #15 Exhaust Port Temp Deviating
If a warning is generated, the engine performance is not immediately affected.
• E835 (3) Cyl #15 Exhaust Port Temp Deviating
The engine will be shut down if the trip point for the shutdown is exceeded.
If a warning is generated, the alarm output is activated.
Troubleshooting:
High (warning)
High (shutdown)
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
i01762537
E837 Cyl #17 Exhaust Port Temp Deviating High SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Results:
• OK – STOP. i01635661
System Response:
E836 Cyl #16 Exhaust Port Temp Deviating High
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E837 (1) Cyl #17 Exhaust Port Temp Deviating
Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
High (warning)
• E837 (3) Cyl #17 Exhaust Port Temp Deviating High (shutdown)
If a warning is generated, the alarm output is activated.
188 Troubleshooting Section
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP. i01762539
E839 Cyl #19 Exhaust Port Temp Deviating High SMCS Code: 1059-038 Conditions Which Generate This Code:
• OK – STOP. i01762538
E838 Cyl #18 Exhaust Port Temp Deviating High SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E838 (1) Cyl #18 Exhaust Port Temp Deviating High (warning)
The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E839 (1) Cyl #19 Exhaust Port Temp Deviating High (warning)
• E839 (3) Cyl #19 Exhaust Port Temp Deviating High (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
• E838 (3) Cyl #18 Exhaust Port Temp Deviating
If a warning is generated, the engine performance is not immediately affected.
If a warning is generated, the alarm output is activated.
The engine will be shut down if the trip point for the shutdown is exceeded.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
Troubleshooting:
High (shutdown)
Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:
• OK – STOP.
189 Troubleshooting Section
i01762540
System Response:
E840 Cyl #20 Exhaust Port Temp Deviating High
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E841 (1) Cyl #1 Exhaust Port Temp Deviating Low (warning)
Conditions Which Generate This Code:
• E841 (3) Cyl #1 Exhaust Port Temp Deviating Low
The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
(shutdown)
If a warning is generated, the alarm output is activated.
System Response:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
The following event codes are logged according to the trip points for the temperature:
Possible Performance Effect:
• E840 (1) Cyl #20 Exhaust Port Temp Deviating
If a warning is generated, the engine performance is not immediately affected.
• E840 (3) Cyl #20 Exhaust Port Temp Deviating
The engine will be shut down if the trip point for the shutdown is exceeded.
If a warning is generated, the alarm output is activated.
Troubleshooting:
High (warning)
High (shutdown)
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP.
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
i01635667
E842 Cyl #2 Exhaust Port Temp Deviating Low SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature (High)”.
Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Results:
• OK – STOP. i01635664
System Response:
E841 Cyl #1 Exhaust Port Temp Deviating Low
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E842 (1) Cyl #2 Exhaust Port Temp Deviating Low
Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
(warning)
• E841 (3) Cyl #2 Exhaust Port Temp Deviating Low (shutdown)
If a warning is generated, the alarm output is activated.
190 Troubleshooting Section
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP. i01635670
E844 Cyl #4 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code:
• OK – STOP. i01635668
E843 Cyl #3 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E843 (1) Cyl #3 Exhaust Port Temp Deviating Low (warning)
The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E844 (1) Cyl #4 Exhaust Port Temp Deviating Low (warning)
• E844 (3) Cyl #4 Exhaust Port Temp Deviating Low (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
• E843 (3) Cyl #3 Exhaust Port Temp Deviating Low
If a warning is generated, the engine performance is not immediately affected.
If a warning is generated, the alarm output is activated.
The engine will be shut down if the trip point for the shutdown is exceeded.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
Troubleshooting:
(shutdown)
Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP.
191 Troubleshooting Section
i01635672
System Response:
E845 Cyl #5 Exhaust Port Temp Deviating Low
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E846 (1) Cyl #6 Exhaust Port Temp Deviating Low (warning)
Conditions Which Generate This Code:
• E846 (3) Cyl #6 Exhaust Port Temp Deviating Low
The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
(shutdown)
If a warning is generated, the alarm output is activated.
System Response:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
The following event codes are logged according to the trip points for the temperature:
Possible Performance Effect:
• E845 (1) Cyl #5 Exhaust Port Temp Deviating Low
If a warning is generated, the engine performance is not immediately affected.
• E845 (3) Cyl #5 Exhaust Port Temp Deviating Low
The engine will be shut down if the trip point for the shutdown is exceeded.
If a warning is generated, the alarm output is activated.
Troubleshooting:
(warning)
(shutdown)
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP.
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
i01635677
E847 Cyl #7 Exhaust Port Temp Deviating Low SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”.
Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Results:
• OK – STOP. i01635673
System Response:
E846 Cyl #6 Exhaust Port Temp Deviating Low
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E847 (1) Cyl #7 Exhaust Port Temp Deviating Low
Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
(warning)
• E847 (3) Cyl #7 Exhaust Port Temp Deviating Low (shutdown)
If a warning is generated, the alarm output is activated.
192 Troubleshooting Section
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP. i01635683
E849 Cyl #9 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code:
• OK – STOP. i01635680
E848 Cyl #8 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E848 (1) Cyl #8 Exhaust Port Temp Deviating Low (warning)
The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E849 (1) Cyl #9 Exhaust Port Temp Deviating Low (warning)
• E849 (3) Cyl #9 Exhaust Port Temp Deviating Low (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
• E848 (3) Cyl #8 Exhaust Port Temp Deviating Low
If a warning is generated, the engine performance is not immediately affected.
If a warning is generated, the alarm output is activated.
The engine will be shut down if the trip point for the shutdown is exceeded.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
Troubleshooting:
(shutdown)
Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP.
193 Troubleshooting Section
i01635684
System Response:
E850 Cyl #10 Exhaust Port Temp Deviating Low
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E851 (1) Cyl #11 Exhaust Port Temp Deviating Low (warning)
Conditions Which Generate This Code:
• E851 (3) Cyl #11 Exhaust Port Temp Deviating
The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Low (shutdown)
If a warning is generated, the alarm output is activated.
System Response:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
The following event codes are logged according to the trip points for the temperature:
Possible Performance Effect:
• E850 (1) Cyl #10 Exhaust Port Temp Deviating
If a warning is generated, the engine performance is not immediately affected.
• E850 (3) Cyl #10 Exhaust Port Temp Deviating
The engine will be shut down if the trip point for the shutdown is exceeded.
If a warning is generated, the alarm output is activated.
Troubleshooting:
Low (warning)
Low (shutdown)
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP.
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
i01635688
E852 Cyl #12 Exhaust Port Temp Deviating Low SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”.
Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Results:
• OK – STOP. i01635685
System Response:
E851 Cyl #11 Exhaust Port Temp Deviating Low
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E852 (1) Cyl #12 Exhaust Port Temp Deviating
Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Low (warning)
• E852 (3) Cyl #12 Exhaust Port Temp Deviating Low (shutdown)
If a warning is generated, the alarm output is activated.
194 Troubleshooting Section
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP. i01635692
E854 Cyl #14 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code:
• OK – STOP. i01635691
E853 Cyl #13 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E853 (1) Cyl #13 Exhaust Port Temp Deviating Low (warning)
The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E854 (1) Cyl #14 Exhaust Port Temp Deviating Low (warning)
• E854 (3) Cyl #14 Exhaust Port Temp Deviating Low (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
• E853 (3) Cyl #13 Exhaust Port Temp Deviating
If a warning is generated, the engine performance is not immediately affected.
If a warning is generated, the alarm output is activated.
The engine will be shut down if the trip point for the shutdown is exceeded.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
Troubleshooting:
Low (shutdown)
Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP.
195 Troubleshooting Section
i01635694
System Response:
E855 Cyl #15 Exhaust Port Temp Deviating Low
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E856 (1) Cyl #16 Exhaust Port Temp Deviating Low (warning)
Conditions Which Generate This Code:
• E856 (3) Cyl #16 Exhaust Port Temp Deviating
The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Low (shutdown)
If a warning is generated, the alarm output is activated.
System Response:
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
The following event codes are logged according to the trip points for the temperature:
Possible Performance Effect:
• E855 (1) Cyl #15 Exhaust Port Temp Deviating
If a warning is generated, the engine performance is not immediately affected.
• E855 (3) Cyl #15 Exhaust Port Temp Deviating
The engine will be shut down if the trip point for the shutdown is exceeded.
If a warning is generated, the alarm output is activated.
Troubleshooting:
Low (warning)
Low (shutdown)
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP.
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
i01762541
E857 Cyl #17 Exhaust Port Temp Deviating Low SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”.
Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Results:
• OK – STOP. i01635695
System Response:
E856 Cyl #16 Exhaust Port Temp Deviating Low
The following event codes are logged according to the trip points for the temperature:
SMCS Code: 1059-038
• E857 (1) Cyl #17 Exhaust Port Temp Deviating
Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
Low (warning)
• E857 (3) Cyl #17 Exhaust Port Temp Deviating Low (shutdown)
If a warning is generated, the alarm output is activated.
196 Troubleshooting Section
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP. i01762545
E859 Cyl #19 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code:
• OK – STOP. i01762544
E858 Cyl #18 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E858 (1) Cyl #18 Exhaust Port Temp Deviating Low (warning)
The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
• E859 (1) Cyl #19 Exhaust Port Temp Deviating Low (warning)
• E859 (3) Cyl #19 Exhaust Port Temp Deviating Low (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
• E858 (3) Cyl #18 Exhaust Port Temp Deviating
If a warning is generated, the engine performance is not immediately affected.
If a warning is generated, the alarm output is activated.
The engine will be shut down if the trip point for the shutdown is exceeded.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
Troubleshooting:
Low (shutdown)
Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
• OK – STOP.
197 Troubleshooting Section
i01762546
E860 Cyl #20 Exhaust Port Temp Deviating Low SMCS Code: 1059-038
System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance is not immediately affected.
Conditions Which Generate This Code:
Troubleshooting:
The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response:
Refer to Troubleshooting, “Gas Fuel Differential Pressure (Low)”. Results:
• OK – STOP.
The following event codes are logged according to the trip points for the temperature:
• E860 (1) Cyl #20 Exhaust Port Temp Deviating Low (warning)
• E860 (3) Cyl #20 Exhaust Port Temp Deviating Low (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
i01637716
E865 High Gas Fuel Differential Pressure SMCS Code: 1250-038 Conditions Which Generate This Code: The Gas Shutoff Valve (GSOV) is energized. The difference in fuel pressure between the inlet and the outlet of the fuel metering valve is greater than the trip point. The delay time has expired. System Response:
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance is not immediately affected. Troubleshooting:
Refer to Troubleshooting, “Exhaust Port Temperature (Low)”. Results:
Refer to Troubleshooting, “Gas Fuel Differential Pressure (High)”. Results:
• OK – STOP.
• OK – STOP. i01637712
E864 Low Gas Fuel Differential Pressure SMCS Code: 1250-038 Conditions Which Generate This Code: The gas shutoff valve (GSOV) is energized. The difference in fuel pressure between the outlet and the inlet of the fuel metering valve is less than the trip point. The delay time has expired.
i01637720
E866 Low Gas Fuel Flow Rate SMCS Code: 1250-038 Conditions Which Generate This Code: The fuel metering valve is fully open. However, the flow rate that is computed by the valve does not match the fuel demand for a delay time of 5 seconds.
198 Troubleshooting Section
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance is not immediately affected.
The engine performance is not immediately affected.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Gas Fuel Flow Rate (Low)”.
Refer to Troubleshooting, “Fuel Metering Valve”.
Results:
Results:
• OK – STOP.
• OK – STOP. i01761860
E867 Improper Gas Flow Control Valve Response SMCS Code: 1741-038 Conditions Which Generate This Code: The fuel metering valve is not responding correctly to the master Electronic Control Module (ECM) and the delay time has expired. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance is not immediately affected. Troubleshooting: Refer to Troubleshooting, “Fuel Metering Valve”. Results:
• OK – STOP. i01761863
E868 Gas Flow Control Valve Malfunction SMCS Code: 1741-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has detected a malfunction for the fuel metering valve and the delay time has expired.
199 Troubleshooting Section
Diagnostic Functional Tests
A “5 Volt Sensor DC Power Supply short to ground” diagnostic code will be activated if both of these conditions occur: i02088364
+5V Sensor Voltage Supply SMCS Code: 5574-038 System Operation Description: The master Electronic Control Module (ECM) supplies 5.0 ± 0.5 VDC to the sensors for these parameters:
• Inlet air temperature • Engine oil temperature • Unfiltered engine oil pressure • Filtered engine oil pressure Terminals J1-2 and J1-18 are connected together inside the master ECM. A short circuit on one of these terminals will cause a short circuit on the other terminal. A “+5 V sensor supply” diagnostic code is probably caused by a short circuit or an open circuit in a harness. The next likely cause is a sensor problem. The least likely cause is a problem with the master ECM. Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved. “DESIRED SPEED” Potentiometer (if equipped) The master ECM also provides 5.0 ± 0.5 VDC to the “DESIRED SPEED” potentiometer (if equipped). A “5 Volt Sensor DC Power Supply short to +batt” diagnostic code will be activated if both of these conditions occur:
• The desired speed signal wire is shorted to a voltage source that is greater than +5 volts.
• The “DESIRED SPEED” potentiometer is near
the maximum desired speed or at the maximum desired speed.
• The desired speed signal wire is shorted to ground. • The “DESIRED SPEED” potentiometer is near
the maximum desired speed or at the maximum desired speed.
200 Troubleshooting Section
Illustration 20 Schematic for the 5 V supply
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201 Troubleshooting Section
Test Step 1. Inspect the Electrical Connectors and Wiring
• J1/P1 connectors • J6/P6, and J7/P7 connectors a. Check the torque of the allen head screws for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 21
g01054206
Junction box (1) 35 amp circuit breaker
Illustration 23
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
Illustration 22
Harness side of the P1 connector (P1-2) 5 volt supply (P1-3) Return (P1-14) Signal for the inlet manifold air temperature (P1-16) Signal for the desired speed (P1-17) Signal for the engine oil temperature (P1-18) 5 volt supply (P1-24) Signal for the filtered engine oil pressure (P1-26) Signal for the unfiltered engine oil pressure (P1-35) Return
g01065031
Terminal box (2) J1/P1 connectors for the master ECM (3) J6/P6 connectors for the customer (4) J7/P7 connectors for the harness from the 5 volt sensors
B. Thoroughly inspect each of the following connectors:
g01053671
Illustration 24 Harness side of the J6 connector (J6-5) 5 volt supply (J6-15) Return (J6-25) Signal for desired speed (J6-35) Shield
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202 Troubleshooting Section
Illustration 26
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Right side view (5) Engine oil temperature sensor (6) Unfiltered oil pressure sensor (7) Filtered oil pressure sensor Illustration 25
g00929117
Harness side of the J7 connector (J7-3) Signal for the inlet manifold air temperature (J7-4) Signal for the filtered engine oil pressure (J7-5) Signal for the engine oil temperature (J7-6) Signal for the unfiltered engine oil pressure (J7-17) Return for the inlet manifold air temperature (J7-18) Return for the filtered engine oil pressure (J7-19) Return for the engine oil temperature (J7-20) Return for the unfiltered engine oil pressure (J7-31) Shield for the inlet manifold air temperature (J7-32) Shield for the filtered engine oil pressure (J7-33) Shield for the engine oil temperature (J7-34) Shield for the unfiltered engine oil pressure (J7-45) 5 volt supply for the inlet manifold air temperature (J7-46) 5 volt supply for the filtered engine oil pressure (J7-47) 5 volt supply for the engine oil temperature (J7-48) 5 volt supply for the unfiltered engine oil pressure
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the 5 V sensors. Illustration 27
g01065033
Top view (8) Inlet air temperature sensor
d. Check the harness and wiring for corrosion, abrasion and pinch points from the 5 volt sensors to the master ECM. Expected Result: All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.
203 Troubleshooting Section
Results:
• OK – All connectors, pins, and sockets are
connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. The components are in good condition with proper connections. Proceed to Test Step 2.
• Not OK – At least one of the connectors, pins, or sockets are not connected properly. At least one of the connectors and the wiring has corrosion, abrasion, and/or pinch points. Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Repair: There may be a problem with the wiring and/or a connector. Refer to Troubleshooting, “Inspecting Electrical Connectors”. Verify that the wiring and/or connectors are OK. Check for diagnostic codes again. Proceed to Test Step 3, if necessary.
Test Step 3. Check the Analog Speed Circuit Note: If the engine is not equipped with a “DESIRED SPEED” potentiometer, proceed to Test Step 9. A. Rotate the “DESIRED SPEED” potentiometer (if equipped) clockwise to the maximum speed position.
Test Step 2. Check for Diagnostic Codes
Expected Result:
A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”.
The 262-03 code or the 262-04 code is not active.
B. Rotate the “DESIRED SPEED” potentiometer (if equipped) counterclockwise to the minimum speed position.
• No codes – Rotating the “DESIRED SPEED”
C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. D. Observe the “Active Diagnostic” screen on Cat ET. Wait at least 30 seconds so that any codes may become activated. Look for these codes:
• 262-03 5 Volt Sensor DC Power Supply short to +batt
• 262-04 5 Volt Sensor DC Power Supply short to ground
E. Observe the “Logged Diagnostic” screen on Cat ET. Look for the same codes.
Results: potentiometer clockwise to the maximum speed position did not cause an active code. The +5 V sensor voltage supply is operating correctly at this time. Resume normal operation. STOP.
• Active code – Rotating the “DESIRED SPEED”
potentiometer clockwise to the maximum speed position caused an active code. There is a problem with the analog speed circuit. Proceed to Test Step 4.
Test Step 4. Check the Wiring for the “DESIRED SPEED” Potentiometer A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
Expected Result:
B. Label the wiring that is connected to the “DESIRED SPEED” potentiometer. Disconnect the wiring from the “DESIRED SPEED” potentiometer.
The 262-03 code or the 262-04 code is not active or logged.
C. Disconnect the P1 connector from the master ECM.
Results:
D. Measure the resistance between terminals P1-16 and P1-69.
• No codes – There are no active codes or logged codes. Proceed to Test Step 3.
• Active code – The 262-03 code or the 262-04 code is active. Proceed to Test Step 5.
• Logged code – The 262-03 code or the 262-04
code is not active. However, there is at least one logged code for the 5 volt sensor supply.
Expected Result: The resistance is greater than 20,000 Ohms. Results:
• OK – The resistance is greater than 20,000
Ohms. The wiring for the “DESIRED SPEED” potentiometer appears to be OK.
204 Troubleshooting Section
Repair: The “DESIRED SPEED” potentiometer may have a problem. Perform the following procedure: 1. Check the “DESIRED SPEED” potentiometer in order to ensure that the potentiometer does not have an internal short circuit. Replace the “DESIRED SPEED” potentiometer, if necessary. Continue with this procedure when the “DESIRED SPEED” potentiometer is operating correctly. 2. Reconnect the wiring to the “DESIRED SPEED” potentiometer. Be sure to connect the wires to the appropriate terminals. 3. Reconnect the P1 connector to the master ECM. 4. Perform this entire procedure again. Verify that the original problem is resolved. STOP.
• Not OK – The resistance is less than 20,000
Ohms. There is a problem with the wiring for the “DESIRED SPEED” potentiometer. The problem could be between the P1 connector and the J6 connector. Alternatively, the problem could be in the P6 connector or the wiring that is connected to the P6 connector. Repair: Perform any necessary repairs or replace parts, if necessary. STOP.
Results:
• No codes – The 262-03 code or the 262-04 code is not active. Disconnecting all of the +5 V wiring from the master ECM eliminated the active “5 Volt Sensor Supply” diagnostic code. There is a problem with a connector and/or the wiring in a harness. Proceed to Test Step 6.
• Active code – The 262-03 code or the 262-04
code is active. Disconnecting all of the 5 volt wiring from the master ECM did not eliminate the active “5 Volt Sensor Supply” diagnostic code. There may be a problem with the master ECM. Repair: It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
Test Step 6. Connect the 5 Volt Wiring for the Analog Speed Circuit to the Master ECM
Test Step 5. Isolate the Wiring Harnesses from the Master ECM
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
B. Insert terminal P1-18 into the P1 connector. Pull on the wire in order to verify that the terminal is fully inserted into the connector.
B. Reconnect the P1 connector to the master ECM. C. Use a 151-6320 Wire Removal Tool to remove terminals P1-2 and P1-18. This will disconnect all of the +5 V wiring from the master ECM. D. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
C. Rotate the “DESIRED SPEED” potentiometer clockwise to the maximum speed position. D. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. E. Use Cat ET to look for diagnostic codes.
E. Use Cat ET to look for diagnostic codes.
Expected Result:
Expected Result:
No active codes
No active codes
205 Troubleshooting Section
Results:
• Unfiltered engine oil pressure
• No codes – The 262-03 code or the 262-04 code
• Filtered engine oil pressure
is not active. Connecting the wiring for the analog speed circuit to the master ECM did not cause a diagnostic code. The wiring for the analog speed circuit appears to be OK. Proceed to Test Step 7.
• Active codes – The 262-03 code or the 262-04
code is active. Connecting the wiring for the analog speed circuit to the master ECM caused a diagnostic code. Proceed to Test Step 4.
Test Step 7. Connect the 5 Volt Wiring for the Sensors to the Master ECM A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Insert terminal P1-2 into the P1 connector. Pull on the wire in order to verify that the terminal is fully inserted into the connector. C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. D. Use Cat ET to look for diagnostic codes.
C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Note: An “Open Circuit” code will be generated for each sensor that is disconnected. This is normal. Clear the codes after you complete this procedure. D. Observe the “Active Diagnostic” screen on Cat ET. Verify that the 262-03 code or the 262-04 code is not active. E. Reconnect the sensors for the following parameters one at a time. After you reconnect each sensor, wait for at least 30 seconds and then observe the “Active Diagnostic” screen on Cat ET.
• Inlet air temperature • Engine oil temperature • Unfiltered engine oil pressure • Filtered engine oil pressure
Expected Result:
Expected Result:
No active codes
The original “5 Volt Sensor” diagnostic code is activated when a particular sensor is disconnected.
Results:
• No codes – The 262-03 code or the 262-04 code
is not active. Connecting the 5 VDC for the sensors did not cause a diagnostic code. The problem appears to be resolved. Repair: The initial diagnostic code was probably caused by a poor electrical connection. Resume normal operation. STOP.
• Active code – The 262-03 code or the 262-04 code is active. Connecting the 5 VDC for the sensors caused a diagnostic code. Proceed to Test Step 8.
Test Step 8. Disconnect the 5 Volt Sensors and Look For Active Diagnostic Codes. A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the sensors for the following parameters:
• Inlet air temperature • Engine oil temperature
Results:
• Yes – The original “5 Volt Sensor” diagnostic
code is activated when a particular sensor is reconnected. The sensor and/or the wiring for the sensor has a short circuit. Repair: Perform the following procedure: 1. Set the engine control to the OFF/RESET mode. 2. Disconnect the suspect sensor. 3. Set the engine control to the STOP mode. Use Cat ET to clear the logged 262-03 or 262-04 code. 4. Reconnect the suspect sensor. Verify that the diagnostic code recurs. If these conditions are true, replace the sensor. 5. Clear all of the diagnostic codes. Verify that the problem is eliminated. STOP.
206 Troubleshooting Section
• No – The original “5 Volt Sensor” diagnostic code was still active while all of the 5 volt sensors were disconnected. Do not reconnect the sensors. Proceed to Test Step 9.
Test Step 9. Check the Harnesses A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the P1 connector. Verify that all of the sensors for the following parameters are disconnected from the engine harness:
• Inlet air temperature • Engine oil temperature • Unfiltered engine oil pressure • Filtered engine oil pressure C. Measure the resistance between terminal P1-2 and the points that are listed in Table 11. During each measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors for the disconnected sensors. Also, wiggle the harness at the P7 connector.
Results:
• OK – Each check of the resistance is greater
than 20,000 Ohms. The 5 volt wires in the engine harnesses do not have a problem. The problem appears to be resolved. The initial diagnostic code was probably caused by a poor electrical connection. Repair: Reconnect all of the connectors. Resume normal operation. STOP.
• Not OK – At least one check of the resistance is
less than 20,000 Ohms. There is a problem with a connector and/or at least one of the 5 volt wires in a harness. Repair: The problem may be between the P1 connector and the P7 connector. Alternatively, the problem may be in the engine harness that is connected to the J7 connector. Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved. STOP. i02088517
Table 11
Measure the Resistance for the Engine Harness. Connector and Terminal P1-2 5 volt supply
Connector and Terminal P1-14 (inlet air temperature) P1-17 (engine oil temperature) P1-26 (unfiltered engine oil pressure) P1-24 (filtered engine oil pressure) P1-3 (analog return)
+8V Sensor Voltage Supply SMCS Code: 5574-038 System Operation Description: The master Electronic Control Module (ECM) supplies 8.0 ± 0.8 VDC to these sensors:
• Sensor for engine coolant pressure (outlet)
Ground strap for the engine
• Sensor for inlet air pressure
P1-69 (−Battery terminal)
• The detonation sensors for the left side of the
P1-57 (unswitched +Battery) P1-70 (switched +Battery)
Expected Result: Each check of the resistance is greater than 20,000 Ohms.
engine
Terminals J1-4 and J2-56 are connected together inside the master ECM. A short circuit on one of these terminals will cause a short circuit on the other terminal. The slave ECM supplies 8.0 ± 0.8 VDC to the detonation sensors for the right side of the engine. A “+8 V sensor supply” diagnostic code is probably caused by a short circuit or an open circuit in a harness. The next likely cause is a sensor problem. The least likely cause is a problem with an ECM.
207 Troubleshooting Section
Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
208 Troubleshooting Section
Illustration 28
g01065067
209 Troubleshooting Section
Schematic for the 8 V supply
Test Step 1. Inspect the Electrical Connectors and Wiring
B. Thoroughly inspect each of the following connectors:
• J1/P1 and J2/P2 connectors for the master ECM • J4/P4 connectors for the slave ECM • J7/P7 and J8/P8 connectors on the terminal box a. Check the torque of the allen head screws for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 29
g01054206
Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
Illustration 31 Harness side of the P1 connector (P1-4) 8 volt supply for the pressure sensors (P1-5) Return for the pressure sensors (P1-10) Signal for the inlet air pressure
Illustration 30
g01065068
Terminal box (2) J2/P2 connectors for the master ECM (3) J1/P1 connectors for the master ECM (4) J7/P7 connectors for the harness from the 8 volt sensors (5) J8/P8 connectors for the detonation sensors (6) J4/P4 connectors for the slave ECM
g01065914
210 Troubleshooting Section
Illustration 32
g01065070
Harness side of the P2 connector (P2-36) (P2-37) (P2-38) (P2-39) (P2-44) (P2-54) (P2-55) (P2-56) (P2-57) (P2-68)
Detonation sensor signal for cylinders 2 and 4 Detonation sensor signal for cylinders 6 and 8 Detonation sensor signal for cylinders 10 and 12 Detonation sensor signal for cylinders 14 and 16 Detonation sensor signal for cylinders 18 and 20 Return for the detonation sensors Return for the detonation sensors 8 volt supply for the detonation sensors 8 volt supply for the detonation sensors Signal for the engine coolant pressure
Illustration 34 Harness side of the J7 connector (J7-1) Signal for the inlet air pressure (J7-2) Signal for the engine coolant pressure (J7-15) Return for the inlet air pressure (J7-16) Return for the engine coolant pressure (J7-29) Shield for the inlet air pressure (J7-30) Shield for the engine coolant pressure (J7-43) 8 volt supply for the inlet air pressure (J7-44) 8 volt supply for the engine coolant pressure
Illustration 33
g01065071
Harness side of the P4 connector (P4-36) (P4-37) (P4-38) (P4-39) (P4-44) (P4-54) (P4-55) (P4-56) (P4-57)
Detonation sensor signal for cylinders 1 and 3 Detonation sensor signal for cylinders 5 and 7 Detonation sensor signal for cylinders 9 and 11 Detonation sensor signal for cylinders 13 and 15 Detonation sensor signal for cylinders 17 and 19 Return for the detonation sensors Return for the detonation sensors 8 volt supply for the detonation sensors 8 volt supply for the detonation sensors
g00929364
211 Troubleshooting Section
Illustration 36
g01065072
Top view (7) Engine coolant pressure sensor (8) Inlet air pressure sensor
Illustration 35
g00929380
Harness side of the J8 connector (J8-1) 8 V Supply for the detonation sensor for cylinders 2 and 4 (J8-2) 8 V Supply for the detonation sensor for cylinders 6 and 8 (J8-3) 8 V Supply for the detonation sensor for cylinders 10 and 12 (J8-4) 8 V Supply for the detonation sensor for cylinders 14 and 16 (J8-5) 8 V Supply for the detonation sensor for cylinders 18 and 20 (J8-6) 8 V Supply for the detonation sensor for cylinders 1 and 3 (J8-7) 8 V Supply for the detonation sensor for cylinders 5 and 7 (J8-8) 8 V Supply for the detonation sensor for cylinders 9 and 11 (J8-9) 8 V Supply for the detonation sensor for cylinders 13 and 15 (J8-10) 8 V Supply for the detonation sensor for cylinders 17 and 19 (J8-11) Return for the detonation sensor for cylinders 2 and 4 (J8-12) Return for the detonation sensor for cylinders 6 and 8 (J8-13) Return for the detonation sensor for cylinders 10 and 12 (J8-14) Return for the detonation sensor for cylinders 14 and 16 (J8-15) Return for the detonation sensor for cylinders 18 and 20 (J8-16) Return for the detonation sensor for cylinders 1 and 3 (J8-17) Return for the detonation sensor for cylinders 5 and 7 (J8-18) Return for the detonation sensor for cylinders 9 and 11 (J8-19) Return for the detonation sensor for cylinders 13 and 15 (J8-20) Return for the detonation sensor for cylinders 17 and 19 (J8-21) Signal from the detonation sensor for cylinders 2 and 4 (J8-22) Signal from the detonation sensor for cylinders 6 and 8 (J8-23) Signal from the detonation sensor for cylinders 10 and 12 (J8-24) Signal from the detonation sensor for cylinders 14 and 16 (J8-25) Signal from the detonation sensor for cylinders 18 and 20 (J8-26) Signal from the detonation sensor for cylinders 1 and 3 (J8-27) Signal from the detonation sensor for cylinders 5 and 7 (J8-28) Signal from the detonation sensor for cylinders 9 and 11 (J8-29) Signal from the detonation sensor for cylinders 13 and 15 (J8-30) Signal from the detonation sensor for cylinders 17 and 19 (J8-31) Shield for the detonation sensor for cylinders 2 and 4 (J8-32) Shield for the detonation sensor for cylinders 6 and 8 (J8-33) Shield for the detonation sensor for cylinders 10 and 12 (J8-34) Shield for the detonation sensor for cylinders 14 and 16 (J8-35) Shield for the detonation sensor for cylinders 18 and 20 (J8-36) Shield for the detonation sensor for cylinders 1 and 3 (J8-37) Shield for the detonation sensor for cylinders 5 and 7 (J8-38) Shield for the detonation sensor for cylinders 9 and 11 (J8-39) Shield for the detonation sensor for cylinders 13 and 15 (J8-40) Shield for the detonation sensor for cylinders 17 and 19
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the 8 volt sensors.
Illustration 37
g01065074
Detonation sensors
d. Check the harness and wiring for abrasion and pinch points from the 8 volt sensors to the electronic control modules. Expected Result: All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. Results:
• OK – All connectors, pins, and sockets are
connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. The components are in good condition with proper connections. Proceed to Test Step 2.
212 Troubleshooting Section
• Not OK – At least one of the connectors, pins, and sockets are not connected properly. At least one of the connectors and/or the wiring has corrosion, abrasion, and/or pinch points. Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Test Step 2. Check for Diagnostic Codes A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. C. Observe the “Active Diagnostic” screen on Cat ET. Wait at least 30 seconds so that any codes may become activated. Look for these codes:
• 41-03 8 Volt DC Supply short to +batt • 41-04 8 Volt DC Supply short to ground D. Observe the “Logged Diagnostic” screen on Cat ET. Look for the same codes. Expected Result: The 41-03 code or the 41-04 code is not active.
B. Disconnect each 8 volt sensor one at a time. After you disconnect each sensor, wait for at least 30 seconds and then observe the “Active Diagnostic” screen on Cat ET. Note: An “Open Circuit” code will be generated for each sensor that is disconnected. This is normal. Clear the codes after you complete this procedure. Expected Result: The original “8 Volt DC Supply” diagnostic code is deactivated when a particular sensor is disconnected. Results:
• Yes – The original “8 Volt DC Supply” diagnostic
code is deactivated when a particular sensor is disconnected. The sensor and/or the wiring for the sensor has a short circuit. Repair: Perform the following procedure: 1. Reconnect the suspect sensor. Verify that the diagnostic code recurs. 2. Disconnect the suspect sensor. Verify that the diagnostic code is deactivated. If these conditions are true, repair the sensor or the sensor’s harness. Replace parts, if necessary.
Results:
3. Clear all of the diagnostic codes. Verify that the problem is eliminated.
• No codes – The 41-03 code or the 41-04 code is
STOP.
not active. The 8 volt sensor supply is operating correctly at this time. STOP.
• Active code – The 41-03 code or the 41-04 code is active. Proceed to Test Step 3.
• Logged code – The 41-03 code or the 41-04 code
is not active. However, there is at least one logged code for the 8 volt sensor supply. Repair: There may be a problem with the wiring and/or a connector. Refer to Troubleshooting, “Inspecting Electrical Connectors”. Verify that the wiring and/or connectors are OK. Check for diagnostic codes again. Proceed to Test Step 3, if necessary.
Test Step 3. Disconnect the 8 Volt Sensors and Look for Active Diagnostic Codes. A. Turn on the “Active Diagnostic” screen on Cat ET. Verify that the “41-03” or “41-04” code is active.
• No – The original “8 Volt DC Supply” diagnostic code is still active when a particular sensor is disconnected. Do not reconnect the sensors. Proceed to Test Step 4.
Test Step 4. Isolate the Wiring Harnesses from the Electronic Control Modules A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. If you are troubleshooting an 8 volt problem with the master ECM, use a 151-6320 Wire Removal Tool to remove the wires from the following terminals:
• P1-4 • P2-56 • P2-57
213 Troubleshooting Section
C. If you are troubleshooting an 8 volt problem with the slave ECM, use a 151-6320 Wire Removal Tool to remove the wires from the following terminals:
• P4-56 • P4-57 D. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. E. Wait for at least 30 seconds and then observe the “Active Diagnostics” screen on Cat ET. Determine if a 41-03 code or a 41-04 code is active. Expected Result: No active codes Results:
• No codes – The 41-03 code or the 41-04 code is
not active. Disconnecting all of the 8 volt wiring from the ECM eliminated the active “8 Volt DC Supply” diagnostic code. There is a problem in a connector and/or the wiring in a harness. Proceed to Test Step 5.
• Active code – There is an active 41-03 or 41-04
Test Step 5. Check the Wiring Harnesses on the Left Side of the Engine A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Insert all of the terminals that were removed. Pull on the wires in order to verify that the terminals are fully inserted into the connector. C. Disconnect all of the 8 volt sensors. D. Disconnect the P1 connector and the P2 connector for the master ECM. E. Measure the resistance between the terminals that are listed in Table 12. During each measurement, wiggle the harnesses in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors. Table 12
Points for the Measurement of Resistance for the Left Side of the Engine Connector and Terminal
Connector and Terminal
P1-4 (8 volt supply)
All of the remaining terminals on the P1 connector
code. Disconnecting all of the 8 volt wiring from the ECM did not eliminate the active “8 Volt DC Supply” diagnostic code. There may be a problem with an ECM.
All of the terminals on the P2 connector P2-56 (8 volt supply)
Repair: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Insert all of the terminals that were removed. Pull on the wires in order to verify that the terminals are fully inserted into the connector.
All of the terminals on the P1 connector P2-57 (8 volt supply)
It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
All of the remaining terminals on the P2 connector
All of the remaining terminals on the P2 connector All of the terminals on the P1 connector
Expected Result: Each check of the resistance is greater than 20,000 Ohms. Results:
• OK – Each check of the resistance is greater than 20,000 Ohms. The 8 volt wires and connectors on the left side of the engine do not have a short circuit. Proceed to Test Step 6.
• Not OK – At least one check of the resistance is
less than 20,000 Ohms. There is a problem with a connector and/or at least one of the 8 volt wires in a harness.
214 Troubleshooting Section
Repair: The problem may be inside the terminal box. Alternatively, the problem may be in an engine harness.
Repair: The problem could be inside the terminal box. Alternatively, the problem may be in an engine harness.
Repair the connection and/or the wire, when possible. Replace parts, if necessary.
Repair the connection and/or the wire, when possible. Replace parts, if necessary.
STOP.
STOP.
Test Step 6. Check the Wiring Harnesses on the Right Side of the Engine A. Disconnect the P3 connector and the P4 connector for the slave ECM. B. Measure the resistance between the terminals that are listed in Table 13. During each measurement, wiggle the harnesses in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors. Table 13
Points for the Measurement of Resistance for the Right Side of the Engine Connector and Terminal
Connector and Terminal
P4-56 (8 volt supply)
All of the remaining terminals on the P4 connector
P4-57 (8 volt supply)
All of the remaining terminals on the P4 connector
Expected Result: Each check of the resistance is greater than 20,000 Ohms. Results:
• OK – Each check of the resistance is greater than 20,000 Ohms. The 8 volt wires and connectors on the right side of the engine do not have a short circuit. The problem seems to be resolved. The initial diagnostic code was probably caused by a poor electrical connection. Repair: Reconnect all of the connectors and resume normal operation. STOP.
• Not OK – At least one check of the resistance is
less than 20,000 Ohms. There is a problem with a harness on the right side of the engine.
i02088679
Analog Sensor Signal SMCS Code: 5574-038 System Operation Description: Use this procedure to troubleshoot diagnostic codes for open circuits or short circuits for the sensors of these parameters:
• Engine coolant temperature • Inlet air temperature • Engine oil temperature • Filtered engine oil pressure • Unfiltered engine oil pressure Note: The engine coolant temperature sensor does not require +5 VDC from the master Electronic Control Module (ECM). The engine coolant temperature sensor is a passive sensor of the analog type. The sensor operates without a voltage supply from the master ECM. The master ECM can be configured for one of these types of speed control:
• Potentiometer • 4-20 ma The “DESIRED SPEED” potentiometer (if equipped) must be supplied with +5 VDC from the master ECM. If the “DESIRED SPEED” potentiometer has a short circuit or the potentiometer’s wiring has a short circuit, a 262-03 or 262-04 diagnostic code may be activated. There are no diagnostic codes for the circuit of the “DESIRED SPEED” potentiometer. The -03 code is probably caused by a problem in an engine harness. There may be an open circuit in a harness, or a short circuit to a positive voltage source in a harness. The next likely cause is a sensor problem. The least likely cause is a problem with the master ECM.
215 Troubleshooting Section
The -04 code is probably caused by a short circuit to ground in an engine harness. The next likely cause is a sensor problem. The least likely cause is a problem with the master ECM. Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic code after the problem is resolved.
216 Troubleshooting Section
Illustration 38 Schematic for the analog sensors
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217 Troubleshooting Section
Test Step 1. Inspect the Electrical Connectors and Wiring
• J1/P1 connectors • J6/P6, and J7/P7 connectors a. Check the torque of the allen head screws for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the terminal box’s connectors. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 39
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Junction box (1) 35 amp circuit breaker
Illustration 41
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
Illustration 40
g01065031
Terminal box (2) J1/P1 connectors for the master ECM (3) J6/P6 connectors for the customer (4) J7/P7 connectors for the harness from the 5 volt sensors
B. Thoroughly inspect each of the following connectors:
Harness side of the P1 connector (P1-2) 5 volt supply (P1-3) Return (P1-14) Signal for the inlet manifold air temperature (P1-16) Signal for the desired speed (P1-17) Signal for the engine oil temperature (P1-18) 5 volt supply (P1-24) Signal for the filtered engine oil pressure (P1-26) Signal for the unfiltered engine oil pressure (P1-27) Signal for the engine coolant temperature (P1-35) Return
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218 Troubleshooting Section
Illustration 42
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Harness side of the J6 connector (J6-5) 5 volt supply (J6-15) Return (J6-25) Signal for desired speed (J6-35) Shield Illustration 43
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Harness side of the J7 connector (J7-3) Signal for the inlet manifold air temperature (J7-4) Signal for the filtered engine oil pressure (J7-5) Signal for the engine oil temperature (J7-6) Signal for the unfiltered engine oil pressure (J7-7) Signal for the engine coolant temperature (J7-17) Return for the inlet manifold air temperature (J7-18) Return for the filtered engine oil pressure (J7-19) Return for the engine oil temperature (J7-20) Return for the unfiltered engine oil pressure (J7-21) Return for the engine coolant temperature (J7-31) Shield for the inlet manifold air temperature (J7-32) Shield for the filtered engine oil pressure (J7-33) Shield for the engine oil temperature (J7-34) Shield for the unfiltered engine oil pressure (J7-35) Shield for the engine coolant temperature (J7-45) 5 volt supply for the inlet manifold air temperature (J7-46) 5 volt supply for the filtered engine oil pressure (J7-47) 5 volt supply for the engine oil temperature (J7-48) 5 volt supply for the unfiltered engine oil pressure
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the analog sensors.
219 Troubleshooting Section
Results:
• OK – All connectors, pins, and sockets are
connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. The components are in good condition with proper connections. Proceed to Test Step 2.
• Not OK – At least one of the connectors, pins,
and/or sockets are not connected properly. At least one of the connectors and/or the wiring has corrosion, abrasion, or pinch points. Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Test Step 2. Check for Diagnostic Codes for the Power Supply Illustration 44
g01065032
Right side view (5) Engine oil temperature sensor (6) Unfiltered oil pressure sensor (7) Filtered oil pressure sensor
A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. C. Observe the “Active Diagnostic” screen on ET. Allow a minimum of 30 seconds for any codes to activate. Look for these codes:
• 262-03 5 Volt Sensor DC Power Supply short to +batt
• 262-04 5 Volt Sensor DC Power Supply short to ground
Expected Result: There are no active “5 Volt Sensor DC Power Supply” diagnostic codes. Results:
• No codes – There are no active “5 Volt Sensor DC Illustration 45
g01065110
Top view (8) Engine coolant temperature sensor (9) Engine coolant pressure sensor (outlet)
d. Check the harness and wiring for abrasion and for pinch points from the analog sensors to the master ECM. Expected Result: All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.
Power Supply” diagnostic codes. Proceed to Test Step 3.
• Active code – There is an active “5 Volt Sensor DC
Power Supply” diagnostic code. This procedure will not work when this type of code is active. Repair: Refer to Troubleshooting, “+5V Sensor Supply”. If necessary, return to this functional test in order to troubleshoot the analog sensor after the “+5 V Sensor Supply” diagnostic code has been resolved. STOP.
220 Troubleshooting Section
Test Step 3. Check for Active Analog Sensor Diagnostic Codes
• Active “short to ground” (FMI 04) – There is an
A. Observe the “Active Diagnostic” screen on Cat ET. Wait at least 30 seconds so that any codes may become activated. Look for the codes that are listed in Table 14:
Test Step 4. Create an Open Circuit for the Sensor
Table 14
Analog Sensor Diagnostic Codes
active “short to ground” diagnostic code. Proceed to Test Step 4.
A. Set the engine control to the OFF/RESET mode. B. Disconnect the sensor that has the “short to ground” diagnostic code.
100-03
Engine Oil Pressure open/short to +batt
100-04
Engine Oil Pressure short to ground
C. Set the engine control to the STOP mode.
110-03
Engine Coolant Temperature open/short to +batt
110-04
Engine Coolant Temperature short to ground
172-03
Intake Manifold Air Temp open/short to +batt
D. Observe the “Active Diagnostic” screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. Look for an active “open/short to +batt” diagnostic code.
172-04
Intake Manifold Air Temp short to ground
Expected Result:
175-03
Engine Oil Temperature open/short to +batt
175-04
Engine Oil Temperature short to ground
There is an active “open/short to +batt” diagnostic code for the disconnected sensor.
542-03
Unfiltered Engine Oil Pressure open/short to +batt
Results:
542-04
Unfiltered Engine Oil Pressure short to ground
• Yes – Before the suspect sensor was
B. If one of the above codes is active, identify the type of diagnostic according to the condition: the diagnostic code is either “open/short to +batt” (FMI 03) or “short to ground” (FMI 04). Expected Result: None of the above codes are active. Results:
• No active codes – None of the above codes are active.
Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshooting, “Troubleshooting Without a Diagnostic Code”. If the engine is running properly at this time, there may be an intermittent problem in the harness that is causing the codes to be logged. Refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Active “open/short to +batt” (FMI 03) – There is an active “open/short to +batt” diagnostic code. If you are troubleshooting the sensor for engine coolant temperature, proceed to Test Step 6. Otherwise, proceed to Test Step 5.
disconnected, there was an active “short to ground” diagnostic code for the sensor. After the suspect sensor was disconnected, there was an active “open/short to +batt” diagnostic code for the sensor. Repair: Reconnect the sensor. If the active “short to ground” diagnostic code recurs, replace the original sensor. Verify that the code does not activate when the new sensor is installed. Clear the logged diagnostic code from the master ECM. STOP.
• No – Before the suspect sensor was disconnected, there was an active “short to ground” diagnostic code for the sensor. After the suspect sensor was disconnected, the active “open/short to +batt” diagnostic code remained. If you are troubleshooting the sensor for engine coolant temperature, proceed to Test Step 6. Otherwise, proceed to Test Step 5.
Test Step 5. Check the Supply Voltage at the Sensor Connector A. Verify that the suspect sensor is disconnected from the engine harness.
221 Troubleshooting Section
Illustration 46
g00889729
Illustration 47
Harness connectors for the various sensors
Harness connectors for the various sensors
(A) 5 volt supply (B) Return (C) Signal
(A) 5 volt supply (B) Return (C) Signal (1) Signal (2) Return
B. At the harness connector for the suspect sensor, measure the voltage between terminals A and B. Expected Result: The voltage is between 4.5 VDC and 5.5 VDC. Results:
• OK – The voltage between terminals A and B is
between 4.5 VDC and 5.5 VDC. The 5 volt supply is present at the sensor connector. Proceed to Test Step 6.
• Not OK – The voltage between terminals A and terminal B is not between 4.5 VDC and 5.5 VDC. The 5 volt supply is not present at the sensor connector. The 5 volts must be present at the sensor in order to continue this procedure. The 5 volt wiring problem may be inside the terminal box, or in the engine harness. Repair: Verify that the wiring and/or connectors are OK. Repair any faulty wiring and/or connectors, when possible. Replace parts, if necessary. Refer to Troubleshooting, “Inspecting Electrical Connectors”. Check for diagnostic codes again. STOP.
Test Step 6. Check the Pull-Up Voltage at the Sensor A. Verify that the suspect sensor’s connector is disconnected from the engine harness.
g00889801
B. At the harness connector for the suspect sensor, measure the voltage between terminals B and C, or between terminals 1 and 2. Expected Result: The voltage is between 6.0 VDC and 7.0 VDC. Results:
• OK – The voltage between the signal terminal and the return terminal is between 6.0 VDC and 7.0 VDC. The pull-up voltage that is created by the master ECM is present at the sensor connector. The signal wire and the return wire for the suspect sensor appear to be OK. Proceed to Test Step 8.
• Not OK – The voltage between the signal terminal and the return terminal is not between 6.0 VDC and 7.0 VDC. The pull-up voltage that is created by the master ECM is not present at the sensor connector. Proceed to Test Step 7.
Test Step 7. Check the Pull-Up Voltage at the Master ECM A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Use a 151-6320 Wire Removal Tool to remove the signal wire for the suspect sensor from the P1 connector. C. Use a jumper wire with Deutsch terminals on the ends. Insert one end of the jumper wire into the open terminal of the P1 connector. D. Connect a multimeter lead to the end of the jumper wire that is not inserted into the connector. E. At the harness side of the P1 connector, insert a 7X-1710 Multimeter Probe along terminal 3. F. Connect the other multimeter lead to the probe. G. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
222 Troubleshooting Section
H. Measure the pull-up voltage at the master ECM.
Results:
Expected Result:
• OK – No diagnostic codes are activated when a
The voltage is between 6.0 VDC and 7.0 VDC.
good sensor is temporarily installed. Connecting a new sensor resolved the problem.
Results:
Repair: Perform the following procedure:
• OK – The pull-up voltage for the suspect sensor at
1. Reconnect the suspect sensor. Verify that the “open/short to +batt” diagnostic code recurs.
the master ECM is between 6.0 VDC and 7.0 VDC. The master ECM is producing a pull-up voltage that is valid. There is a problem with the signal wire between P1 and the harness connector for the sensor. There may be a problem with a connector. Repair: Perform the following procedure: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Disconnect the multimeter leads.
Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P1 connector. Reinstall the terminal that was removed from the P1 connector. Pull on the wire in order to verify proper installation of the terminal. Verify that the wiring and/or connectors are OK. Repair any faulty wiring and/or connectors, when possible. Replace any wiring and/or connectors, if necessary. Refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Not OK – The pull-up voltage for the suspect
sensor at the master ECM is not between 6.0 VDC and 7.0 VDC. Proceed to Test Step 9.
Test Step 8. Check the Sensor A. Temporarily connect a sensor that is known to be good to the engine harness. B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. C. Observe the “Active Diagnostic” screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. Expected Result: No diagnostic codes are activated.
2. Disconnect the suspect sensor. Verify that the “open/short to +batt” diagnostic code is deactivated. 3. Connect the new connector. Verify that no diagnostic codes are activated. If these conditions are true, replace the faulty sensor with the new sensor. For the proper torque value for the new sensor, refer to the Specifications manual. 4. Clear all of the diagnostic codes. Verify that the problem has been resolved. STOP.
• Not OK – The active “open/short to +batt” code
remains. Connecting a new sensor did not resolve the problem. Proceed to Test Step 9.
Test Step 9. Check the Operation of the Master ECM A. Verify that the signal wire for the suspect sensor has been removed from the P1 connector. B. Clear any existing diagnostic codes. C. Observe the “Active Diagnostic” screen on ET. Allow a minimum of 30 seconds for any codes to activate. An active “open/short to +batt” diagnostic code is generated for the sensor. D. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. E. Use a jumper wire that is the appropriate length with Deutsch terminals on the ends. Install one end of the jumper wire into the terminal for the signal wire that was removed from the P1 connector. Install the other end of the jumper wire into terminal 19 of the P1 connector. This will replace the sensor circuit with a short circuit. F. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
223 Troubleshooting Section
G. Observe the “Active Diagnostic” screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. An active “short to ground” diagnostic code is generated. Expected Result: Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps.
i02088853
CAT Data Link SMCS Code: 1901-038 System Operation Description: The CAT data link is used to share information between the following components:
• Master Electronic Control Module (ECM)
Results:
• Slave ECM
• OK – Active “open/short to +batt” and “short to
• Integrated Temperature Sensing Module (ITSM)
ground” diagnostic codes are generated according to the above steps. The master ECM is operating correctly. The initial diagnostic code was probably caused by a poor electrical connection. Repair: Perform the following procedure: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P1 connector. Reinstall the terminal that was removed from the P1 connector. Pull on the wire in order to verify proper installation of the terminal. Resume normal operation. STOP.
• Not OK – No active “open/short to +batt” and
“short to ground” diagnostic codes were generated. The master ECM is not operating correctly. Repair: It is unlikely that the master ECM has failed. Exit this procedure and perform this entire procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
• Service tool • Customer installed components Illustration 48 shows the information that is shared between the master ECM and the slave ECM via the CAT data link.
224 Troubleshooting Section
g00951847
Illustration 48 Information that is shared between the master ECM and the slave ECM
Each ECM and the ITSM communicate with the Caterpillar Electronic Technician Cat ET via the CAT data link. The CAT data link consists of two wires that are twisted together. One wire is designated as +. The other wire is designated as -. The signals on the data link wires are a square wave type signal. The signals operate at a very high frequency. The signals cannot be measured with common service tools. Therefore, only continuity measurements can be made on the wires for the CAT data link. The most likely cause of a diagnostic code for the CAT data link are an open circuit or a short circuit. Connector terminals that are not fully seated in the connector body can create an open circuit condition. Be careful not to interchange the + wire and the - wire in a connector. The CAT data link will not operate if the + wire and the - wire are interchanged in a connector. The CAT data link can fail if a module is not receiving power. This can happen if there is a problem with the wiring that provides power to the module. The CAT data link can fail if a module is programmed with the wrong flash file, or if a module has not been programmed with a flash file. Verify that all modules have been programmed with the proper flash file.
Perform this procedure for all problems that are associated with the CAT data link. If this procedure does not solve the problem, there may be a faulty ignition transformer. A faulty ignition transformer can cause the ECM to reset. When the reset occurs, the ECM also generates a diagnostic code for the CAT data link. If the engine is not running, the engine will not start. If the engine is running, the engine will shut down. Temporarily install a transformer that is known to be good into a cylinder. Then check for the diagnostic code. If the code is still active, install the good transformer into a different cylinder. When the suspect transformer is removed, the ECM will not reset. Harness Code for the Slave ECM The harness inside the terminal box has a jumper wire (harness code) that connects terminals J3-29 and J3-60. The ECM that is connected to the harness reads the harness code. This allows the ECM to operate as the slave ECM. If the jumper wire is disconnected, the slave ECM will assume the function of a master ECM. Cat ET will not communicate with any of the modules. Cat ET will display “Duplicate Type on data link. Unable to Service”.
225 Troubleshooting Section
g01065141
Illustration 49 Schematic of the CAT data link
Test Step 1. Inspect the Electrical Connectors and Wiring
Illustration 50
Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
g01054206
Illustration 51
Junction Box
Terminal box
(1) 35 amp circuit breaker
(2) (3) (4) (5) (6) (7)
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position.
Ground strap J5 connector for Cat ET J1/P1 connectors for the master ECM J6 connector for the customer J9/P9 connectors for the CAT data link J3/P3 connectors for the slave ECM
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226 Troubleshooting Section
Illustration 53
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Harness side of the P1 connector (P1-8) CAT data link + (P1-9) CAT data link −
Illustration 52
g01065149
(8) ITSM (9) 14-pin connectors for the harness to the terminal box for the master ECM
B. Thoroughly inspect each of the following connectors:
• J1/P1 connectors • J3/P3 connectors • J5, J6, and J9/P9 connectors • 14-pin connectors for the ITSM a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (53 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 54
g01065147
Harness side of the P3 connector (P3-8) CAT data link + (P3-9) CAT data link − (P3-29) Harness code (P3-60) harness code
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the CAT data link. d. Check the harness and wiring for abrasion and for pinch points from the slave ECM to the master ECM. e. Check the harnesses and wiring for abrasion and for pinch points from the ITSM to the master ECM. Expected Result: The connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.
227 Troubleshooting Section
Results:
• OK – The components are in good condition with proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good condition and/or at least one connection is improper.
Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Test Step 2. Check the CAT Data Link A. Verify that the engine control is in the OFF/RESET mode. Verify that the 35 amp circuit breaker is OFF. B. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. C. Set the engine control to the STOP mode. Switch the 35 amp circuit breaker ON. D. Select the “File/Select ECM” menu on the Cat ET. Verify that all of the modules are displayed on the “ECM Selector” screen. Verify that the following diagnostic codes are not activated.
• 0590-09 Unable to communicate with Engine ECM
• 1636-09 Loss of communication with Engine #2 (Slave)
• 1042-09 Unable to communicate with ITSM Note: If Cat ET displays “Duplicate Type on data link. Unable to Service”, there may be a problem with the harness inside the terminal box. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Check the continuity between terminals J3-29 and J3-60. Verify that the jumper wire is in good condition. Make repairs, as needed. Expected Result: All of the modules are displayed on the “ECM Selector” screen. There are no active diagnostic codes for the CAT data link. Results:
• OK – All of the modules are displayed on the “ECM Selector” screen. There are no active diagnostic codes for the CAT data link. The problem seems to be resolved.
Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshooting, “Troubleshooting Without a Diagnostic Code”. If any of the above codes are logged and the engine is running properly, there may be an intermittent problem in a connector or a wiring harness. Refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Not OK – At least one of the modules is not
displayed on the “ECM Selector” screen. There may be an active diagnostic code for the CAT data link. Proceed to Test Step 3.
Test Step 3. Check the Wiring for the CAT Data Link A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect Cat ET from the service tool connector. C. Disconnect the following connectors:
• P1 connector from the master ECM • P3 connector from the slave ECM • P6 connector (if equipped) • 14-pin connector from the ITSM D. Measure the resistance between the points that are listed in Table 15. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
228 Troubleshooting Section
Table 15
Resistance Measurements for the CAT Data Link Connector and Terminal
Connector and Terminal
P1-8
P3-8 J5-D J6-7 Terminal J of the 14-pin connector on the ITSM
P3-8
J5-D
P1-9
P3-9 J5-E J6-17 Terminal N of the 14-pin connector on the ITSM
P3-9
J5-E
P1-34
Ground strap for the master ECM
P1-50
Ground strap for the master ECM
Expected Result: Each check of the resistance between the connectors is less than 5 Ohms. Each check of the resistance between the connector and the ground strap is greater than 20,000 Ohms. Results:
• OK – Each check of the resistance for the CAT
data link is within the specification. The wiring for the CAT data link appears to be OK. Repair: Perform the following procedure: 1. Connect the following connectors:
• P1 connector to the master ECM • P3 connector to the slave ECM • P6 connector (if equipped) • 14-pin connector to the ITSM 2. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. 3. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
4. Verify that Cat ET is able to communicate with each of the modules. 5. If Cat ET is unable to communicate with a module, there may be a problem with the supply voltage to the module. Refer to Troubleshooting, “Electrical Power Supply”. 6. If the problem is not resolved, there may be a problem with the wiring for the CAT data link between the J6 connector and the customer’s equipment. Verify that the wiring for the CAT data link between the J6 connector and the customer’s equipment is working properly. 7. If the problem is not resolved, there may be a problem with the module that is not communicating with Cat ET. It is unlikely that a module has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, temporarily replace the module that is not communicating. Refer to Troubleshooting, “Replacing the ECM” or Troubleshooting, “Replacing the ITSM”. Verify that the problem is resolved. If the problem is resolved with the new module, reinstall the original module and verify that the problem returns. If the new module works correctly and the original module does not work correctly, replace the original module. Refer to Troubleshooting, “Replacing the ECM” or Troubleshooting, “Replacing the ITSM”. STOP.
• Not OK – At least one check of the resistance for the CAT data link is incorrect. There is a problem with the wiring for the CAT data link.
Repair: Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved. STOP.
229 Troubleshooting Section
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Compressor Bypass SMCS Code: 1052-038-BV System Operation Description: A bypass valve is connected between the outlets for the turbocharger compressors and the inlets for the turbocharger compressors. The bypass valve is activated by an actuator. The master Electronic Control Module (ECM) activates the actuator for the bypass valve during these conditions:
• Turbocharger surge • Engine shutdown Turbocharger Surge A rapid drop in the output power of the generator can cause the engine’s speed to quickly increase. The increased speed of the engine causes the turbochargers to overspeed temporarily. This is called a turbocharger surge. Surging can damage the turbochargers. The master ECM continuously monitors the speed of the engine. The master ECM responds to a rapid increase in the speed of the engine by activating the actuator for the bypass valve. The actuator opens the valve. The valve allows the compressed air/fuel mixture in the aftercooler’s inlet to flow into the intake of the turbocharger’s compressor. This reduces the boost pressure in the air inlet manifold. Engine Shutdown Engine shutdown occurs when the output for the fuel control relay is OFF and the engine RPM is above 100. The master ECM activates the actuator for the bypass valve until the engine RPM drops to zero. This scavenges any unburned gases in the components of the system during engine shutdown. CAN Data Link The master ECM and the actuator communicate via the CAN data link. The master ECM sends a command signal to the actuator. The actuator sends the following information to the master ECM: actuator position, CCM heartbeat, software version, and internal fault diagnosis.
If the master ECM cannot communicate with the actuator, the master ECM activates a 1720-09 diagnostic code and the engine is shut down. A 1720-09 diagnostic code is probably caused by a problem with an electrical connector or a harness. The next likely cause is a problem with the actuator. The least likely cause is a problem with the master ECM. Terminating resistors must be connected to each end of the CAN data link. The terminating resistors improve the communication between the devices. If there is an intermittent diagnostic code for any of the devices that are connected to the CAN data link, be sure to check the terminating resistor that is inside the terminal box. Also check the jumper wire that is connected between terminals J and K on the actuator for the bypass valve. Make repairs, when possible. Replace parts, if necessary. Identification on the CAN Data Link When the actuator for the bypass valve is powered up, the actuator looks for a ground on terminal N. If there is a ground on terminal N, the actuator will have a unique identification on the CAN data link. If there is no ground on terminal N and the actuator is powered up, the actuator for the bypass valve and the throttle actuator will have the same identification. The master ECM will not communicate with the actuator for the bypass valve. Instead, the master ECM will activate a 1720-09 diagnostic code. The engine will not start. The electrical connector for the actuator is designed so that the terminals for electrical power are connected before terminal N. For this reason, electrical power must be removed before the connector for the actuator is connected.
230 Troubleshooting Section
Illustration 55 Schematic for the circuit of the actuator for the bypass valve
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231 Troubleshooting Section
Test Step 1. Inspect the Electrical Connectors and Wiring
B. Thoroughly inspect each of the following connectors:
• J1/P1 connectors • J9/P9 connectors • Connectors on the actuator for the bypass valve a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 56
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Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Illustration 58
Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
Illustration 57
Harness side of the P1 connector (P1-34) CAN data link − (P1-42) CAN shield (P1-50) CAN data link +
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Terminal box (2) (3) (4) (5)
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Ground strap J1/P1 connectors for the master ECM J9/P9 connectors for the CAN data link J10/P10 connectors for the terminating resistor for the CAN data link
Illustration 59 Harness side of the J9 connector (J9-6) CAN data link + (J9-12) CAN data link − (J9-18) CAN shield
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232 Troubleshooting Section
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the actuator for the bypass valve.
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Illustration 60 Right side views
d. Check the wiring for abrasion and for pinch points from the actuator for the bypass valve to the master ECM. Expected Result:
B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. C. Use Cat ET in order to determine if a 1720-09 diagnostic code is active.
All of the connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.
Expected Result:
Results:
Results:
• OK – The components are in good condition with
• OK – The 1720-09 code is not active. The
proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good condition and/or at least one connection is improper.
Repair: Perform the necessary repairs and/or replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
Test Step 2. Check for a Diagnostic Code A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
The 1720-09 code is not active.
communication between the master ECM and the actuator for the bypass valve appears to be OK at this time. However, diagnostic codes may be logged. Repair: If you are troubleshooting an intermittent problem, refer to Troubleshooting, “Inspecting Electrical Connectors”.
233 Troubleshooting Section
Terminating resistors must be connected to each end of the CAN data link. The terminating resistors improve the communication between the devices. If there is an intermittent diagnostic code for any of the devices that are connected to the CAN data link, be sure to check the terminating resistor that is inside the terminal box. Also check the jumper wire that is connected between terminals J and K on the actuator for the bypass valve. Make repairs, when possible. Replace parts, if necessary. STOP.
Repair: The open circuit could be caused by a poor electrical connection in a connector. Alternatively, the open circuit could be caused by one of the following components:
• The harness inside the terminal box • The harness between the terminal box and the fuel metering valve
• The harness between the fuel metering valve and the throttle actuator
• Not OK (Active 1720-09) – The master ECM
has detected a problem with the communication between the master ECM and the actuator for the bypass valve. Proceed to Test Step 3.
Test Step 3. Check the CAN Data Link for Continuity Between the Actuator for the Bypass Valve and the Master ECM A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
• The harness between the throttle actuator and the actuator for the bypass valve
• The fuel metering valve • The throttle actuator Make repairs, when possible. Replace parts, if necessary. STOP.
B. Disconnect the P1 connector. Disconnect the connector for the actuator for the bypass valve.
Test Step 4. Check the CAN Data Link for a Short Circuit
C. Use a multimeter to check for continuity between the points that are listed in Table 16. During each measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harness near each of the connectors. Be sure to wiggle the harness near the fuel metering valve and the throttle actuator.
A. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF.
Table 16
Points to Check for Continuity Connector and Terminal
Harness Connector for the Actuator for the Bypass Valve
P1-34
Terminal “B” (CAN data link −)
P1-50
Terminal “A” (CAN data link +)
P1-42
Terminal “M” (CAN shield)
Expected Result:
B. Use a multimeter to check for continuity between the points that are listed in Table 17. During each measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harness near each of the connectors. Be sure to wiggle the harness near the fuel metering valve and the throttle actuator. Table 17
Points to Check for Continuity Connector and Terminal
Connector and Terminal
P1-34 (CAN data link −)
P1-50 (CAN data link +) P1-42 (CAN shield) P1-52 (+ Battery) Ground strap for the ECM
P1-50 (CAN data link +)
P1-42 (CAN shield) P1-52 (+ Battery) Ground strap for the ECM
P1-42 (CAN shield)
P1-52 (+ Battery) Ground strap for the ECM
The continuity of the circuits between the terminals is good. Results:
• OK – The continuity of the circuits between the terminals is good. Proceed to Test Step 4.
• Not OK – At least one of the continuity checks
indicates an open circuit. There is an open circuit for the CAN data link between the actuator for the bypass valve and the master ECM.
Expected Result: All of the measurements indicate an open circuit. Results:
• OK – All of the measurements indicate an open
circuit. The CAN data link does not have a short circuit.
234 Troubleshooting Section
Repair: Reconnect the P1 connector. Reconnect the connector for the actuator for the bypass valve.
Repair: The active 1720-09 code could be caused by one of the following components:
Proceed to Test Step 5.
• The master ECM
• Not OK – At least one of the measurements indicate a short circuit.
Repair: The short circuit could be caused by a poor electrical connection in a connector. Alternatively, the short circuit could be caused by one of the following components:
• The harness inside the terminal box • The harness between the terminal box and the fuel metering valve
• The harness between the fuel metering valve and the throttle actuator
• The harness between the throttle actuator and the actuator for the bypass valve
• The fuel metering valve • The throttle actuator Make repairs, when possible. Replace parts, if necessary. STOP.
Test Step 5. Check for a Diagnostic Code A. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. B. Use Cat ET in order to determine if a 1720-09 diagnostic code is active. Expected Result: The 1720-09 code is not active. Results:
• OK – The 1720-09 code is not active. The problem seems to be resolved. The initial diagnostic code was probably caused by a poor electrical connection. Repair: If there is an intermittent problem that is causing the code to be logged, refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Not OK – The 1720-09 code is active.
• The throttle actuator • The actuator for the bypass valve • The fuel metering valve It is unlikely that any of the components that are listed above have failed. Exit this procedure and perform this procedure again. If the 1720-09 code remains active, perform the following procedure: 1. Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is not resolved with a new ECM, install the original ECM. Continue with this procedure. 2. Temporarily install a new actuator for the throttle actuator. If the new throttle actuator operates correctly, the problem is resolved. If the new throttle actuator does not operate correctly, install the original throttle actuator and continue with this procedure. 3. Temporarily install a new actuator for the bypass valve. If the new actuator for the bypass valve operates correctly, the problem is resolved. If the new actuator for the bypass valve does not operate correctly, install the original actuator for the bypass valve and continue with this procedure. 4. Temporarily install a new fuel metering valve. If the new fuel metering valve operates correctly, the problem is resolved. If the new fuel metering valve does not operate correctly, install the original fuel metering valve. Refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
235 Troubleshooting Section
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Desired Speed Input (4 - 20 mA)
The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
SMCS Code: 1901-038 System Operation Description: Note: For this troubleshooting procedure, the “Desired Speed Input” configuration parameter must be set to “4-20 mA Input” in the “Service/Configuration” screen of the Caterpillar Electronic Technician (ET). Do not select “PWM”. The master Electronic Control Module (ECM) cannot be configured to accept a PWM input signal for control of the engine speed. The selection of the “4-20 mA Input” setting requires a 4 to 20 mA signal for regulation of the desired engine speed. If the “Desired Speed Input” is set to “0-5 VDC Input”, do not use this procedure to troubleshoot the circuit. When the desired speed input is correspondingly configured, the master ECM controls the engine speed according to the 4 to 20 mA current.
Illustration 61
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Schematic of the 4 to 20 mA desired speed input
Test Step 1. Inspect the Electrical Connectors and Wiring
The value of the current corresponds to a range of desired engine speeds between minimum high idle and maximum high idle. The “Minimum Engine High Idle Speed” and the “Maximum Engine High Idle Speed” are set with the “Service/Configuration” screen of ET. For more information, refer to Systems Operation/Testing and Adjusting, “Electronic Control System Parameters”. When the “Idle/Rated” switch is in the Rated position, a current value of 4.0 mA corresponds to the programmed “Minimum Engine High Idle Speed”. A current value of 20.0 mA corresponds to “Maximum Engine High Idle Speed”. Current values within this range will vary the desired engine speed in a linear fashion between “Minimum Engine High Idle Speed” and “Maximum Engine High Idle Speed”. Current values that are greater than 22.0 mA will activate the “524-03 Desired Engine Speed Sensor short to +batt” diagnostic code. Current values that are less than 2.0 mA will activate the “524-04 Desired Engine Speed Sensor short to ground” diagnostic code. The most likely causes of the diagnostic code are a poor connection or a problem in a wiring harness. The next likely cause is a problem with a component. The least likely cause is a problem with the master ECM. Logged diagnostic codes provide a historical record. Before you begin this procedure, use ET to print the logged codes to a file.
Illustration 62
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Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
236 Troubleshooting Section
Illustration 64
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Harness side of the P1 connector (P1-36) + Signal (P1-37) - Signal
Illustration 63
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Terminal box (2) Ground strap (3) J1/P1 connectors for the master ECM (4) J6/P6 connectors for the customer
B. Thoroughly inspect the following components:
• J1/P1 connectors • J6/P6 connectors • Wiring and the connections between the
terminal box and the device that supplies the 4 to 20 mA signal
a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the terminal box’s connectors. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 65
g00929720
Harness side of the J6 connector (J6-37) + Signal (J6-27) - Signal
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the 4 to 20 mA circuit. d. Check the harness and wiring for abrasion and for pinch points between the device that supplies the 4 to 20 mA signal and the master ECM. Expected Result: All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.
237 Troubleshooting Section
Results:
• OK – The components are in good condition with
proper connections. If you are troubleshooting a “524-03 Desired Engine Speed Sensor short to +batt” diagnostic code, proceed to Test Step 2. If you are troubleshooting a “524-04 Desired Engine Speed Sensor short to ground” diagnostic code, proceed to Test Step 5.
• Not OK – The components are not in good condition and/or at least one connection is improper.
Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved. STOP.
Test Step 3. Check for a Short Circuit to the +Battery at Terminal P1-36 A. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. B. Make sure that there is no electrical power to the device that provides the 4 to 20 mA signal. C. Use an ohmmeter to measure the resistance between terminals P1-36 and P1-57 on the ECM side of the P1 connector.
Test Step 2. Check for an Open Circuit
Expected Result:
A. Remove the two wires (“+” and “-”) for the 4 to 20 mA signal from the device that supplies the 4 to 20 mA signal.
The resistance is greater than 20,000 Ohms.
B. Install a jumper wire between the two wires (“+” and “-”) that were removed from the device that supplies the 4 to 20 mA signal.
• Yes – The resistance is greater than 20,000 Ohms.
C. Disconnect the P1 connector from the master ECM. D. Use an ohmmeter to measure the resistance between terminals P1-36 and P1-37 on the ECM side of the P1 connector. Expected Result: The resistance is less than 5 Ohms. Results:
• OK – The resistance is less than 5 Ohms. The circuit is not open.
Repair: Remove the jumper wire. Insulate the wire leads with electrical tape in order to ensure that the leads do not create a short circuit. Proceed to Test Step 3.
• Not OK – The resistance is greater than 5 Ohms. There is a problem with a connector and/or the wiring from the P1 connector.
Repair: The problem may be between the P1 connector and the J6 connector. Alternatively, the problem may be between the J6 connector and the device that provides the 4 to 20 mA signal.
Results: The wiring from terminal P1-36 is not shorted to the +Battery side. Do not reconnect any connectors. Proceed to Test Step 4.
• No – The resistance is less than 20,000 Ohms.
There is a problem with a connection and/or the wiring from terminal P1-36. Repair: The problem may be between the P1 connector and the J6 connector. Alternatively, the problem may be between the P6 connector and the device that provides the 4 to 20 mA signal. Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved. STOP.
Test Step 4. Check for a Short to Ground at Terminal P1-37 A. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. B. Make sure that the leads of the wires for the 4 to 20 mA signal do not create a short circuit. C. Use an ohmmeter to measure the resistance between the ground strap for the master ECM and terminal P1-37. Expected Result: The resistance is greater than 20,000 Ohms.
238 Troubleshooting Section
The wiring from terminal P1-37 appears to be OK.
Repair: The problem may be between the P1 connector and the J6 connector. Alternatively, the problem may be between the J6 connector and the device that provides the 4 to 20 mA signal.
Repair: Reconnect the P1 connector. Reconnect the two wires (“+” and “-”) for the 4 to 20 mA signal to the device that supplies the 4 to 20 mA signal.
Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved.
Proceed to Test Step 7.
STOP.
Results:
• Yes – The resistance is greater than 20,000 Ohms.
• No – The resistance is less than 20,000 Ohms.
There is a problem with a connection and/or the wiring that is connected to P1-37. Repair: The problem may be between the P1 connector and the J6 connector. Alternatively, the problem may be between the P6 connector and the device that provides the 4 to 20 mA signal.
Test Step 6. Check for a Short Circuit to Ground at Terminal P1-36 A. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. B. Make sure that the ends of the wires for the 4 to 20 mA signal do not create a short circuit.
Locate the wire with the short circuit and replace the wire. Verify that the problem is resolved.
C. Use an ohmmeter to measure the resistance between ground strap (2) and terminal P1-36.
STOP.
Expected Result:
Test Step 5. Check for a Short Circuit to the +Battery Side at Terminal P1-37 A. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. B. Make sure that there is no electrical power to the device that provides the 4 to 20 mA signal. C. Remove the two wires (“+” and “-”) for the 4 to 20 mA signal from the device that supplies the 4 to 20 mA signal. Insulate the wire leads with electrical tape in order to ensure that the leads do not create a short circuit. D. Disconnect the P1 connector from the master ECM. E. Use an ohmmeter to measure the resistance between terminals P1-37 and P1-57. Expected Result: The resistance is greater than 20,000 Ohms. Results:
The resistance is greater than 20,000 Ohms. Results:
• Yes – The resistance is greater than 20,000 Ohms. The wiring from terminal P1-36 appears to be OK. Do not reconnect any connectors. Proceed to Test Step 7.
• No – The resistance is less than 20,000 Ohms.
There is a problem with a connection and/or the wiring from terminal P1-36.
Repair: The problem may be between the P1 connector and the J9 connector. Alternatively, the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal. Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved. STOP.
Test Step 7. Check the Device that Provides the 4 to 20 mA Signal
• Yes – The resistance is greater than 20,000 Ohms.
Measure the 4 to 20 mA signal according to the literature that is provided by the OEM of the device that provides the 4 to 20 mA signal. Verify that the correct signal is provided to the master ECM.
• No – The resistance is less than 20,000 Ohms.
Verify the correct 4 to 20 mA signal at terminals P1-36 and P1-37.
The wiring from terminal P1-37 is not shorted to the +Battery side. Do not reconnect any connectors. Proceed to Test Step 6. There is a problem with a connection and/or the wiring from terminal P1-37.
239 Troubleshooting Section
Expected Result: The correct 4 to 20 mA signal is provided to the master ECM. Results:
• Yes – The correct 4 to 20 mA signal is provided to the master ECM. However, the master ECM is not responding correctly to the signal. There may be a problem with the master ECM.
Repair: It is unlikely that the master ECM is faulty. Exit this procedure and perform this procedure again. If the problem is not resolved, replace the master ECM according to Troubleshooting, “Replacing the ECM”. Verify that the problem is resolved. STOP.
• No – The master ECM is not receiving the correct 4 to 20 mA signal. There is probably a problem with the device that provides the 4 to 20 mA.
Repair: Service the device that provides the 4 to 20 mA according to the literature that is provided by the OEM of the device. Verify that the problem is resolved. STOP. i02089065
Detonation Sensors SMCS Code: 1559-038 System Operation Description: Detonation sensors are located on the upper cylinder block between every two cylinders. Each sensor monitors two adjacent cylinders. For example, one sensor monitors cylinders 1 and 3 and one sensor monitors cylinders 2 and 4.
The master Electronic Control Module (ECM) and the slave ECM supply 8 VDC in order to power the sensors. The detonation sensors provide electrical signals to the modules that indicate mechanical engine vibrations. Each sensor outputs an electrical signal. The signal is amplified and the signal is filtered. The frequency of the signal corresponds to the mechanical frequency of the vibrations. The amplitude of the signal is proportional to the intensity of the vibrations. The master ECM monitors the detonation sensors on the left side of the engine. The slave ECM monitors the detonation sensors on the right side of the engine. Each ECM monitors the signals in order to determine the presence and the severity of the detonation. The master ECM can retard the timing of the cylinders on the left side of the engine in order to limit detonation levels. The slave ECM can retard the timing of the cylinders on the right side of the engine in order to limit detonation levels. The timing may be retarded for a single cylinder or for more than one cylinder. The timing may be retarded for all of the cylinders, if necessary. If retardation of the timing does not sufficiently limit the detonation, the master ECM will shut down the engine. An ECM can retard timing by as few as three degrees for light detonation levels. The timing can be retarded up to six degrees for severe detonation. For most applications, the minimum allowable actual timing is ten degrees BTC (five degrees BTC for propane operation). A proportional strategy is used for advancing the timing after the timing has been retarded. The rate of advance is based upon the level of detonation. The rate is faster for lighter detonation. The fastest rate of proportional timing advance is one degree per minute. Each ECM will diagnose the detonation sensors for a signal that is shorted to the −Battery side, to the +Battery side, or for an open circuit. To avoid detecting vibrations that are not related to detonation, each ECM only monitors a detonation sensor when one of the pistons that is monitored by that sensor is between top center and 40 degrees after top center on the power stroke. Therefore, the “Block Tap” method of testing the detonation sensors does not work for the G3500C Engine. An input from a detonation sensor that is diagnosed by an ECM as “open/shorted to +battery” may measure 0 VDC on a voltmeter. This is caused by the lack of pull up resistors in the detonation sensor’s circuits inside the ECM.
Illustration 66 Arrangement of the detonation sensors
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Each ECM also supports related event codes when the levels of detonation warrant a reaction from the ECM. If the timing has been retarded by the maximum amount and the level of detonation remains high, the master ECM will shut down the engine. Detonation protection is disabled when the engine speed is less than 250 rpm.
240 Troubleshooting Section
Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The most likely causes of the diagnostic code are a poor connection or a problem in a wiring harness. The next likely cause is a problem with a sensor. The least likely cause is a problem with an ECM. The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
241 Troubleshooting Section
Illustration 67 Schematic for the detonation sensors
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242 Troubleshooting Section
Test Step 1. Inspect the Electrical Connectors and Wiring
B. Thoroughly inspect each of the following connectors:
• J2/P2 connectors • J8/P8 connectors • J4/P4 connectors • Connectors for each of the detonation sensors a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 68
g01054206
Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
Illustration 70
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Harness side of the side of the P2 connector (P2-36) Detonation sensor signal for cylinders 2 and 4 (P2-37) Detonation sensor signal for cylinders 6 and 8 (P2-38) Detonation sensor signal for cylinders 10 and 12 (P2-39) Detonation sensor signal for cylinders 14 and 16 (P2-44) Detonation sensor signal for cylinders 18 and 20 (P2-54) Return for the detonation sensors (P2-55) Returnfor the detonation sensors (P2-56) +8 V supplyfor the detonation sensors (P2-57) +8 V supplyfor the detonation sensors
Illustration 69 Terminal box (2) J2/P2 connectors for the master ECM (3) J8/P8 connectors for the detonation sensors (4) J4/P4 connectors for the slave ECM
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243 Troubleshooting Section
Illustration 72
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Harness side of the P4 connector for the slave ECM
Illustration 71
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Harness side of the J8 connector (J8-1) 8 V Supply for the detonation sensor for cylinders 2 and 4 (J8-2) 8 V Supply for the detonation sensor for cylinders 6 and 8 (J8-3) 8 V Supply for the detonation sensor for cylinders 10 and 12 (J8-4) 8 V Supply for the detonation sensor for cylinders 14 and 16 (J8-5) 8 V Supply for the detonation sensor for cylinders 18 and 20 (J8-6) 8 V Supply for the detonation sensor for cylinders 1 and 3 (J8-7) 8 V Supply for the detonation sensor for cylinders 5 and 7 (J8-8) 8 V Supply for the detonation sensor for cylinders 9 and 11 (J8-9) 8 V Supply for the detonation sensor for cylinders 13 and 15 (J8-10) 8 V Supply for the detonation sensor for cylinders 17 and 19 (J8-11) Return for the detonation sensor for cylinders 2 and 4 (J8-12) Return for the detonation sensor for cylinders 6 and 8 (J8-13) Return for the detonation sensor for cylinders 10 and 12 (J8-14) Return for the detonation sensor for cylinders 14 and 16 (J8-15) Return for the detonation sensor for cylinders 18 and 20 (J8-16) Return for the detonation sensor for cylinders 1 and 3 (J8-17) Return for the detonation sensor for cylinders 5 and 7 (J8-18) Return for the detonation sensor for cylinders 9 and 11 (J8-19) Return for the detonation sensor for cylinders 13 and 15 (J8-20) Return for the detonation sensor for cylinders 17 and 19 (J8-21) Signal from the detonation sensor for cylinders 2 and 4 (J8-22) Signal from the detonation sensor for cylinders 6 and 8 (J8-23) Signal from the detonation sensor for cylinders 10 and 12 (J8-24) Signal from the detonation sensor for cylinders 14 and 16 (J8-25) Signal from the detonation sensor for cylinders 18 and 20 (J8-26) Signal from the detonation sensor for cylinders 1 and 3 (J8-27) Signal from the detonation sensor for cylinders 5 and 7 (J8-28) Signal from the detonation sensor for cylinders 9 and 11 (J8-29) Signal from the detonation sensor for cylinders 13 and 15 (J8-30) Signal from the detonation sensor for cylinders 17 and 19 (J8-31) Shield for the detonation sensor for cylinders 2 and 4 (J8-32) Shield for the detonation sensor for cylinders 6 and 8 (J8-33) Shield for the detonation sensor for cylinders 10 and 12 (J8-34) Shield for the detonation sensor for cylinders 14 and 16 (J8-35) Shield for the detonation sensor for cylinders 18 and 20 (J8-36) Shield for the detonation sensor for cylinders 1 and 3 (J8-37) Shield for the detonation sensor for cylinders 5 and 7 (J8-38) Shield for the detonation sensor for cylinders 9 and 11 (J8-39) Shield for the detonation sensor for cylinders 13 and 15 (J8-40) Shield for the detonation sensor for cylinders 17 and 19
(P4-36) Detonation sensor signal for cylinders 1 and 3 (P4-37) Detonation sensor signal for cylinders 5 and 7 (P4-38) Detonation sensor signal for cylinders 9 and 11 (P4-39) Detonation sensor signal for cylinders 13 and 15 (P4-44) Detonation sensor signal for cylinders 17 and 19 (P4-54) Return for the detonation sensors (P4-55) Return for the detonation sensors (P4-56) 8 volt supply for the detonation sensors (P4-57) 8 volt supply for the detonation sensors
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the detonation sensors.
Illustration 73
g00929792
Detonation sensors
d. Check the harness and wiring for abrasion and for pinch points from the detonation sensors to each ECM. e. Make sure that the detonation sensors are properly installed according to the torque in Specifications, “Detonation Sensors”. Expected Result: All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. All of the detonation sensors are properly installed.
244 Troubleshooting Section
Results:
• OK – The components are in good condition with proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good condition and/or at least one connection is improper.
Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Test Step 2. Check for Diagnostic Codes for the 8 Volt DC Supply A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. C. Observe the “Active Diagnostic” screen of Cat ET. Wait at least 30 seconds so that any codes may become activated. Look for these codes:
• “41-03 8 Volt DC Supply short to +batt” • “41-04 8 Volt DC Supply short to ground” Expected Result: Neither of the “8 Volt DC Supply” diagnostic codes are active. Results:
• OK – Neither of the “8 Volt DC Supply” diagnostic codes are active. Proceed to Test Step 3.
• Not OK – At least one of the “8 Volt DC Supply” diagnostic codes is active.
Repair: The “8 Volt DC Supply” diagnostic code must be resolved before you can proceed with this functional test. Exit this procedure and refer to Troubleshooting, “+8V Sensor Voltage Supply”. If necessary, return to this functional test in order to troubleshoot the detonation sensor after the “8 Volt DC Supply” diagnostic code has been resolved. STOP.
Test Step 3. Check for Active Diagnostic Codes for the Detonation Sensors Note: The run relay and the crank terminate relay must be energized before a diagnostic code for a detonation sensor can be generated. Therefore, the engine must be running. The engine will shut down soon after the diagnostic code for the detonation sensor is activated. A. Start the engine and run the engine. B. Allow a minimum of 30 seconds for any diagnostic codes to become active. Observe the “Active Diagnostic” screen of Cat ET and look for the diagnostic codes that are listed in Table 18:
245 Troubleshooting Section
Results:
Table 18
Description
Code 1501-03
Cylinder #1 Detonation Sensor short to +batt
1501-04
Cylinder #1 Detonation Sensor short to ground
1502-03
Cylinder #2 Detonation Sensor short to +batt
1502-04
Cylinder #2 Detonation Sensor short to ground
1505-03
Cylinder #5 Detonation Sensor short to +batt
1505-04
Cylinder #5 Detonation Sensor short to ground
1506-03
Cylinder #6 Detonation Sensor short to +batt
1506-04
Cylinder #6 Detonation Sensor short to ground
1509-03
Cylinder #9 Detonation Sensor short to +batt
1509-04
Cylinder #9 Detonation Sensor short to ground
1510-03
Cylinder #10 Detonation Sensor short to +batt
1510-04
Cylinder #10 Detonation Sensor short to ground
1513-03
Cylinder #13 Detonation Sensor short to +batt
1513-04
Cylinder #13 Detonation Sensor short to ground
1514-03
Cylinder #14 Detonation Sensor short to +batt
1514-04
Cylinder #14 Detonation Sensor short to ground
1517-03
Cylinder #17 Detonation Sensor short to +batt
1517-04
Cylinder #17 Detonation Sensor short to ground
1518-03
Cylinder #18 Detonation Sensor short to +batt
1518-04
Cylinder #18 Detonation Sensor short to ground
Cylinders
• OK (No active codes) – None of the above codes
1 and 3
are active at this time. The problem seems to be resolved. The original diagnostic code was probably caused by a poor electrical connection in one of the harness connectors.
2 and 4
Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshooting, “Troubleshooting Without a Diagnostic Code”.
5 and 7
6 and 8
If any of the above codes are logged and the engine is running properly, there may be an intermittent problem in a connector or a wiring harness. Refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Not OK (Active Code) – A “short to +batt” or “short to ground” diagnostic code was activated.
9 and 11
Repair: Note the diagnostic code and note the location of the suspect detonation sensor. Proceed to Test Step 4.
10 and 12
13 and 15
Test Step 4. Verify the Presence of the Supply Voltage at the Sensor A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the detonation sensor with the diagnostic code.
14 and 16
C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
17 and 19
18 and 20
Note: A “short to ground” diagnostic code can indicate either an actual short to ground or an open circuit. Expected Result: None of the above diagnostic codes are active.
Illustration 74
g00890518
Harness connector for the detonation sensors (A) 8 volt supply (B) Return (C) Signal
D. Measure the voltage between terminals A and B on the harness connector for the sensor. Expected Result: The voltage is between 7.6 VDC and 8.4 VDC.
246 Troubleshooting Section
• No – The voltage is not between 0.4 VDC and 0.6
Results:
• OK – The voltage is between 7.6 VDC and 8.4
VDC. The correct voltage is available to the sensor. Do not reconnect the sensor. Proceed to Test Step 5.
• Not OK – The voltage is not between 7.6 VDC and
8.4 VDC. The correct voltage is not available to the sensor. There is probably an open circuit in the 8 volt supply or in the return for the sensor. Repair: The open circuit may be caused by a poor electrical connection or a wiring problem between the ECM and the connector for the sensor. Repair the electrical connection and/or the wiring, when possible. Replace the harness, if necessary. STOP.
Test Step 5. Measure the Voltage of the Signal Wire at the Sensor
Illustration 75
g00890518
Harness connector for the detonation sensors (A) 8 volt supply (B) Return (C) Signal
A. Measure the voltage between terminals B and C on the harness connector for the suspect sensor. Expected Result: The voltage is between 0.4 VDC and 0.6 VDC. Results:
• Yes – The voltage is between 0.4 VDC and 0.6 VDC.
Repair: Reconnect the suspect sensor. Start the engine again and check for the diagnostic code. If the diagnostic code recurs, replace the detonation sensor with a known good detonation sensor. Tighten the detonation sensor according to the torque in Specifications, “Detonation Sensor”. Verify that the problem is resolved. STOP.
VDC. If the voltage is less than 0.4 VDC, there is probably a short to ground or an open circuit between the connector for the detonation sensor and the ECM. If the voltage is greater than 4.8 VDC, there is probably a short circuit to a +Battery source between the connector for the detonation sensor and the ECM. If you are troubleshooting a detonation sensor for the master ECM, proceed to Test Step 6. If you are troubleshooting a detonation sensor for the slave ECM, proceed to Test Step 7.
Test Step 6. Check the Operation of the Master ECM A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Use a 151-6320 Wire Removal Tool to remove the signal wire for the suspect sensor from the P2 connector. This will replace the sensor circuit with an open circuit. C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Note: The run relay and the crank terminate relay must be energized before a diagnostic code for a detonation sensor can be generated. Therefore, the engine must be running. The engine will shut down soon after the diagnostic code for the detonation sensor is activated. D. Start the engine. Observe the “Active Diagnostic” screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. An active “open/short to +batt” diagnostic code is generated for the sensor. E. Set the engine control to the OFF/RESET mode.
247 Troubleshooting Section
Repair: Remove the jumper wire. Insert the terminal that was removed from the P2 connector. Pull on the wire in order to verify that the terminal is fully inserted into the connector. Repair the harness, when possible. Replace the harness, if necessary. STOP.
• Not OK – No active “open/short to +batt” and
“short to ground” diagnostic codes were generated. The master ECM is not operating correctly. Repair: It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”.
Illustration 76
g01065294
Master ECM with jumper wire (1) P2 connector (2) P1 connector (3) Jumper wire
F. Fabricate a jumper wire that is long enough to reach between the P1 connector and the P2 connector. Install Deutsch terminals on the ends. Install one end of jumper wire (3) into the terminal for the signal wire that was removed from the P2 connector (1). Install the other end of the jumper wire into terminal 19 of the P1 connector (2). This will replace the sensor circuit with a short circuit to ground. G. Start the engine. Observe the “Active Diagnostic” screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. An active “short to ground” diagnostic code is generated for the sensor. Expected Result: Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. Results:
• OK – Active “open/short to +batt” and “short to
ground” diagnostic codes are generated according to the above steps. The master ECM is operating correctly. There is probably an open circuit in a harness between the master ECM and the connector for the sensor.
If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
Test Step 7. Check the Operation of the Slave ECM A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Use a 151-6320 Wire Removal Tool to remove the signal wire for the suspect sensor from the P4 connector. This will replace the sensor circuit with an open circuit. C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Note: The run relay and the crank terminate relay must be energized before a diagnostic code for a detonation sensor can be generated. Therefore, the engine must be running. The engine will shut down soon after the diagnostic code for the detonation sensor is activated. D. Start the engine. Observe the “Active Diagnostic” screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. An active “open/short to +batt” diagnostic code is generated for the sensor. E. Set the engine control to the OFF/RESET mode.
248 Troubleshooting Section
Repair: Remove the jumper wire. Insert the terminal that was removed from the P4 connector. Pull on the wire in order to verify that the terminal is fully inserted into the connector. Repair the harness, when possible. Replace the harness, if necessary. STOP.
• Not OK – No active “open/short to +batt” and
“short to ground” diagnostic codes were generated. The slave ECM is not operating correctly. Repair: It is unlikely that the slave ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new slave ECM. Refer to Troubleshooting, “Replacing the ECM”.
Illustration 77
g01065295
Slave ECM with jumper wire (1) P4 connector (2) P3 connector (3) Jumper wire
F. Fabricate a jumper wire that is long enough to reach between the P4 connector and the P3 connector. Install Deutsch terminals on the ends. Install one end of jumper wire (3) into the terminal for the signal wire that was removed from the P4 connector (1). Install the other end of the jumper wire into terminal 19 of the P3 connector (2). This will replace the sensor circuit with a short circuit to ground. G. Start the engine. Observe the “Active Diagnostic” screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. An active “short to ground” diagnostic code is generated for the sensor. Expected Result: Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. Results:
• OK – Active “open/short to +batt” and “short to
ground” diagnostic codes are generated according to the above steps. The slave ECM is operating correctly. There is probably an open circuit in the harness between the slave ECM and the connector for the sensor.
If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP. i02089084
ECM Output Circuit (Fuel Control) SMCS Code: 1901-038 System Operation Description: The master Electronic Control Module (ECM) contains the logic and the outputs for starting and stopping the engine. The logic for starting and stopping is customer programmable. The logic responds to inputs from the following components: engine control switch, emergency stop switch, remote start switch, data link, and other inputs. The fuel control relay is energize-to-run. To enable fuel flow to the engine, the relay for the Gas Shutoff Valve (GSOV) must be energized. The master ECM provides +Battery voltage to the relay for the GSOV when the logic determines that fuel is required for engine operation. For engine shutdown, the master ECM removes the voltage from the fuel control relay. This stops the fuel flow.
249 Troubleshooting Section
The output circuit for the relay for the GSOV includes the J6 connector. If the J6 connector is not used, a jumper wire must be connected between terminals 21 and 31. The voltage will be removed from the fuel control relay if the jumper wire is not connected. The jumper wire must be connected in order for the engine to start. The jumper wire must remain connected in order for the engine to run. Refer to Illustration 78 for the schematic diagram. Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with the GSOV. The least likely cause is a problem with the master ECM. The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved. Connections for the Fuel Control Relay The fuel control relay may be connected to either of the following connectors:
• P6 via wiring that is provided by the customer • P7 via the engine harness If the fuel control relay is connected to P6, terminals P6-21 and P6-24 are used. If the fuel control relay is connected to P7, a jumper wire must be connected between terminals P6-21 and P6-31. This procedure may be used to troubleshoot either configuration.
250 Troubleshooting Section
Illustration 78 Optional connections for the fuel control relay
g01065314
251 Troubleshooting Section
Test Step 1. Inspect the Electrical Connectors and Wiring
C. Thoroughly inspect the following connectors and the wiring harnesses for the connectors:
• J2/P2 connectors • J6/P6, and J7/P7 connectors • Connectors for the fuel control relay a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 79
g01054206
Junction box (1) 35 amp circuit breaker
A. Switch 35 amp circuit breaker (1) to the OFF position. Illustration 81
g00930126
Harness side of the P2 connector (P2-11) Circuit driver for the fuel control relay (P2-21) Return
Illustration 80
g01065317
Terminal box (2) J2/P2 connectors for the master ECM (3) J6/P6 connector for the customer (4) J7/P7 connectors for the harness from the fuel control relay
B. Set the engine control to the OFF/RESET mode. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
Illustration 82 Harness side of the J6 connector (J6-21) Circuit driver for the fuel control relay (J6-24) Return (J6-31) Circuit for the fuel control relay
g00952066
252 Troubleshooting Section
Expected Result: All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. Results:
• OK – The components are in good condition with proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good condition and/or at least one connection is improper.
Repair: Perform the necessary repairs, when possible. Replace parts, if necessary. STOP.
Test Step 2. Check for Diagnostic Codes A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”.
Illustration 83
g00929957
B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. C. Wait for 30 seconds and use Cat ET to check for an active “17-05 Fuel Shutoff Valve open circuit” diagnostic code.
Harness side of the J7 connector (J7-50) Circuit driver for the fuel control relay (J7-64) Return
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel control relay.
If there is an active “17-05 Fuel Shutoff Valve open circuit” diagnostic code, proceed to the “Results” for this Test Step. Otherwise, continue this procedure. Note: The “17-05 Fuel Shutoff Valve open circuit” diagnostic code cannot be detected when the output for the fuel control relay is ON. The output is ON when the engine control is in the START mode and the engine speed is not zero. D. Use Cat ET to check the logged diagnostic codes. If there is a “17-06 Fuel Shutoff Valve short to ground” or a “17-12 Fuel Shutoff Valve malfunction” diagnostic code, clear the code.
Illustration 84
g00869737
Typical fuel control relay
d. Check the harness and wiring for abrasion and pinch points from the fuel control relay to the master ECM.
Note: This diagnostic condition cannot be detected by the master ECM when the output for the fuel control relay is OFF. The output is OFF when the engine control is in the STOP mode. E. To prevent the engine from starting, shut the gas supply OFF.
253 Troubleshooting Section
Note: To provide the output for the fuel control relay, the sequence for engine start-up must be initiated. Otherwise, a “17-06 Fuel Shutoff Valve short to ground” or a “17-12 Fuel Shutoff Valve malfunction” diagnostic code cannot be generated.
Test Step 3. Check for a Short Circuit to the +Battery Side
F. Set the engine control to the START mode for at least 30 seconds. Then set the engine control to the STOP mode. G. Use Cat ET to look for a logged “17-06 Fuel Shutoff Valve short to ground” or a “17-12 Fuel Shutoff Valve malfunction” diagnostic code again.
Gaseous fuel is present. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Contact you local gas provider immediately for assistance in the event of a leak.
Expected Result:
Note: Open sparks can be generated during this test.
When the engine control was in the STOP mode, there was no active “17-05 Fuel Shutoff Valve open circuit” diagnostic code.
A. Make sure that no combustible gas is present in the surrounding atmosphere.
After the engine was cranked, there was no logged “17-06 Fuel Shutoff Valve short to ground” or “17-12 Fuel Shutoff Valve malfunction” diagnostic code. Results:
• OK – No diagnostic codes were generated. The
output for the fuel control relay seems to be OK at this time. The initial diagnostic code was probably caused by a poor electrical connection. Repair: If there is an intermittent problem that is causing the codes to be logged, refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Not OK (“17-05 Fuel Shutoff Valve open circuit”
diagnostic code) – A “17-05 Fuel Shutoff Valve open circuit” diagnostic code was activated. This can be caused by an actual open circuit or by a short circuit to the +Battery side. Proceed to Test Step 3.
• Not OK (“17-06 Fuel Shutoff Valve short to ground” diagnostic code) – After the engine was cranked, a “17-06 Fuel Shutoff Valve short to ground” diagnostic code was generated. Proceed to Test Step 7.
• Not OK (“17-12 Fuel Shutoff Valve malfunction”
diagnostic code) – After the engine was cranked, a “17-12 Fuel Shutoff Valve malfunction” diagnostic code was generated. The master ECM disabled the ignition. Repair: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Replace the fuel control relay. STOP.
B. Verify that the engine control is in the STOP mode. C. Disconnect the connector from the fuel control relay. Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. The relay is not energized when the engine control is in the STOP mode. Results:
• OK – There is no audible click and/or vibration
when the relay is disconnected and connected. There is no short circuit to the +Battery side. There is an open circuit. Proceed to Test Step 5.
• Not OK – There is an audible click and/or vibration
when the relay is disconnected and connected. The relay is receiving power when the engine control is in the STOP mode. There is probably a short circuit to the +Battery side in a connector or a wiring harness. Proceed to Test Step 4.
254 Troubleshooting Section
Test Step 4. Determine the Cause of the Energized Relay
Gaseous fuel is present. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Contact you local gas provider immediately for assistance in the event of a leak. Note: Open sparks can be generated during this test. A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
4. Disconnect the connector from the fuel control relay. Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. If the relay is not energized, there is an intermittent problem with a connector and/or the wiring. Refer to Troubleshooting, “Inspecting Electrical Connectors”. If the relay is energized, there may be a problem with the master ECM.
B. Use a 151-6320 Wire Removal Tool to remove terminals P2-11 and P2-21.
It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps:
C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”.
D. Disconnect the connector from the fuel control relay. Then reconnect the connector. Listen for an audible click from the relay.
If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”.
If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. The relay is not energized when the wiring is removed from the P2 connector.
STOP.
• Not OK – There is an audible click and/or vibration when the relay is disconnected and reconnected. The relay is energized when the wiring is removed from the P2 connector. There is a short circuit to the +Battery side in a harness.
Results:
Repair: Repair the wiring and/or the connector, when possible. Replace parts, if necessary.
• OK – There is no audible click and/or vibration
STOP.
when the solenoid is disconnected and reconnected. The relay is not energized when the wiring is removed from the P2 connector.
Test Step 5. Create a Short Circuit in order to Check for an Open Circuit
Repair: Use the following procedure to determine whether the circuit driver for the relay is faulty:
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
B. Disconnect the fuel control relay’s connector.
2. Reinstall terminals P2-11 and P2-21. Pull on the wires in order to verify proper installation of the terminals. 3. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
255 Troubleshooting Section
If the problem is not resolved, replace the fuel control relay. STOP.
• Not OK – A “17-05 Fuel Shutoff Valve open circuit” diagnostic code was generated when the jumper wire was installed. There may be an open circuit in a harness. Proceed to Test Step 6.
Test Step 6. Check the Master ECM A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Illustration 85
g01065318
(1) Connector for the fuel control relay (2) Jumper wire
B. Use the 151-6320 Wire Removal Tool to remove terminals P2-11 and P2-21.
C. Install a jumper wire (2) into the two terminals of the relay’s connector (1) on the engine harness. D. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Note: The “17-05 Fuel Shutoff Valve open circuit” diagnostic code can only be detected when the output for the fuel control relay is OFF. The output is OFF when the engine control is in the STOP mode and the engine is not running. E. Wait for 30 seconds and use the “Active Diagnostic” screen of Cat ET to look for a “17-05 Fuel Shutoff Valve open circuit” diagnostic code. Expected Result: A “17-05 Fuel Shutoff Valve open circuit” diagnostic code was not generated when the jumper wire was installed. Results:
• OK – A “17-05 Fuel Shutoff Valve open circuit”
Illustration 86
g01065319
P2 connector with jumper wire (1) Jumper wire (2) P2 connector
diagnostic code was not generated when the jumper wire was installed. The harness and the ECM are OK. There is a problem with the relay.
C. Install a jumper wire (1) into terminals P2-11 and P2-21. Pull on the jumper wire in order to verify proper installation.
Repair: Perform the following procedure:
D. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Remove the jumper wire from the relay’s connector on the engine harness. 3. Inspect the relay’s connector for damage, for moisture, and for corrosion. 4. Make repairs, as needed.
Note: The “17-05 Fuel Shutoff Valve open circuit” diagnostic code can only be detected when the output for the fuel control relay is OFF. The output is OFF when the engine control is in the STOP mode and the engine is not running. E. Wait for 30 seconds and use the “Active Diagnostic” screen of Cat ET to look for an active “17-05 Fuel Shutoff Valve open circuit” diagnostic code.
256 Troubleshooting Section
Expected Result: There is no active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. Results:
• OK – When the jumper wire was installed, there
was no active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. The master ECM detects the jumper wire at the P2 connector. However, the master ECM did not detect the jumper wire at the connector for the fuel control relay. There is a problem between the P2 connector and the connector for the fuel control relay. Repair: Perform the following procedure: 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. 3. Reinstall the terminals into P2-11 and P2-21. Pull on the wires in order to verify proper installation of the terminals. 4. Thoroughly inspect the J6/P6 and J7/P7 connectors. Inspect the wiring that is connected to terminals J6-21 and J6-31. 5. Make repairs, if necessary. STOP.
• Not OK – When the jumper wire was installed, a
“17-05 Fuel Shutoff Valve open circuit” diagnostic code was activated. The master ECM did not detect the jumper wire. There is a problem with the master ECM. Repair: Perform the following procedure: 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector.
3. Reinstall the terminals into P2-11 and P2-21. Pull on the wires in order to verify proper installation of the terminals. 4. Replace the master ECM according to Troubleshooting, “Replacing the ECM”. Verify that the problem is resolved. STOP.
Test Step 7. Create an Open Circuit in order to Check for a Short Circuit to Ground A. Set the engine control to the OFF/RESET mode. B. Disconnect the connector from the fuel control relay. C. Set the engine control to the STOP mode. D. Use Cat ET to clear the logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code. E. To prevent the engine from starting, shut OFF the main gas supply. Note: To provide the output for the fuel control relay, the sequence for engine start-up must be initiated. Otherwise, a “17-06 Fuel Shutoff Valve short to ground” diagnostic code cannot be generated. F. Set the engine control to the START mode for at least 30 seconds. Then set the engine control to the STOP mode. G. Use Cat ET to look for a logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code again. Expected Result: A “17-06 Fuel Shutoff Valve short to ground” was not generated. Results:
• OK – When the relay was connected, a “short to
ground” diagnostic code was generated. When the relay was disconnected, no “short to ground” diagnostic code was generated. There is a problem with the relay. Repair: Perform the following procedure: 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Inspect the relay’s connectors for damage and/or for corrosion. 3. Make repairs, as needed. If the problem is not resolved, replace the relay. STOP.
• Not OK – A “short to ground” diagnostic code
was generated when the relay was disconnected. There is a problem with the wiring or with the ECM. Proceed to Test Step 8.
257 Troubleshooting Section
Test Step 8. Check the Master ECM A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Use the 151-6320 Wire Removal Tool to remove terminal P2-11.
• Not OK – A “17-06 Fuel Shutoff Valve short to
ground” diagnostic code was generated when the output to the relay was disconnected from the P2 connector. There may be a problem with the master ECM. Repair: Perform the following procedure:
C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
D. Use Cat ET to clear the logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code.
2. Reinstall the terminal that was removed from P2-11. Pull on the wire in order to verify proper installation of the terminal.
E. To prevent the engine from starting, shut OFF the main gas supply. Note: To provide the output for the fuel control relay, the sequence for engine start-up must be initiated. Otherwise, a “17-06 Fuel Shutoff Valve short to ground” diagnostic code cannot be generated. F. Set the engine control to the START mode for at least 30 seconds. Then set the engine control to the STOP mode. G. Use Cat ET to look for a logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code again. Expected Result: The “17-06 Fuel Shutoff Valve short to ground” diagnostic code was not generated. Results:
• OK – When the output to the relay was
disconnected from the P2 connector, the “17-06 Fuel Shutoff Valve short to ground” diagnostic code was not generated. However, a “short to ground” diagnostic code was generated when the connector was disconnected from the fuel control relay. There is a problem in the wiring between the P2 connector and the connector for the fuel control relay. Repair: Perform the following procedure: 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Reinstall the terminal that was removed from P2-11. Pull on the wire in order to verify proper installation of the terminal. 3. Repair the harness, when possible. Replace the harness, if necessary. STOP.
3. It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP. i02089116
ECM Output Circuit (Starting Motor) SMCS Code: 1901-038 System Operation Description: The master Electronic Control Module (ECM) contains the logic and the outputs for starting the engine. The logic for starting is customer programmable. The logic responds to inputs from the following components: engine control switch, emergency stop switch, remote start switch, data link, and other inputs. Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with a magnetic switch or with a relay. The least likely cause is a problem with the master ECM.
258 Troubleshooting Section
The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved. Electric Start The master ECM supplies +Battery voltage to two magnetic switches when the logic determines that it is necessary. Each magnetic switch provides +Battery voltage to a solenoid on an electric starting motor. The master ECM removes the voltage when the crank terminate relay is energized. The voltage is also removed if the customer programmable “Overcrank Time” has expired. Air Start The master ECM supplies +Battery voltage to the air start relay when the logic determines that it is necessary. The master ECM removes the voltage when the crank terminate relay is energized. The voltage is also removed if the customer programmable “Overcrank Time” has expired.
259 Troubleshooting Section
Illustration 87
g01065332
Schematic for the electric starting system
Illustration 88 Schematic for the air starting system
g01065333
260 Troubleshooting Section
Test Step 1. Inspect the Electrical Connectors and Wiring
B. Thoroughly inspect the following connectors and the wiring harnesses for the connectors:
• J2/P2 connectors • J7/P7 connectors a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 89
g01054206
Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
Illustration 90
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Terminal box (2) J2/P2 connectors for the master ECM (3) J7/P7 connectors for the wiring from the starting system
Illustration 91 Harness side of the P2 connector (P2-10) Start command (P2-20) Return for the start command
g01055043
261 Troubleshooting Section
Test Step 2. Check for Diagnostic Codes A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Note: The “444-05 Start Relay open circuit” diagnostic code can only be detected when the output for the start command is OFF. The output is normally OFF when the engine control is in the STOP mode or when the crank terminate relay is energized. C. Wait for 30 seconds and use Cat ET to check for an active “444-05 Start Relay open circuit” diagnostic code. If there is an active “444-05 Start Relay open circuit” diagnostic code, proceed to the “Results” for this Test Step. Otherwise, continue this procedure. D. Use Cat ET to check the logged diagnostic codes. If there is a logged “444-06 Start Relay short to ground” diagnostic code, clear the code. Illustration 92
g00931050
Harness side of the J7 connector (J7-28) Start command (J7-56) Return for the start command
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the starter motor relay. d. Check the harness and wiring for abrasion and for pinch points from the starter motor relay to the master ECM. Expected Result: All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.
E. To prevent the engine from starting, shut the gas supply OFF. Note: The “444-06 Start Relay short to ground” diagnostic code can only be detected when the output for the start command is ON. The output is normally ON when the engine control is set from the STOP mode to the START mode. The output remains ON until the crank terminate relay is energized. F. Set the engine control to the START mode for at least six seconds. Then set the engine control to the STOP mode. G. Use Cat ET to look for a logged “444-06 Start Relay short to ground” diagnostic code again. Expected Result:
• OK – The components are in good condition with
When the engine control was in the STOP mode, there was no active “444-05 Start Relay open circuit” diagnostic code.
• Not OK – The components are not in good
After the engine was cranked, there was no logged “444-06 Start Relay short to ground” diagnostic code.
Results: proper connections. Proceed to Test Step 2. condition and/or at least one connection is improper.
Repair: Perform the necessary repairs, when possible. Replace parts, if necessary. STOP.
Results:
• OK – No diagnostic codes were activated. The
output for the start command seems to be OK at this time. The initial diagnostic code was probably caused by a poor electrical connection.
262 Troubleshooting Section
Repair: If there is an intermittent problem that is causing the codes to be logged, refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Not OK (“444-05 Start Relay open circuit”
diagnostic code) – A “444-05 Start Relay open circuit” diagnostic code was activated. This can be caused by an actual open circuit or by a short circuit to the +Battery side. If the engine is equipped with an air starting system, proceed to Test Step 3. If the engine is equipped with an electric starting system, proceed to Test Step 9.
• Not OK (“444-06 Start Relay short to ground”
diagnostic code) – After the engine was cranked, a “444-06 Start Relay short to ground” diagnostic code was activated. If the engine is equipped with an air starting system, proceed to Test Step 7. If the engine is equipped with an electric starting system, proceed to Test Step 10.
Test Step 3. Check for a Short Circuit to the +Battery Side
Gaseous fuel is present. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Contact you local gas provider immediately for assistance in the event of a leak.
Results:
• OK – There is no audible click and/or vibration
when the air start relay is disconnected and connected. There is no short circuit to the +Battery side. There is an open circuit. Proceed to Test Step 4.
• Not OK – There is an audible click and/or vibration when the air start relay is disconnected and connected. The relay is receiving power when the engine control is in the STOP mode. Proceed to Test Step 6.
Test Step 4. Create a Short Circuit in order to Check for an Open Circuit A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the harness connector from the air start relay. C. Install a jumper wire into the two terminals of the harness connector for the air start relay. D. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. E. Wait for 30 seconds and use the “Active Diagnostic” screen of Cat ET to look for a “444-05 Start Relay open circuit” diagnostic code. Expected Result: A “444-05 Start Relay open circuit” diagnostic code was not activated when the jumper wire was installed.
Note: Open sparks can be generated during this test.
Results:
A. Make sure that no combustible gas is present in the surrounding atmosphere.
• OK – A “444-05 Start Relay open circuit” diagnostic
B. Ensure that the engine control is in the STOP mode. C. Disconnect the connector from the air start relay. Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the air start relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. Expected Result: There is no audible click and/or vibration when the air start relay is disconnected and reconnected. The relay is not energized when the engine control is in the STOP mode.
code was not activated when the jumper wire was installed. The master ECM detected the short circuit. The harness and the master ECM are OK. There is a problem with the air start relay. Repair: Perform the following procedure: 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Remove the jumper wire from the harness connector. 3. Inspect the relay’s connector and the harness connector for the relay. Check for damage, for moisture, and for corrosion. 4. Make repairs, as needed.
263 Troubleshooting Section
If the problem is not resolved, replace the air start relay.
4. Repair the harness, when possible. Replace the harness, if necessary.
STOP.
STOP.
• Not OK – A “444-05 Start Relay open circuit”
diagnostic code was activated when the jumper wire was installed. The master ECM did not detect the short circuit. Proceed to Test Step 5.
Test Step 5. Check the Master ECM A. Ensure that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF.
• No – When the jumper wire was installed, a
“444-05 Start Relay open circuit” diagnostic code was activated. The master ECM did not detect the jumper wire. There is a problem with the master ECM. Repair: Perform the following procedure: 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
B. Use a 151-6320 Wire Removal Tool to remove terminals P2-10 and P2-20.
2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector.
C. Install a jumper wire into terminals P2-10 and P2-20. Pull on the jumper wire in order to verify proper installation.
3. Reinstall terminals P2-10 and P2-20. Pull on the wires in order to verify proper installation of the terminals.
D. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps:
E. Wait for 30 seconds and use the “Active Diagnostic” screen of Cat ET to look for an active “444-05 Start Relay open circuit” diagnostic code. Expected Result: There is no active “444-05 Start Relay open circuit” diagnostic code. Results:
• OK – When the jumper wire was installed,
Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
there was no active “444-05 Start Relay open circuit” diagnostic code. The master ECM detects the jumper wire at the P2 connector. However, the master ECM did not detect the jumper wire at the relay’s connector. There is a problem with the wiring.
Test Step 6. Create an Open Circuit in order to Check for a Short Circuit
The problem could be between the P2 connector and the J7 connector. Alternatively, the problem could be in the P7 connector or the wiring that is connected to the P7 connector.
B. Use a 151-6320 Wire Removal Tool to remove terminals P2-10 and P2-20.
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
Repair: Perform the following procedure:
C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
D. To prevent the engine from starting, shut OFF the main gas supply.
2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector.
E. Set the engine control to the START mode for at least six seconds. Then set the engine control to the STOP mode.
3. Reinstall terminals P2-10 and P2-20. Pull on the wires in order to verify proper installation of the terminals.
264 Troubleshooting Section
Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. The relay is not energized when the engine control is in the STOP mode. Results:
• OK – When the master ECM was connected, the
relay was receiving power. When the master ECM was not connected, the relay was not receiving power. There may be a problem with the master ECM. Repair: Perform the following procedure: 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Reinstall terminals P2-10 and P2-20. Pull on the wires in order to verify proper installation of the terminals.
It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
• Not OK – When the master ECM was connected,
B. Disconnect the harness connector from the air start relay. C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. D. To prevent the engine from starting, shut OFF the main gas supply. Note: The “444-06 Start Relay short to ground” diagnostic code can only be detected when the output for the start command is ON. The output is normally ON when the engine control is set from the STOP mode to the START mode. The output remains ON until the crank terminate relay is energized. E. Set the engine control to the START mode for at least six seconds. Then set the engine control to the STOP mode. F. Use Cat ET to look for a logged “444-06 Start Relay short to ground” diagnostic code again. Expected Result: A “444-06 Start Relay short to ground” was not activated. Results:
• OK – A “444-06 Start Relay short to ground”
diagnostic code was not activated when the air start relay was disconnected. There is a problem with the air start relay. Repair: Perform the following procedure: 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Remove the jumper wire from the connector.
the relay was receiving power. When the master ECM was not connected, the relay was still receiving power. There is a problem with the wiring.
3. Inspect the connectors for the air start relay. Check for damage, for moisture, and for corrosion.
The problem could be between the P2 connector and the J7 connector. Alternatively, the problem could be in the P7 connector or the wiring that is connected to the P7 connector.
4. Make repairs, as needed.
Repair: Repair the harness, when possible. Replace the harness, if necessary. STOP.
Test Step 7. Create an Open Circuit at the Air Start Relay A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
If the problem is not resolved, replace the air start relay. STOP.
• Not OK – A “444-06 Start Relay short to ground”
diagnostic code was activated when the air start relay was disconnected. The air start relay is OK. Proceed to Test Step 8.
265 Troubleshooting Section
Test Step 8. Check the Master ECM
Repair: Perform the following procedure:
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
B. Use the 151-6320 Wire Removal Tool to remove terminals P2-10 and P2-20.
2. Reinstall terminals P2-10 and P2-20. Pull on the wires in order to verify proper installation of the terminals.
C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. D. To prevent the engine from starting, shut OFF the main gas supply. Note: The “444-06 Start Relay short to ground” diagnostic code can only be detected when the output for the start command is ON. The output is normally ON when the engine control is set from the STOP mode to the START mode. The output remains ON until the crank terminate relay is energized. E. Set the engine control to the START mode for at least six seconds. Then set the engine control to the STOP mode. F. Use Cat ET to look for a logged “444-06 Start Relay short to ground” diagnostic code again. Expected Result:
It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
Test Step 9. Check the “SM” Circuit Breaker
The “444-06 Start Relay short to ground” diagnostic code was not activated. Results:
• OK – When the wiring was disconnected from
the master ECM, a “444-06 Start Relay short to ground” diagnostic code was not activated. There is a problem with the wiring. The problem could be between the P2 connector and the J7 connector. Alternatively, the problem could be in the P7 connector or the wiring that is connected to the P7 connector. Repair: Perform the following procedure: 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Reinstall terminals P2-10 and P2-20. Pull on the wires in order to verify proper installation of the terminals. 3. Repair the harness, when possible. Replace the harness, if necessary. STOP.
• Not OK – When the wiring was disconnected from the master ECM, a “444-06 Start Relay short to ground” diagnostic code was activated. There seems to be a problem with the master ECM.
Illustration 93
g01055051
“SM” circuit breaker (2.5 amp)
A. Verify that the “SM” circuit breaker is in the ON position. Expected Result: The “SM” circuit breaker is in the ON position.
266 Troubleshooting Section
Results:
• OK – The “SM” circuit breaker is in the ON position. Proceed to Test Step 10.
• Not OK – The “SM” circuit breaker is not in the ON position.
Repair: Switch the “SM” circuit breaker to the ON position. If the circuit breaker remains in the ON position, the problem may be resolved. Perform the following procedure: 1. Verify that the 35 amp circuit breaker is ON. Set the engine control to the STOP mode. Note: The “444-05 Start Relay open circuit” diagnostic code can only be detected when the output for the start command is OFF. The output is normally OFF when the engine control is in the STOP mode or when the crank terminate relay is energized. 2. Wait for 30 seconds and use Cat ET to check for an active “444-05 Start Relay open circuit” diagnostic code. If there is no active “444-05 Start Relay open circuit” diagnostic code, the problem appears to be resolved. Resume normal operation.
Illustration 94
g00931289
Terminals on the junction box
B. Verify that the power is disconnected by checking for voltage at the “+” and “-” terminals on the junction box. The voltage on the terminals should be zero VDC.
If there is an active “444-05 Start Relay open circuit” diagnostic code, proceed to Test Step 10.
Test Step 10. Inspect the Inside of the Junction Box A. Disconnect the +24 V power supply from the engine.
Illustration 95
g00931303
Fasteners for the junction box
C. Remove seven bolts and nuts. Open the junction box. D. Inspect the inside of the junction box. Check for moisture and for corrosion. Verify that each electrical connection inside the junction box is securely connected.
267 Troubleshooting Section
Expected Result:
Expected Result:
The inside of the junction box does not have moisture or corrosion. All of the electrical connections inside the junction box are securely connected.
All of the measurements are an open circuit.
Results:
• OK – All of the measurements are an open circuit.
• OK – The inside of the junction box does not
have moisture or corrosion. All of the electrical connections inside the junction box are securely connected. Proceed to Test Step 11.
• Not OK – The inside of the junction box has moisture or corrosion and/or there is a loose electrical connection.
Repair: Perform the necessary repairs, when possible. Replace parts, if necessary. STOP.
Test Step 11. Check for an Open Circuit A. Use a 151-6320 Wire Removal Tool to remove terminals P2-10 and P2-20.
Results: There is not a short circuit to the +Battery. Proceed to Test Step 12.
• Not OK – At least one measurement is not an
open circuit. There is a short circuit to the +Battery. Repair: Repair the wiring and/or the connection, when possible. Replace parts, if necessary. STOP.
Test Step 12. Check for a Short Circuit A. Verify that the “SM” circuit breaker is in the ON position. B. Use a multimeter to check for a short circuit between the points that are listed in Table 20: Note: Refer to Illustration 87, if necessary. Table 20
Points to Check for a Short Circuit Point
g01055064
Illustration 96 Section view of the junction box (1) Coil terminals on the magnetic switches (2) Terminals on the “SM” circuit breaker
B. Use a multimeter to check for an open circuit between the points that are listed in Table 19:
Point
P2-10
The connection for the “SM”circuit breaker that is connected to wire “P6B0A-RD”
One of the connections for the “SM” circuit breaker
The other connection for the “SM” circuit breaker
The connection for the “SM” circuit breaker that is connected to wire “P6B0B-RD”
The coil terminal of each magnetic switch that is connected to wire “C990-RD”
The coil terminal of each magnetic switch that is connected to wire “C991-BK”
P2-20
Expected Result:
Table 19
Points to Check for an Open Circuit Point
Point
All of the measurements are less than two Ohms. Results:
P2-20
“+” terminal on the junction box
P2-10
“+” terminal on the junction box
Ohms. There is not an open circuit. Proceed to Test Step 13.
Each coil terminal (1) on each magnetic switch
“+” terminal on the junction box
• Not OK – At least one measurement is more than
Each terminal (2) on the “SM” circuit breaker
“+” terminal on the junction box
• OK – All of the measurements are less than two
two Ohms. There is a problem with the wiring or with the “SM” circuit breaker.
268 Troubleshooting Section
Repair: Repair the wiring and/or the connection, when possible. Replace parts, if necessary.
D. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
STOP.
E. Reinstall terminals P2-10 and P2-20. Pull on the wires in order to verify proper installation of the terminals.
Test Step 13. Check the Coils for the Magnetic Switches A. Use a multimeter to measure the resistance of the coil for each magnetic switch. Expected Result: The resistance of each coil is between 16 and 20 Ohms. Results:
• OK – The resistance of each coil is between 16
Ohms and 20 Ohms. The coil resistance for each magnetic switch is correct. Repair: 1. Install the seven bolts and nuts for the junction box. 2. Reconnect the +24 V power supply to the engine. Proceed to Test Step 14.
• Not OK – The resistance of a coil is not between
16 Ohms and 20 Ohms. The resistance of a coil for a magnetic switch is incorrect. Repair: Replace the magnetic switch. Verify that the original problem is resolved. STOP.
Test Step 14. Check the Operation of the Master ECM A. Verify that terminals P2-10 and P2-20 are removed from the P2 connector. B. Verify that the 35 amp circuit breaker is ON. Verify that the “SM” circuit breaker is ON. Note: The “444-05 Start Relay open circuit” diagnostic code can only be detected when the output for the start command is OFF. The output is normally OFF when the engine control is in the STOP mode or when the crank terminate relay is energized. C. Set the engine control to the STOP mode. A “444-05 Start Relay open circuit” diagnostic code should not be activated.
F. Switch the 35 amp circuit breaker ON. Note: The “444-06 Start Relay short to ground” diagnostic code can only be detected when the output for the start command is ON. The output is normally ON when the engine control is set from the STOP mode to the START mode. The output remains ON until the crank terminate relay is energized. G. Set the engine control to the START mode. Look for a “444-06 Start Relay short to ground” diagnostic code. A “444-06 Start Relay short to ground” diagnostic code should not be activated. Expected Result: No diagnostic codes were activated. Results:
• OK – No diagnostic codes were activated. The
initial diagnostic code was probably caused by a poor electrical connection. Repair: If there is an intermittent problem that is causing the codes to be logged, refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Not OK – A diagnostic code was activated. There may be a problem with the master ECM.
Repair: It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
269 Troubleshooting Section
i02089153
ECM Status Indicator Output SMCS Code: 7400-038-IND System Operation Description: The master Electronic Control Module (ECM) has four outputs in order to indicate the status of engine operation: “Run Relay”, “Crank Terminate Relay”, “Engine Control Alarm Status”, and “Fault Relay”. These outputs can be used to energize indicator lamps or the outputs can be used to interface with other controls. The ECM opens an internal circuit in order to set an output to OFF. The ECM closes the circuit in order to set the output to ON. When the circuit is closed and the output is ON, the ECM allows a maximum current of 0.3 amperes to flow through the circuit to a ground that is inside the ECM. If excessive current flows through the circuit, a diagnostic code is generated. A short circuit to the +battery side will also activate a diagnostic code. Note: These circuits do not sink enough current for illumination of standard incandescent lights. If a lamp is burned out, replace the lamp with the lamp that is specified in the engine’s Parts Manual. “Run Relay” – This output indicates that the engine is in the “Run” status. The engine will start soon or the engine is running. While this output is energized, a short circuit to a positive voltage source or excessive current through the circuit will cause a diagnostic code to become activated. The master ECM cannot diagnose this output while the output is OFF. “Crank Terminate Relay” – This output indicates that the engine rpm is greater than the programmed engine speed that is required for disengagement of the starting motor. While this output is energized, a short circuit to a positive voltage source or excessive current through the circuit will cause a diagnostic code to become activated. The master ECM cannot diagnose this output while the output is OFF. “Engine Control Alarm Status” – This is the alarm output. This output indicates that the master ECM has detected an electrical problem or an abnormal operating condition. While this output is energized, a short circuit to a positive voltage source or excessive current through the circuit will cause a diagnostic code to become activated. The master ECM cannot diagnose this output while the output is OFF.
“Fault Relay” – This is the shutdown output. This output indicates that a potentially damaging operating condition was detected by the master ECM. The master ECM has shut down the engine. While this output is energized, a short circuit to a positive voltage source or excessive current through the circuit will cause a diagnostic code to become activated. The master ECM cannot diagnose this output while the output is OFF. A “323-03 Shutdown Lamp short to +batt” or “324-03 Warning Lamp short to +batt” diagnostic code can only be generated if a shutdown condition or an alarm condition is active. Failure to correct these serious conditions can result in engine damage. Use the Caterpillar Electronic Technician (ET) to determine the event code or the diagnostic code that corresponds to the 323-03 or 324-03 diagnostic code. Troubleshoot that event code or that diagnostic code before you troubleshoot the 323-03 or 324-03 diagnostic code. Refer to Troubleshooting, “Troubleshooting with an Event Code” or Troubleshooting, “Troubleshooting with a Diagnostic Code”. The most likely causes of a diagnostic code for a status indicator is a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with an indicator. The least likely cause is a problem with the master ECM. Logged diagnostic codes provide a historical record. Before you begin this procedure, use ET to print the logged codes to a file. The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
270 Troubleshooting Section
g01065354
Illustration 97 Schematic for the status indicators
Test Step 1. Inspect the Electrical Connectors and Wiring
Illustration 99
g01065355
Terminal box Illustration 98
g01054206
Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: Some indicators may obtain the status of the engine via a data link. If all of the status indicators are not directly controlled by the master ECM, do not proceed with this test.
(2) J2/P2 connectors for the master ECM (3) J6/P6 connectors for the customer
B. Thoroughly inspect each of the following connectors:
• J2/P2 connectors • J6/P6 connectors a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
271 Troubleshooting Section
e. Check the harness and wiring for abrasion and for pinch points from the customer’s equipment to the master ECM. Expected Result: All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. Results:
• OK – The components are in good condition with proper connections. Proceed to Test Step 2.
Illustration 100
g01055309
(P2-28) (P2-29) (P2-30) (P2-31)
• Not OK – The components are not in good condition and/or at least one connection is improper.
Harness side of the P2 connector Run Relay Crank Terminate Relay Fault Relay Engine Control Alarm Status
Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Test Step 2. Check for Diagnostic Codes A. Connect Cat ET to the service tool connector on the terminal box. Refer to Troubleshooting, “Electronic Service Tools”. B. Switch the 35 amp circuit breaker ON. C. Attempt to start the engine and observe the status indicators. Allow a minimum of 30 seconds for any diagnostic codes to activate. Use the “Active Diagnostic” screen on Cat ET to look for the codes that are listed in Table 21: Table 21
Diagnostic Codes and Descriptions with Corresponding ECM Outputs Illustration 101
g00930208
Code
Description
ECM Output
Harness side of the J6 connector
323-03
Shutdown Lamp short to +batt
“Fault Relay”
(J6-22) (J6-23) (J6-32) (J6-33)
324-03
Warning Lamp short to +batt
“Engine Control Alarm Status”
443-03
Crank Terminate Relay short to +batt
“Crank Terminate Relay”
445-03
Run Relay short to +batt
“Run Relay”
Run Relay Fault Relay Crank Terminate Relay Engine Control Alarm Status
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the status indicators. Note: These outputs do not provide enough current for illumination of standard incandescent lights. If a lamp is burned out, replace the lamp with the lamp that is specified in the engine’s Parts Manual. d. Inspect the wiring and the receptacles for the status indicators.
Expected Result: There are no active diagnostic codes. The “Engine On” indicator and the “Crank Terminate” indicator (if equipped) illuminated normally. The “Active Alarm” indicator and the “Engine Failure” indicator did not illuminate.
272 Troubleshooting Section
Results:
• Yes (Original 443-03 or 445-03 Diagnostic Code) –
The original diagnostic code was “443-03 Crank Terminate Relay short to +batt” or “445-03 Run Relay short to +batt”. When the engine was started, the “Run Relay” indicator and the “Crank Terminate Relay” indicator (if equipped) illuminated normally. The “Engine Control Alarm Status” indicator and the “Fault Relay” indicator did not illuminate. There are no active diagnostic codes. Repair: The outputs for the status indicators seem to be operating correctly at this time. The original diagnostic code was probably caused by a poor electrical connection. If there is an intermittent problem that is causing the codes to be logged, refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Yes (Original 323-03 or 324-03 Diagnostic
Code) – The original diagnostic code was “323-03 Shutdown Lamp short to +batt” or “324-03 Warning Lamp short to +batt”. When the engine was started, the “Run Relay” indicator and the “Crank Terminate Relay” indicator (if equipped) illuminated normally. The “Engine Control Alarm Status” indicator and the “Fault Relay” indicator did not illuminate. There are no active diagnostic codes.
Exit this procedure. After you have resolved the condition, return to this procedure in order to troubleshoot the 323-03 and/or 324-03 diagnostic code, if necessary. STOP.
• Not OK (Active 443-03 or 445-03 Diagnostic
Code) – When the engine was started, the “Run Relay” indicator and/or the “Crank Terminate Relay” indicator (if equipped) did not illuminate normally. The “Engine Control Alarm Status” indicator and the “Fault Relay” indicator did not illuminate. A 443-03 or 445-03 diagnostic code was activated. There is a problem with the output for the “Run Relay” indicator and/or the “Crank Terminate Relay” indicator (if equipped). Proceed to Test Step 4.
Test Step 3. Check for Proper Operation of the Status Indicators for the Alarm and Shutdown Note: All active diagnostic codes and active event codes must be cleared in order for the “Engine Control Alarm Status” indicator to be OFF. Allow the engine operation to continue for this procedure. Operate the engine under low load.
Repair: The 323-03 and 324-03 diagnostic codes can only be activated when the corresponding indicator is activated. There may still be a problem with the output for the alarm indicator or the shutdown indicator. The alarm and/or the shutdown must be activated. Allow the engine operation to continue. Proceed to Test Step 3.
• Not OK (Active 323-03 or 324-03 Diagnostic
Code) – There is an active “323-03 Shutdown Lamp short to +batt” or “324-03 Warning Lamp short to +batt”. There must be a shutdown condition before a 323-03 diagnostic code can be generated. There must be an alarm condition before a 324-03 diagnostic code can be generated. Both of these conditions are serious. Repair: Use Cat ET to determine the event code or the diagnostic code that corresponds to the 323-03 or 324-03 diagnostic code. Troubleshoot that event code or that diagnostic code before you troubleshoot the 323-03 or 324-03 diagnostic code. Refer to Troubleshooting, “Troubleshooting with an Event Code” or Troubleshooting, “Troubleshooting with a Diagnostic Code”.
Illustration 102
g01065357
Right side view (1) Unfiltered engine oil pressure sensor (2) Filtered engine oil pressure sensor
A. During engine operation, disconnect the connector for the unfiltered engine oil pressure sensor (1). Observe the “Engine Control Alarm Status” indicator on the control panel (if equipped).
273 Troubleshooting Section
If you are only troubleshooting a “324-03 Warning Lamp short to +batt”, proceed to the “Expected Result”.
Test Step 4. Measure the Voltage of the Suspect Indicator at the P2 Connector
Note: When the filtered engine oil pressure sensor is disconnected, the engine will shut down. B. Disconnect the connector for the filtered engine oil pressure sensor (2). Observe the “Fault Relay” indicator on the control panel (if equipped). C. Use the “Diagnostics” screen on Cat ET to look for active diagnostic codes. Expected Result: The “Engine Control Alarm Status” indicator illuminated and a “542-03 Unfiltered Engine Oil Pressure open/short to +batt” diagnostic code was activated when the unfiltered engine oil pressure sensor is disconnected. The “Fault Relay” indicator illuminated and a “100-03 Engine Oil Pressure open/short to +batt” diagnostic code was activated when the filtered engine oil pressure sensor is disconnected. The engine was shut down. Results:
• OK – The indicators, diagnostic codes, and
shutdown were activated according to the “Expected Result”. The outputs for the status indicators seem to be operating correctly at this time. The original problem seems to be resolved. Repair: The original diagnostic code was probably caused by a poor electrical connection. If there is an intermittent problem that is causing the codes to be logged, refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Not OK – The “Engine Control Alarm Status”
indicator and/or the “Fault Relay” indicator did not illuminate normally when the sensors were disconnected. A “323-03 Shutdown Lamp short to +batt” and/or a “324-03 Warning Lamp short to +batt” diagnostic code was generated. There is a problem with the output for the status indicators. The “542-03” and the “100-03” diagnostic codes were generated. The engine was shut down. Proceed to Test Step 4.
Illustration 103
g00930238
Terminal box (1) Ground strap for the master ECM (P2-28) Run Relay (P2-29) Crank Terminate Relay (P2-30) Fault Relay (P2-31) Engine Control Alarm Status
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Insert a 7X-1710 Multimeter Probe into the suspect control terminal in the P2 connector. C. Connect the positive lead of a voltmeter to the end of the 7X-1710 Multimeter Probe. Connect the voltmeter’s negative lead to ground strap (1). D. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. E. Note the voltage that is displayed on the voltmeter. F. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. G. If the customer has equipment for the status indicators, disconnect one wire from the suspect indicator. Be sure to disconnect the wire that comes from the master ECM.
274 Troubleshooting Section
H. Insulate the end of the wire with electrical tape in order to ensure that the wire does not create a short circuit. I. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. J. Note the voltage that is displayed on the voltmeter. Expected Result: Before the suspect indicator was disconnected, voltage was displayed on the voltmeter. After the suspect indicator was disconnected, the voltmeter displayed approximately zero volts. Results:
• Yes – Before the suspect indicator was
disconnected, voltage was displayed on the voltmeter. After the suspect indicator was disconnected, the voltmeter displayed approximately zero volts. There is a problem in the customer’s equipment.
Repair: The problem could be caused by a poor electrical connection, a wire, or a component in the customer’s equipment. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Thoroughly inspect all wiring and all connectors in the customer’s equipment. Refer to Troubleshooting, “Inspecting Electrical Connectors”. If you suspect that the indicator has an internal short circuit, temporarily install a known good indicator for the suspect indicator. Test the indicator. Verify that the problem is resolved. Make the necessary repairs, when possible. Replace parts, if necessary. STOP.
• No – Before the suspect indicator was
disconnected, voltage was displayed on the voltmeter. After the suspect indicator was disconnected, the voltage was still displayed on the voltmeter. Proceed to Test Step 5.
Test Step 5. Check the Master ECM A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the voltmeter leads and remove the 7X-1710 Multimeter Probe from the P2 connector.
C. Use a 151-6320 Wire Removal Tool to remove the suspect terminal from the ECM P2 connector. D. Insulate the terminal with electrical tape in order to ensure that the terminal does not create a short circuit. E. Fabricate a jumper wire with Deutsch terminals on the ends. Insert one end of the jumper wire into the open terminal of the P2 connector. F. Connect a voltmeter lead to the end of the jumper wire that is not inserted into the connector. G. Connect the other lead of the voltmeter to the ground strap for the master ECM. H. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Observe the voltage reading on the voltmeter. Expected Result: The voltmeter displays approximately zero volts. Results:
• The voltage is approximately zero – After the
suspect terminal was removed from connector P2, the reading on the voltmeter was approximately zero. There is a problem with a connection and/or the wiring between the customer’s equipment and the ECM. Repair: Perform the following procedure: 1. Switch the 35 amp circuit breaker OFF. Set the engine control to the OFF/RESET mode. 2. Disconnect the voltmeter leads. 3. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the ECM P2 connector. 4. Insert the terminal for the output wire into the P2 connector. Pull on the wire in order to verify that the terminal is fully inserted into the connector. Repair the connection and/or the wiring, when possible. Replace parts, if necessary.
STOP.
• The voltage remained – After the suspect terminal was removed from the P2 connector, voltage was still displayed on the voltmeter. There may be a problem with the master ECM.
275 Troubleshooting Section
Repair: It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP. i02089172
Electrical Power Supply SMCS Code: 1408-038 System Operation Description: Electrical power is supplied to the following components:
• Master Electronic Control Module (ECM) • Slave ECM • Integrated Temperature Sensing Module (ITSM) • Fuel metering valve • Actuator for the throttle • Actuator for the compressor bypass group The cause of an intermittent power supply can occur on either the positive side or the negative side of the power supply. The 24 VDC power supply for the engine can be provided by a battery or by an electrical power supply. If the power is provided by an electrical power supply, the maximum allowable AC ripple is 150 mV AC peak to peak. The minimum requirement for the power supply is 22 VDC at 30 amperes. The wiring from the power supply to the ECM must provide a maximum voltage drop of 1.0 VDC. The master ECM input at terminal 70 of the P1 connector (“Switched +Battery”) receives battery voltage from the engine control when the control is in the START mode, in the STOP mode, or in the AUTO mode. When the master ECM detects battery voltage at this input, the master ECM will power up. When battery voltage is removed from this input, the master ECM will power down after the engine has shut down.
For the slave ECM, the input at terminal 70 of the P3 connector (“Switched +Battery”) receives battery voltage from the engine control when the control is in the START mode, in the STOP mode, or in the AUTO mode. When the slave ECM detects battery voltage at this input, the slave ECM will power up. The “168-02” diagnostic code indicates that the voltage of the power supply is intermittent or low while the engine is running. If the supply voltage drops to zero and stays at zero, neither ECM will log this code. The engine will shut down. The “336-02” diagnostic code indicates that the master ECM has detected a problem with the circuit for the engine control. Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
276 Troubleshooting Section
Illustration 104
g01065369
277 Troubleshooting Section
Schematic for the electrical power
Test Step 1. Inspect the Electrical Connectors and Wiring
Illustration 106
g01065370
Terminal box Illustration 105
g01055400
Junction box (1) Circuit breaker for the engine control (2.5 ampere) (2) Circuit breaker for the customer (10 ampere) (3) Circuit breaker for the engine (35 ampere) (4) Circuit breaker for the master ECM output for the electrical starting motor (2.5 ampere)
(5) J5 connector for the service tool (6) J1/P1 connectors for the master ECM (7) J6/P6 connectors for the customer (8) J7/P7 connectors for the harness for electrical power (9) J3/P3 connectors for the slave ECM
B. Thoroughly inspect each of the following connectors:
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (3) to the OFF position.
• J1/P1 connectors
Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
• J5, J6/P6 and J7/P7 connectors
• J3/P3 connectors
• Connectors for the 24 VDC power supply • Connectors for the engine control a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
278 Troubleshooting Section
Illustration 107
g01055407
Harness side of connectors P1 and P3 (P1-31) (P1-52) (P1-53) (P1-55) (P1-57) (P1-61) (P1-62) (P1-63) (P1-64) (P1-65) (P1-67) (P1-69) (P1-70)
Digital return Unswitched +Battery Unswitched +Battery Unswitched +Battery Unswitched +Battery Stop (Master ECM) Start (Master ECM) -Battery Auto (Master ECM) -Battery -Battery -Battery Switched +Battery Illustration 109
g00931545
Harness side of the J7 connector (J7-57) (J7-58) (J7-60) (J7-61) (J7-62) (J7-65) (J7-70)
Unswitched +Battery Unswitched +Battery Power for the engine control Switched +Battery Switched +Battery Power for the customer -Battery
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the electrical power supply. d. Check the harness and wiring for abrasion and for pinch points from the power supply to the master ECM and from the engine control to the master ECM. Expected Result:
Illustration 108 Harness side of the J6 connector (J6-1) +Battery for the customer (10 amperes) (J6-4) Power for the engine control (J6-14) Switched +Battery (J6-19) Stop command (J6-29) Start command (J6-36) Digital return (J6-39) Auto command
g00952120
The connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. Results:
• OK – The components are in good condition with proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good condition and/or at least one connection is improper.
279 Troubleshooting Section
Repair: Perform the necessary repairs and/or replace parts, if necessary. Ensure that all of the seals are properly installed. Make sure that the connectors are properly fastened. Verify that the repair has eliminated the problem. STOP.
Test Step 2. Check the Voltage at the Power Supply, at the Master ECM, and at the Slave ECM A. Make sure that the engine will not crank during this procedure. For an engine with an electric starting motor, make sure that the battery cables are disconnected from the motor. For an engine with an air starting motor, make sure that the pressurized air supply is OFF. Make sure that the air is purged from the system. Note: If a power supply is used instead of batteries, the minimum voltage for the power supply is 22 VDC. Troubleshoot the power supply if the voltage is less than 22 VDC or more than 29 VDC. B. Measure the voltage at the terminals for the power supply. Record the measurement.
Expected Result: The voltage that is measured at the terminals for the power supply is at least 22 VDC. The voltage that is measured at the P1 connector and at the P3 connector is within one volt of the voltage that was measured at the terminals for the power supply. The voltage measurements are constant. Results:
• OK – Each ECM is receiving the correct voltage. Repair: Perform the following procedure: Switch the 35 amp circuit breaker OFF. Remove the probes from the P3 connector. Proceed to Test Step 3.
• Not OK – An ECM is not receiving the correct voltage.
Repair: Perform the following procedure: 1. Switch the 35 amp circuit breaker OFF.
C. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Insert the first probe into terminal 52. Insert the second probe into terminal 63. Connect a multimeter to the probes.
2. Remove the probes from the P3 connector.
D. Switch the 35 amp circuit breaker ON.
4. Make repairs, as needed.
E. Measure the power supply voltage at the P1 connector. During the measurement, wiggle the harness in order to check for an intermittent problem. Be sure to wiggle the harness near each of the connections. Record the measurement.
STOP.
F. Switch the 35 amp circuit breaker OFF. Remove the probes from the P1 connector. G. Insert two 7X-1710 Multimeter Probes into the harness side of the P3 connector. Insert the first probe into terminal 52. Insert the second probe into terminal 63. Connect a multimeter to the probes. H. Switch the 35 amp circuit breaker ON. I. Measure the power supply voltage at the P3 connector. During the measurement, wiggle the harness in order to check for an intermittent problem. Be sure to wiggle the harness near each of the connections. Record the measurement.
3. Use a voltmeter to check the wiring. Refer to the schematic for the electrical system. Locate the source of the voltage drop.
Test Step 3. Check the Engine Control Switch A. Make sure that the engine will not crank during this procedure. For an engine with an electric starting motor, make sure that the battery cables are disconnected from the motor. For an engine with an air starting motor, make sure that the pressurized air supply is OFF. Make sure that the air is purged from the system. B. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. C. Switch the 35 amp circuit breaker ON. Note: An “E225 Engine Overcrank” and/or an “E233 Low Engine Prelube Pressure” event code may be generated during this step. After you have completed this step, clear the events from the “Logged Events” screen of Cat ET.
280 Troubleshooting Section
D. Observe the “Active Diagnostic” screen on Cat ET and set the engine control to the STOP mode, the START mode, and the AUTO mode. Look for an active “336-02 Incorrect ECS Switch inputs” diagnostic code. Repeat this step several times. Expected Result: A “336-02 Incorrect ECS Switch inputs” diagnostic code was not activated when the engine control was set to the STOP mode, the START mode, and the AUTO mode. Results:
• OK – A “336-02 Incorrect ECS Switch inputs”
diagnostic code was not activated. The inputs from the engine control are correct. The problem seems to be resolved. Repair: The problem may be intermittent. Refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Not OK – A “336-02 Incorrect ECS Switch inputs” diagnostic code was activated. The master ECM has detected an invalid pattern of inputs from the engine control switch. Proceed to Test Step 4.
Test Step 4. Check the Circuit of the Engine Control Switch A. Make sure that the engine will not crank during this procedure. For an engine with an electric starting motor, make sure that the battery cables are disconnected from the motor. For an engine with an air starting motor, make sure that the pressurized air supply is OFF. Make sure that the air is purged from the system. B. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
Note: During these measurements, wiggle the harness in order to check for an intermittent problem. Be sure to wiggle the harness near each of the connections. E. Set the engine control to the STOP mode and measure the voltage between terminals P1-31 and P1-61. The correct voltage measurement is less than one volt. F. Remove the probe from terminal 61 and insert the probe into terminal 62. G. Set the engine control to the START mode and measure the voltage between terminals P1-31 and P1-62. The correct voltage measurement is less than one volt. H. Remove the probe from terminal 62 and insert the probe into terminal 64. I. Set the engine control to the AUTO mode and measure the voltage between terminals P1-31 and P1-64. The correct voltage measurement is less than one volt. J. Remove the probe from terminal 31 and insert the probe into terminal 69. Remove the probe from terminal 64 and insert the probe into terminal 70. K. Set the engine control to the STOP mode and measure the voltage between terminals P1-69 and P1-70 connector. The correct voltage measurement is at least 20 VDC. L. Set the engine control to the START mode and measure the voltage between terminals P1-69 and P1-70. The correct voltage measurement is at least +20 VDC. M. Set the engine control to the AUTO mode and measure the voltage between terminals P1-69 and P1-70. The correct voltage measurement is at least 20 VDC.
C. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Insert the first probe into terminal 31. Insert the second probe into terminal 61. Connect a multimeter to the probes.
Expected Result:
D. Switch the 35 amp circuit breaker ON.
• OK – The voltage checks are within the
Note: An “E225 Engine Overcrank” and/or an “E233 Low Engine Prelube Pressure” event code may be generated during the test. After you have completed the test, clear the events from the “Logged Events” screen of Cat ET.
The voltage checks are within the specifications. Results: specifications. Remove the probes from the P1 connector. Start the engine and run the engine. If the original problem is not resolved, the master ECM may have a problem. Repair: It is unlikely that the master ECM has failed. Perform the following procedure:
281 Troubleshooting Section
Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
• Not OK – The P1 connector does not have the correct voltage.
Repair: Perform the following steps: 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Disconnect the wires for the STOP, START, and AUTO modes from the device that provides engine control. The device may be a mechanical switch or an electronic control. 3. If a mechanical switch provides engine control, use an ohmmeter to check the contacts for the switch. Set the switch to each position in order to check the contacts. If an electronic control provides engine control, check the control according to the literature that is provided by the OEM of the control. Verify that the correct signals are generated by the electronic control. 4. If the engine control is faulty, replace the control. If the problem is not resolved, repair the harness, when possible. Replace the harness, if necessary. STOP.
282 Troubleshooting Section
i02089204
Engine Speed/Timing Sensor SMCS Code: 1912-038 System Operation Description:
Illustration 110
g00893441
Speed/Timing sensor and timing ring
The speed/timing sensor provides information about engine speed and the position of the crankshaft to the master Electronic Control Module (ECM) and the slave ECM. The sensor is powered by the sensor supply (12 VDC) from the master ECM. A magnetic pickup is located underneath the plastic sliphead of the sensor. The timing ring is mounted on the rear of the left camshaft. As the teeth of the ring rotate past the sliphead of the sensor, the sensor generates a signal that matches the pattern of the teeth. The timing ring has a special tooth pattern that indicates the position of the camshaft and the direction of rotation. The timing ring has 24 slots in the outer diameter. Twenty one of the slots are narrow. Three of the slots are about 2.5 times wider than the rest of the slots. When the engine rotates in the normal direction, the slots pass the speed/timing sensor in the following order:
• 1 wide slot • 3 narrow slots • 2 wide slots • 18 narrow slots
The number one cylinder is at the top center position when the rising edge of the third narrow slot passes the center of the sliphead. All 24 teeth pass the sliphead during one revolution of the camshaft or two revolutions of the crankshaft. With the information from the engine speed/timing sensor, each ECM is able to calculate the positions of the pistons in the cylinders. Each ECM determines the desired ignition timing according to the engine speed and load. If detonation is detected in any of the cylinders, the appropriate ECM retards the timing of the affected cylinders. Each ECM sends voltage pulses to the ignition transformers for firing the spark plugs according to the desired timing. During engine operation, the master ECM will shut down the engine if either ECM detects a problem with the signal from the speed/timing sensor. The ECM that detected the problem with the signal will activate the corresponding diagnostic code. If there is a problem with the engine speed/timing sensor’s signal during start-up but no corresponding diagnostic code is active, the master ECM will not initiate the ignition. The engine will not start. The corresponding diagnostic code is not activated.
283 Troubleshooting Section
The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with the engine speed/timing sensor. The least likely cause is a problem with an ECM. Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 111 Schematic for the circuit of the speed/timing sensor
g01065386
284 Troubleshooting Section
Test Step 1. Inspect the Electrical Connectors and Wiring
B. Thoroughly inspect the following connections:
• J1/P1 connectors • J3/P3 connectors • J7/P7 connectors a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 112
g01054206
Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
Illustration 114 Harness side of the master ECM P1 connector (P1-33) Signal (P1-43) 12 volt supply (P1-51) Return
Illustration 115 Harness side of the slave ECM P3 connector (P3-33) Signal
Illustration 113
g01065389
Terminal box (2) J1/P1 connectors for the master ECM (3) J7/P7 connectors for the harness from the speed/timing sensor (4) J3/P3 connectors for the slave ECM
g01055533
g01065390
285 Troubleshooting Section
d. Check the harness and wiring for abrasion and for pinch points from the speed/timing sensor to each ECM. Expected Result: The connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. Results:
• OK – The components are in good condition with proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good condition and/or at least one connection is improper.
Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Test Step 2. Check the Sensor
Illustration 116
g00931722
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Remove the speed/timing sensor.
Harness side of the P7 connector (P7-9) Signal (P7-23) Return (P7-37) Shield (P7-51) 12 volt supply
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the speed/timing sensor. Illustration 118
g00931748
Plastic sliphead for the speed/timing sensor
C. Inspect the condition of the plastic sliphead. Look for signs of wear and for contaminants. Clean any debris from the plastic sliphead. D. Check the tension of the plastic sliphead. Gently extend the plastic sliphead for a minimum of 4 mm (0.16 inch). Then push back the plastic sliphead. Expected Result: The sensor is in good condition. At least 22 N (5 lb) of force is required to push in the plastic sliphead from the extended position. Results:
• OK – The sensor is not damaged. The tension of Illustration 117 Left side view (5) Speed/timing sensor
g01065391
the plastic sliphead is correct. Repair: Install the sensor.
286 Troubleshooting Section
NOTICE The plastic sliphead must be fully extended when the speed/timing sensor is installed so that the sensor maintains the correct clearance with the timing ring. If the correct clearance is not maintained, the signal from the sensor will not be generated. Do not install the sensor’s plastic sliphead between the teeth of the timing ring. Damage to the plasic sliphead will result. Before installing the sensor, ensure that a tooth of the ring is visible in the mounting hole for the sensor. 1. Use the following steps to install the speed/timing sensor: a. Ensure that a tooth on the timing ring is visible in the mounting hole for the sensor. b. Fully extend the sliphead. Note: The plastic sliphead is designed to contact the tooth of the timing ring during installation. As the timing ring begins to turn, the radial runout of the timing ring will push the plastic sliphead into the sensor body slightly. This provides the plastic sliphead’s air gap with a self-adjusting function. The maximum allowable clearance between the sliphead and a tooth on the timing ring is 0.5 mm (0.02 inch). c. Coat the threads of the sensor with 4C-5597 Anti-Seize Compound. d. Install the sensor. Tighten the sensor to 40 ± 5 N·m (30 ± 4 lb ft). Proceed to Test Step 3.
• Not OK – The plastic sliphead is damaged and/or the tension of the sliphead is insufficient.
Repair: Install a new sensor. Calibrate the sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor - Calibrate”. If the condition is not resolved, proceed to Test Step 3.
Test Step 3. Check for Active Diagnostic Codes for the 12 Volt Sensor Supply A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
C. Use the “Active Diagnostic” screen on Cat ET. Look for the following codes:
• 145-03 12 Volt DC Power Supply short to +batt • 145-04 12 Volt DC Power Supply short to ground
Expected Result: None of the above codes are active. Results:
• No active codes – None of the above codes are active. However, at least one of the codes is logged. Repair: Clear the logged codes. Proceed to Test Step 4.
• Active code – One of the above codes is active. Proceed to Test Step 5.
Test Step 4. Use Cat ET to Check the Engine RPM A. Use the “Status - Group 1” screen in order to observe “Engine Speed”. Observe the “Engine Speed” parameter on the screen and set the engine control to the START mode. Crank the engine. B. Continue to observe the screen and allow the engine rpm to stabilize at the normal cranking speed. C. Set the engine control to the STOP mode. Expected Result: Before the engine is cranked, the engine speed is “0”. The engine speed increases until the speed stabilizes at the normal cranking speed. When the engine is stopped, the speed decreases back to “0”. A 320-03 diagnostic code or a 320-08 diagnostic code are not activated. Results:
• OK – The engine started and the engine
ran properly. A 320-03 diagnostic code or a 320-08 diagnostic code was not activated. The speed/timing sensor is operating properly. STOP.
• Not OK – The engine cranked. However, Cat
ET did not display the correct engine speed or a 320-03 or a 320-08 diagnostic code was activated. Proceed to Test Step 5.
287 Troubleshooting Section
• Not OK – The engine cranked but the engine did not start. Cat ET displayed the correct engine speed. A 320-03 diagnostic code or a 320-08 diagnostic code was not activated. Each ECM is receiving a valid signal.
Expected Result: When the engine control is in the STOP mode, the voltage is less than 3.0 VDC or the voltage is greater than 10.0 VDC.
Repair: Refer to Troubleshooting, “Engine Cranks But Will Not Start”. Make repairs, as needed.
The voltage varied between 2.0 VDC and 4.0 VDC during cranking.
STOP.
Results:
Test Step 5. Measure the Sensor Supply Voltage at the Sensor A. Set the engine control to the OFF mode. B. Install a 8T-8726 Adapter Cable As (Three-Pin Breakout) in series with the connectors for the speed/timing sensor. C. Set the engine control to the STOP mode. Measure the supply voltage between terminals “A” and “B” of the breakout t. Expected Result: The voltage is between 11.5 VDC and 13.5 VDC. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. Results:
• OK – The sensor is receiving correct supply
voltage. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. Leave the breakout t connected. Proceed to Test Step 6.
• Not OK – The sensor is not receiving correct
• OK – The sensor is producing the correct output signal.
Repair: Remove the breakout t from the connectors for the speed/timing sensor. Reconnect the connectors for the speed/timing sensor. If you are troubleshooting the speed/timing sensor’s signal for the master ECM, proceed to Test Step 8. If you are troubleshooting the speed/timing sensor’s signal for the slave ECM, proceed to Test Step 9.
• Not OK – The sensor is not producing the correct output signal.
Repair: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Remove the breakout t from the connectors for the speed/timing sensor. Install a new speed/timing sensor. Calibrate the sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor - Calibrate”. STOP.
supply voltage or a 145-03 diagnostic code or a 145-04 diagnostic code is active. Remove the breakout t. Proceed to Test Step 7.
Test Step 7. Measure the Sensor Supply Voltage at the Master ECM
Test Step 6. Isolate the Signal Voltage at the Sensor
A. Set the engine control to the OFF/RESET mode.
A. Set the engine control to the OFF/RESET mode.
B. Use two 7X-1710 Multimeter Probes. Insert the probes into terminals P1-33 and P1-51.
B. Ensure that the breakout t is connected in series with the connectors for the speed/timing sensor.
C. Set the engine control to the STOP mode. Measure the supply voltage at the master ECM.
C. Remove the wire from terminal “C” of the breakout t in order to isolate the sensor signal wire.
Expected Result:
D. Set the engine control to the STOP mode. Measure the signal voltage between terminals “B” and “C”. E. Set the engine control to the START mode. Crank the engine and measure the signal voltage between terminals “B” and “C”.
The voltage is between 11.5 VDC and 13.5 VDC. A 145-03 diagnostic code or a 145-04 diagnostic code is not active.
288 Troubleshooting Section
Results:
Expected Result:
• Yes – The sensor supply voltage at the ECM
When the engine control is in the STOP mode, the voltage is less than 3.0 VDC or the voltage is greater than 10.0 VDC.
is between 11.5 VDC and 13.5 VDC. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. The wiring and/or the connectors between the sensor and the master ECM has an open circuit or the circuit has excessive resistance. Repair: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Make the necessary repairs to the harness and/or connectors. STOP.
• No – The master ECM is not producing the correct sensor supply voltage or a 145-03 or a 145-04 diagnostic code is active. There may be a problem with the master ECM. Repair: It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the condition is not resolved, perform the following steps: Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
Test Step 8. Isolate the Sensor Signal at the Master ECM and Measure the Sensor Signal Voltage at the Master ECM A. Set the engine control to the OFF/RESET mode. B. Use a 151-6320 Wire Removal Tool to remove terminals P1-33 and P1-51. C. Connect the leads of a multimeter to the terminals that were removed from the P1 connector. D. Set the engine control to the STOP mode. Measure the signal voltage between the terminals. Record the measurement. E. Set the engine control to the START mode. Crank the engine and measure the signal voltage between the terminals again. Record the measurement.
The voltage varied between 2.0 VDC and 4.0 VDC during cranking. Results:
• OK – Both of the measurements are correct.
However, the master ECM is not reading the signal. There may be a problem with the master ECM. Repair: It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the condition is not resolved, perform the following steps: Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
• Not OK – The signal voltage is not correct. There is an intermittent problem in the circuit for the speed/timing sensor.
Repair: Refer to Troubleshooting, “Inspecting Electrical Connectors”. Make repairs, as needed. STOP.
Test Step 9. Isolate the Sensor Signal at the Slave ECM and Measure the Sensor Signal Voltage at the Slave ECM A. Set the engine control to the OFF/RESET mode. B. Use a 151-6320 Wire Removal Tool to remove terminal 33 from the P3 connector on the slave ECM. Remove terminal 51 from the P1 connector from the master ECM. C. Connect one lead of a multimeter to the terminal that was removed from the P3 connector. Connect the other lead of the multimeter to the terminal that was removed from the P1 connector. D. Set the engine control to the STOP mode. Measure the signal voltage between the terminals. Record the measurement.
289 Troubleshooting Section
E. Set the engine control to the START mode. Crank the engine and measure the signal voltage between the terminals again. Record the measurement. Expected Result: When the engine control is in the STOP mode, the voltage is less than 3.0 VDC or the voltage is greater than 10.0 VDC. The voltage varied between 2.0 VDC and 4.0 VDC during cranking. Results:
• OK – Both of the measurements are correct.
However, the slave ECM is not reading the signal. There may be a problem with the slave ECM. Repair: It is unlikely that the slave ECM has failed. Exit this procedure and perform this procedure again. If the condition is not resolved, perform the following steps: Temporarily install a new slave ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
• Not OK – The signal voltage is not correct. There is an intermittent problem in the circuit for the speed/timing sensor.
Repair: Refer to Troubleshooting, “Inspecting Electrical Connectors”. Make repairs, as needed. STOP. i02089347
Fuel Metering Valve SMCS Code: 1741-038 System Operation Description: The fuel metering valve is an electronic gas valve that controls the flow of fuel to the engine. The valve works with the master Electronic Control Module (ECM) in order to ensure the correct flow of fuel in all conditions of engine operation.
The master ECM sends a command signal for the flow of fuel and information about the specific gravity of the gas to the fuel metering valve. The valve converts the command signal and the information into a valve position that directly corresponds to the desired gas flow. The position of the valve is compensated by these additional factors that are internal to the valve: absolute fuel pressure, differential pressure of the valve, and fuel temperature. The following procedure tests whether the command signal for the flow of fuel and the information about the specific gravity of the gas is properly sent to the fuel metering valve by the master ECM. The command signal is a 180 hertz PWM signal. Information about the specific gravity of the gas is sent to the fuel metering valve via the CAN Data Link. The fuel metering valve sends information to the master ECM via the CAN Data Link. This procedure also tests whether the following information is properly sent to the master ECM by the fuel metering valve: position of the fuel valve, absolute fuel pressure, differential pressure of the valve, and fuel temperature. During normal operation, the valve receives two command signals from the ECM. One of the signals is a digital signal that is received via the CAN data link. The other signal is a pulse width modulated signal (PWM) that is received via a pair of wires. The valve will use the digital signal when both signals are available. If the PWM signal is not available, the valve will continue to use the digital signal. The ECM will activate a 1446-05 diagnostic code. Engine performance will be affected. If the digital signal is not available, the valve will use the PWM signal. The ECM will activate a 1446-09 diagnostic code. Engine performance will be affected. Status Indicator for the Fuel Metering Valve
290 Troubleshooting Section
Illustration 119
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Status indicator for the fuel metering valve
The fuel metering valve contains a status indicator. The indicator flashes in order to indicate the status of the valve. The color of the indicator indicates the severity of the problem. During operation, the status indicator will flash one of the following colors: Green – Normal operation Orange – The valve has detected a problem and the valve continues to operate. Red – The valve has detected a serious problem. The valve has shut down. The flash code indicates the particular error that has been detected by the valve. Before performing maintenance on the valve, observe the status indicator. Refer to Installation and Operation Manual, SEBU7630 for additional information.
291 Troubleshooting Section
Illustration 120 Schematic for the circuit of the fuel metering valve
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292 Troubleshooting Section
Test Step 1. Inspect the Electrical Connectors and Wiring
Illustration 122
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Terminal box Illustration 121
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Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
(2) Ground strap (3) J1/P1 connectors for the master ECM (4) J6/P6 connectors for the customer (5) J7/P7 connectors for the harness from the fuel metering valve (6) J9/P9 connectors for the harness for the CAN data link (7) J10/P10 connectors for the terminating resistor for the CAN data link
B. Thoroughly inspect each of the following connectors:
• J1/P1 connectors • J6/P6, J7/P7, and J9/P9 connectors • Connectors on the fuel metering valve a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
293 Troubleshooting Section
Illustration 123
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Illustration 125
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Harness side of the P1 connector
Harness side of the P24 connector for the fuel metering valve
(P1-34) (P1-42) (P1-50) (P1-58) (P1-60)
(P24-C) CAN Data Link + (P24-D) CAN Data Link + to the throttle actuator (P24-E) CAN Data Link − to the throttle actuator (P24-F) CAN Data Link − (P24-K) Unswitched +Battery (P24-L) −Battery (P24-M) Switched +Battery (P24-S) Signal for the fuel flow (P24-T) Return for the signal for the fuel flow
CAN Data Link − CAN shield CAN Data Link + Signal for the fuel flow Return for the signal for the fuel flow
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel metering valve.
Illustration 124 Harness side of the J7 connector (J7-11) Signal for the fuel flow (J7-25) Return for the signal for the fuel flow (J7-39) Shield (J7-61) Switched +Battery
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294 Troubleshooting Section
Repair: Perform the necessary repairs and/or replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
Test Step 2. Check for Diagnostic Codes A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box. B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. C. Use Cat ET to determine if any of the following diagnostic codes are active:
• 1446-05 “Fuel Metering Module open circuit” • 1446-09 “Unable to communicate with Fuel Metering Module”
• 1446-12 “Fuel Metering Module malfunction” • 1446-13 “Fuel Metering Module calibration required”
• 1447-12 “Fuel Metering Sensor Module malfunction”
Expected Result: Illustration 126
g01065457
There are no active diagnostic codes.
Top view of the engine. The 60 Hz configuration is shown. The 50 Hz configuration is similar.
Results:
(8) Fuel metering valve (9) P24/J24 connectors for the fuel metering valve
• OK – There are no active diagnostic codes. The
d. Check the wiring for abrasion and for pinch points from the fuel metering valve to the master ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. Results:
• OK – The components are in good condition with proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good condition and/or at least one connection is improper.
signal and the communication between the master ECM and the fuel metering valve appear to be OK at this time. However, diagnostic codes may be logged. Repair: If you are troubleshooting an intermittent problem, refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Not OK (Active 1446-05) – The master ECM has
detected an open circuit or a short circuit for the circuit of the fuel flow signal between the ECM and the fuel metering valve. Proceed to Test Step 3.
• Not OK (Active 1446-09) – The master ECM has
detected an open circuit or a short circuit for the circuit of the CAN Data Link between the master ECM and the fuel metering valve. Proceed to Test Step 4.
295 Troubleshooting Section
• Not OK (Active 1446-12) – The fuel metering valve has detected an internal malfunction.
Repair: Refer to Installation and Operation Manual, SEBU7630, “Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar”. STOP.
• Not OK (Active 1446-13) – The fuel metering valve requires calibration.
Repair: Refer to Installation and Operation Manual, SEBU7630, “Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar”. STOP.
• Not OK (Active 1447-12) – There is a malfunction of the sensor module in the fuel metering valve.
Repair: Replace the fuel metering valve. Verify that the repair has eliminated the original problem. STOP.
• Not OK – The voltage, the duty cycle, and/or the
frequency of the signal for the fuel flow is not correct at the master ECM P1 connector. Proceed to Test Step 5.
Test Step 4. Check the Continuity of the Wiring Harness for the CAN Data Link A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the master ECM J1/P1 connectors. Disconnect the harness connector for the fuel metering valve.
Repair: Refer to Installation and Operation Manual, SEBU7630, “Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar”. STOP.
Test Step 3. Check the Signal for the Fuel Flow A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Insert the first probe into terminal 58. Insert the second probe into terminal 60. Use a multimeter that is capable of measuring the frequency and the duty cycle. Connect the multimeter to the probes. C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. D. Measure the DC voltage, the duty cycle, and the frequency of the signal for the fuel flow. Expected Result:
g01065458
Illustration 127 Connections for the circuit for the fuel metering valve (P1) Connector for the ECM (P24) Connector for the fuel metering valve (P1-34) CAN Data Link − (P1-50) CAN Data Link + (P24-F) CAN Data Link − (P24-C) CAN Data Link +
C. Use a multimeter to check for continuity between the points that are listed in Table 22. Table 22
Points to Check for Continuity
The DC voltage is between 13.7 and 15.7.
Connector and Terminal
Connector and Terminal
The duty cycle is between 92 and 98 percent.
P1-34
P24-F
P1-50
P24-C
P1-34
Ground strap for the ECM
P1-50
Ground strap for the ECM
The frequency is between 175 and 185 hertz. Results:
• OK – The voltage, the duty cycle, and the
frequency of the signal for the fuel flow is correct at the master ECM P1 connector. There is a problem with the fuel metering valve.
Expected Result: The continuity of the circuits between the terminals is good.
296 Troubleshooting Section
The continuity between the terminals and the ground strap is open. Results:
• OK – The continuity of the circuits is good. The
continuity of the circuit between the master ECM and the ground strap is open. Repair: Perform the following steps: 1. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. 2. Observe the “Active Diagnostic Codes” screen of Cat ET.
Illustration 128
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Connections for the circuit for the fuel metering valve
If a “1446-09 Unable to communicate with Fuel Metering Module” diagnostic code is activated, troubleshoot the CAN data link. Refer to the engine’s schematic diagram. If a 1446-09 diagnostic code is not activated, proceed to Test Step 6.
• Not OK – At least one of the following conditions
is found: There is an open circuit between the plug for the master ECM and the plug for the fuel metering valve. There is a short circuit between the plug for the master ECM and a component that is at ground potential. Repair: Perform the necessary repairs to the wiring and/or connectors. Replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
Test Step 5. Check the Continuity of the Circuit for the Fuel Flow A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the J1/P1 connector. C. Disconnect the fuel metering valve J24/P24 connector.
(P1) Connector for the ECM (P24) Connector for the fuel metering valve (P1-58) Signal for the fuel flow (P1-60) Return for the signal for the fuel flow (P24-S) Signal for the fuel flow (P24-T) Return for the signal for the fuel flow
D. Use a multimeter to check the continuity of the following circuits:
• P1-58 and P24-S • P1-58 and the ground strap for the ECM • P1-60 and P24-T Expected Result: The continuity of the circuits between the terminals is good. The continuity between the terminal and the ground strap is open. Results:
• OK – The continuity of the circuit between the
master ECM and the fuel metering valve is good. The continuity of the circuit between the master ECM and the ground strap is open. Proceed to Test Step 6.
• Not OK – One or both of the following conditions is
found: There is an open circuit between the master ECM and the fuel metering valve. There is a short circuit between the master ECM and a component that is at ground potential. Repair: Repair the wiring and/or connectors. Replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
297 Troubleshooting Section
Test Step 6. Check the Resistance of the Internal Circuit of the Fuel Metering Valve A. Ensure the following conditions:
• The engine control is in the OFF/RESET mode. • The 35 amp circuit breaker in the terminal box is OFF.
• The fuel metering valve J24/P24 connectors
• The fuel metering valve J24/P24 connectors are disconnected.
B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Note: The “1446-05 Fuel Metering Module open circuit” and “1446-09 Unable to communicate with Fuel Metering Module” diagnostic codes will be activated.
are disconnected.
Illustration 130 Illustration 129
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J24 connector on the fuel metering valve (J24-S) Signal for the fuel flow (J24-T) Return for the signal for the fuel flow
B. Measure the resistance between terminals J24-S and J24-T.
P24 plug on the harness for the fuel metering valve (P24-K) Unswitched +Battery (P24-L) −Battery (P24-M) Switched +Battery
C. Use a multimeter to measure the voltage between the following terminals of the harness connector for the fuel metering valve:
Expected Result:
• P24-M and P24-L
The resistance is between 315,000 Ohms and 325,000 Ohms.
• P24-K and P24-L
Results:
g00952242
Expected Result:
• OK – The resistance is between 315,000 Ohms
The voltage between terminals P24-M and P24-L is between 22.0 VDC and 24.0 VDC.
• Not OK – The resistance is not between 315,000
The voltage between terminals P24-K and P24-L terminals is 22.0 VDC and 24.0 VDC.
and 325,000 Ohms. Proceed to Test Step 7. Ohms and 325,000 Ohms.
Repair: Replace the fuel metering valve. Verify that the repair has eliminated the original problem. STOP.
Results:
• OK – The voltage is correct at the P24 plug for the fuel metering valve. However, the fuel metering valve is not communicating with the master ECM.
Test Step 7. Check the Supply Voltage to the Fuel Metering Valve
Repair: Replace the fuel metering valve. Verify that the repair has eliminated the original problem.
A. Ensure the following conditions:
STOP.
• The engine control is in the OFF/RESET mode. • The 35 amp circuit breaker in the terminal box is OFF.
• Not OK – The voltage is not correct at the P24
plug for the fuel metering valve. There is an open circuit or a short circuit in the harness to the fuel metering valve.
298 Troubleshooting Section
Repair: Perform the necessary repairs for the wiring and/or the connectors. Replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP. i02089358
Generator Output Power Sensor SMCS Code: 5574-038-PWR System Operation Description:
1719-04 Diagnostic Code This code only applies to engines that are equipped with a power sensor. If the engine load is greater than 20 percent and the voltage on terminal J1-25 is less than 0.2 VDC, the master ECM will generate a 1719-04 diagnostic code. If the engine is running, the engine will shut down. 1719-12 Diagnostic Code This code only applies to engines that are equipped with the EMCP II+. The master ECM calculates two values that represent the engine’s load. One value is calculated by using the information on the generator’s load from the GSC+. The other value is calculated from the following inputs:
The master ECM monitors the generator’s output power in order to accurately control the air/fuel ratio. The master ECM uses a load signal from one of the following sources in order to monitor the generator’s output power:
• The value of the “Fuel Quality” parameter
• Electronic Modular Control Panel II+ (EMCP II+)
• Other factors
• Programmable Logic Controller (PLC)
The master ECM compares the two values. If the value that is calculated by using the information from the GSC+ is not within 20 percent of the other value, the master ECM will generate a 1719-12 diagnostic code. If the engine is running, the engine will shut down.
• Wattmeter The PLC and the wattmeter are also called power sensors. Only one load signal is connected to the master ECM. If the generator is equipped with the EMCP II+, the master ECM receives the load signal from the Generator Set Control + (GSC+) via the CAT data link. If the generator is not equipped with the EMCP II+, the master ECM receives the load signal from a power sensor via terminal J1-25. The load signal from the power sensor is an analog voltage. The load signal increases from 0 VDC to 4.8 VDC as the generator’s output increases to the maximum output. 1719-03 Diagnostic Code On powerup, the master ECM will start requesting information on the generator’s load from the GSC+ via the CAT data link. If two seconds elapse and the master ECM does not receive a response from the GSC+, the master ECM will look for a load signal on terminal J1-25. If there is no load signal on terminal J1-25, the master ECM will generate a 1719-03 diagnostic code. If the engine is running, the engine will shut down. A 1719-03 diagnostic code is also generated if the voltage on terminal J1-25 ever exceeds 4.8 VDC. If the engine is running, the engine will shut down.
• Inlet air temperature and pressure
299 Troubleshooting Section
Illustration 131
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Illustration 132
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Schematic of the power sensor’s input with EMCP II+
Schematic of the power sensor’s input with a power sensor
For the actual wiring, refer to the generator’s schematic diagram.
For the actual wiring, refer to the generator’s schematic diagram. The potentiometer is optional. For further information, refer to Troubleshooting, “Generator Output Power Sensor - Calibrate”.
300 Troubleshooting Section
Test Step 1. Inspect the Electrical Connectors and Wiring
B. Thoroughly inspect the following components:
• J1/P1 connectors • J6/P6 connectors • The wiring and the connections between the master ECM and the GSC+ (if equipped)
• The wiring and the connections between the
master ECM and the power sensor (if equipped)
a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 133
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Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”. Illustration 135 Harness side of the P1 connector (P1-8) Cat data link + (P1-9) Cat data link − (P1-19) Load signal + (P1-25) Load signal −
Illustration 134
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Terminal box (2) J1/P1 connectors (3) J6/P6 connectors for the wiring from the power sensor
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301 Troubleshooting Section
B. Start the engine and run the engine. Attempt to apply at least a 30 percent load to the generator. C. Observe the “Active Diagnostic” screen on ET. Allow a minimum of 30 seconds for any codes to activate. Look for these codes:
• 1719-03 • 1719-04 • 1719-12 D. Stop the engine. Expected Result: There are no active codes for the generator output power sensor. Results: Illustration 136
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Harness side of the J6 connector (J6-3) Load signal + (J6-7) Cat data link + (J6-13) Load signal − (J6-17) Cat data link −
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the power sensor. d. Check the harness and wiring for abrasion and for pinch points between the power sensor and the master ECM. Expected Result:
• No active codes – There are no active codes for
the generator output power sensor. There may be a logged code for the generator output power sensor. Repair: If there is a logged code for the generator output power sensor, there may be a problem with the wiring and/or a connector. Refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Active 1719-03 code – There is an active 1719-03
code. If the generator is equipped with EMCP II+, proceed to Test Step 7. Otherwise, proceed to Test Step 3.
All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.
• Active 1719-04 code – There is an active 1719-04
Results:
• Active 1719-12 code – There is an active 1719-12
• OK – The components are in good condition with proper connections. Proceed to Test Step 2. • Not OK – The components are not in good
code. Proceed to Test Step 5. code. Proceed to Test Step 7.
Test Step 3. Check the “Load Signal” Wiring for a Short Circuit
condition and/or at least one connection is improper.
A. Disconnect the P1 connector from the master ECM.
Repair: Perform the necessary repairs and/or replace parts, if necessary.
B. Disconnect the “load signal” wires from the power sensor.
STOP.
C. Check for continuity between P1-25 and all the other terminals on the P1 connector.
Test Step 2. Check for a Diagnostic Code A. Connect the Cat Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”.
D. Check for continuity between P1-19 and all the other terminals on the P1 connector. Expected Result: Each continuity check indicates an open circuit.
302 Troubleshooting Section
Results:
• OK – Each continuity check indicates an open
Test Step 5. Check the “Load Signal +” Wire for a Short Circuit
circuit. The “load signal” wiring does not have a short circuit.
A. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF.
Repair: Reconnect the P1 connector. Reconnect the “load signal” wires to the power sensor. Be sure to observe the correct polarity.
B. Disconnect the P1 connector from the master ECM.
Proceed to Test Step 4.
• Not OK – At least one continuity check indicates a short circuit.
Repair: The problem may be between the P1 connector and the J6 connector. Alternatively, the problem may be between the J6 connector and the power sensor. Repair the harness or the connection, when possible. Replace parts, if necessary. Verify that the problem is resolved. STOP.
Test Step 4. Check the “Load Signal” Wiring for Continuity Note: A potentiometer may be installed in the “load signal” wiring. A high resistance reading may be caused by the potentiometer. A. Check the continuity of the wiring between P1-25 and the power sensor. B. Check the continuity of the wiring between P1-19 and the power sensor. Expected Result:
C. Disconnect the “load signal +” wire from the power sensor. D. Check for continuity between P1-25 and all the other terminals on the P1 connector. Expected Result: Each continuity check indicates an open circuit. Results:
• OK – Each continuity check indicates an open
circuit. The “load signal +” wire does not have a short circuit. Repair: Reconnect the P1 connector. Reconnect the “load signal +” wire to the power sensor. Proceed to Test Step 6.
• Not OK – At least one continuity check indicates
a short circuit. There is a short circuit in a harness or in a connector. Repair: The problem may be between the P1 connector and the J6 connector. Alternatively, the problem may be between the J6 connector and the generator output power sensor.
The “load signal” wiring has continuity.
Repair the harness or the connection, when possible. Replace parts, if necessary. Verify that the problem is resolved.
Results:
STOP.
• OK – The “load signal” wiring has continuity. Proceed to Test Step 6.
• Not OK – The “load signal” wiring has an open circuit. The open circuit may be in a wire, in a connector, or in the potentiometer.
Repair: Repair the component, when possible. Replace parts, if necessary. Verify that the original problem is resolved. STOP.
Test Step 6. Check the Power Sensor, the Potential Transformers, and the Current Transformers Verify that the power sensor, the potential transformers, and the current transformers are operating correctly. Refer to the appropriate service literature for the components. Expected Result: The components are operating correctly.
303 Troubleshooting Section
Results:
2. Reconnect the P1 connector.
• OK – The components are operating correctly.
Proceed to Test Step 8.
Proceed to Test Step 13.
• Not OK – At least one of the components is not
• Not OK – At least one check of the resistance for
operating correctly.
the Cat data link is incorrect. There is a problem with the wiring for the Cat data link.
Repair: Repair the component, when possible. Replace the component, if necessary. Verify that the original problem is resolved.
Repair: Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the original problem is resolved.
STOP.
STOP.
Test Step 7. Check the Continuity of the Cat Data Link A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect Cat ET from the service tool connector. C. Disconnect the wiring for the Cat data link from the GSC+.
Test Step 8. Check the GSC+ Verify that the GSC+ is operating correctly. Refer to the appropriate service literature for the EMCP II+. Expected Result: The GSC+ is operating correctly. Results:
D. Disconnect the P1 connector from the master ECM.
• OK – The GSC+ is operating correctly. Proceed to
E. Measure the resistance between the points that are listed in Table 23. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
• Not OK – The GSC+ is not operating correctly.
Test Step 13.
Repair: Repair the GSC+. Refer to the appropriate service literature for the EMCP II+. Verify that the original problem is resolved. STOP.
Table 23
Resistance Measurements for the Cat Data Link Connector and Terminal
Connector and Terminal
P1-8
Terminal 19 on the GSC+
P1-9
Terminal 20 on the GSC+
P1-8
Ground strap for the ECM
P1-9
Ground strap for the ECM
Test Step 9. Check the “Fuel Quality” parameter Verify that the value of the “Fuel Quality” parameter is correct. Use the value that is obtained from the Caterpillar Software, LEKQ6378, “Methane Number Program”. Expected Result:
Expected Result: Each check of the resistance between the terminals is less than 5 Ohms.
The value of the “Fuel Quality” parameter is correct. Results:
Each check of the resistance between the terminals and the ground strap is greater than 20,000 Ohms.
• OK – The value of the “Fuel Quality” parameter is
Results:
• Not OK – The value of the “Fuel Quality” parameter
• OK – Each check of the resistance for the Cat data link is within the specification. The wiring for the Cat data link appears to be OK. Repair: Perform the following procedure: 1. Reconnect the wiring to the GSC+. Be sure to connect each wire to the appropriate terminal.
correct. Proceed to Test Step 10. is not correct.
Repair: Enter the correct value for the parameter. Verify that the original problem is resolved. STOP.
304 Troubleshooting Section
Test Step 10. Check the Sensors for the Air Inlet Manifold
Test Step 12. Verify that the Output Power Reading is Correct
A. If the engine is running, stop the engine.
Operate the generator at various loads. Verify that the value of the “Generator Real kW” parameter in Status Group 1 is within 1 percent of the generator’s output power.
B. Connect a pressure gauge and a temperature sensor to the air inlet manifold. C. View the Status Group 1 on Cat ET. Compare the values on the instruments with the following parameters:
• “Inlet manifold air pressure (abs)” • “Inlet air temperature” Expected Result: The values of the parameters are correct. Results:
• OK – The values of the parameters are correct. Proceed to Test Step 8.
• Not OK – One or both of the values of the
Expected Result: The value of the “Generator Real kW” parameter is correct. Results:
• OK – The value of the “Generator Real kW”
parameter is correct. Proceed to Test Step 13.
• Not OK – The value of the “Generator Real kW” parameter is incorrect.
Repair: Refer to Troubleshooting, “Generator Output Power Readings Do Not Match”. STOP.
parameters are incorrect.
Test Step 13. Check the Master ECM
Repair: Replace the appropriate sensor. Verify that the original problem is resolved.
It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”.
STOP.
Test Step 11. Check the GSC+ Verify that the GSC+ is operating correctly. Refer to the appropriate service literature for the EMCP II+. Expected Result: The GSC+ is operating correctly. Results:
• OK – The GSC+ is operating correctly. Proceed to Test Step 12.
• Not OK – The GSC+ is not operating correctly. Repair: Repair the GSC+. Refer to the appropriate service literature for the EMCP II+. Verify that the original problem is resolved. STOP.
Expected Result: The problem is resolved when a new master ECM is installed. Results:
• OK – The problem is resolved when a new master ECM is installed.
Repair: Install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the ECM. STOP.
• Not OK – The problem is not resolved when a new ECM is installed.
Repair: Reinstall the original ECM. Consult with Caterpillar customer service for large gas engines. STOP.
305 Troubleshooting Section
i02089430
Ignition Transformers Primary Circuit
Table 24
Diagnostic Conditions and the Combinations of Cylinders that are Affected Condition
SMCS Code: 1561-038
Circuit driver’s side open
System Operation Description:
Return side open
The master Electronic Control Module (ECM) has internal circuit drivers for the ignition transformers on the left side of the engine. Each circuit driver creates a signal of +108 volts. The signal goes to the high side of the primary circuits of the ignition transformers. The transformers deliver high voltage (8000 to 37,000 volts) to the spark plugs. The ignition wiring is continuous from the master ECM P2 connector to the individual transformers for the cylinders with an even number. The slave ECM has internal circuit drivers for the ignition transformers on the right side of the engine. Each circuit driver creates a signal of +108 volts. The signal goes to the high side of the primary circuits of the ignition transformers. The transformers deliver high voltage (8000 to 37,000 volts) to the spark plugs. The ignition wiring is continuous from the P4 connector on the slave ECM to the individual transformers for the cylinders with an odd number. Some circuit drivers and returns are shared. Therefore, a single problem will activate either only one diagnostic code or multiple codes. Circuit Drivers Some circuit drivers send signals to a single cylinder. A high side short circuit will affect only that cylinder. Some circuit drivers send signals to more than one cylinder. For this reason, a high side short circuit will affect more than one cylinder. Return Side The master ECM has internal returns for the ignition transformers on the left side of the engine. Some of the returns consist of groups of terminals that are connected via diodes inside the master ECM. This means that a return short circuit to the +Battery will simultaneously affect all of the cylinders that are grouped. The slave ECM has internal returns for the ignition transformers on the right side of the engine. Some of the returns consist of groups of terminals that are connected via diodes inside the slave ECM. This means that a return short circuit to the +Battery will simultaneously affect all of the cylinders that are grouped. For the combinations of cylinders that can be affected by a condition, refer to Table 24.
Cylinders Only one cylinder is affected.
Return side short to ground Circuit driver’s side short to +Battery for cylinders 1, 2, 7, 8, 9, 10, 11, 12, 17, 18, 19, or 20 Circuit driver’s side short to ground for cylinders 1, 2, 7, 8, 9, 10, 11, 12, 17, 18, 19, or 20 Return side short to +Battery for cylinders 5, 6, 13, or 14 Cylinder 3 or 5 Circuit driver’s side short to +Battery
3 and 5
Cylinder 4 or 6 Circuit driver’s side short to +Battery
4 and 6
Cylinder 13 or 15 Circuit driver’s side short to +Battery
13 and 15
Cylinder 14 or 16 Circuit driver’s side short to +Battery
14 and 16
Return side short to +Battery
1, 3, 7, and 9 11, 15, 17, and 19 2, 4, 8, and 10 12, 16, 18, and 20
Because the circuits are in pairs or groups, multiple diagnostic codes can be activated for a single problem. If multiple diagnostic codes are active for the primary ignition, troubleshooting the circuits one at a time is an effective way to find the root cause. Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with an ignition transformer. The least likely cause is a problem with an ECM.
306 Troubleshooting Section
Illustration 137 Schematic for the primary ignition on the left side of the engine
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307 Troubleshooting Section
Illustration 138 Schematic for the primary ignition on the right side of the engine
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308 Troubleshooting Section
Test Step 1. Inspect the Electrical Connectors and Wiring
Illustration 140
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Terminal box Illustration 139
g01054206
Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
(2) Harness for the primary ignition from the master ECM to the left bank (3) J2/P2 connectors for the master ECM (4) J4/P4 connectors for the slave ECM (5) Harness for the primary ignition from the slave ECM to the right bank
B. Thoroughly inspect the following connectors:
• J2/P2 connectors • J4/P4 connectors a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in).
309 Troubleshooting Section
Illustration 141
g01066020
Illustration 142
Harness side of the P2 connector
Harness side of the P4 connector
(P2-1) Number 2 transformer’s circuit driver (P2-2) Number 2 transformer’s return (P2-3) Number 12 transformer’s circuit driver (P2-4) Number 12 transformer’s return (P2-14) Number 4 transformer’s circuit driver (P2-15) Number 4 transformer’s return (P2-16) Number 16 transformer’s circuit driver (P2-17) Number 16 transformer’s return (P2-24) Number 8 transformer’s circuit driver (P2-25) Number 8 transformer’s return (P2-26) Number 20 transformer’s circuit driver (P2-27) Number 20 transformer’s return (P2-32) Number 10 transformer’s circuit driver (P2-33) Number 10 transformer’s return (P2-34) Number 18 transformer’s circuit driver (P2-35) Number 18 transformer’s return (P2-48) Number 6 transformer’s circuit driver (P2-49) Number 6 transformer’s return (P2-50) Number 14 transformer’s circuit driver (P2-51) Number 14 transformer’s return
(P4-1) Number 1 transformer’s circuit driver (P4-2) Number 1 transformer’s return (P4-3) Number 11 transformer’s circuit driver (P4-4) Number 11 transformer’s return (P4-14) Number 3 transformer’s circuit driver (P4-15) Number 3 transformer’s return (P4-16) Number 15 transformer’s circuit driver (P4-17) Number 15 transformer’s return (P4-24) Number 7 transformer’s circuit driver (P4-25) Number 7 transformer’s return (P4-26) Number 19 transformer’s circuit driver (P4-27) Number 19 transformer’s return (P4-32) Number 9 transformer’s circuit driver (P4-33) Number 9 transformer’s return (P4-34) Number 17 transformer’s circuit driver (P4-35) Number 17 transformer’s return (P4-48) Number 5 transformer’s circuit driver (P4-49) Number 5 transformer’s return (P4-50) Number 13 transformer’s circuit driver (P4-51) Number 13 transformer’s return
g01066020
b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit of the ignition system. C. Check the ignition harnesses and wiring for abrasion and for pinch points from each ignition transformer to each ECM. Expected Result: All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. Results:
• OK – The components are in good condition with proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good condition and/or at least one connection is improper.
Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
310 Troubleshooting Section
Test Step 2. Check for Diagnostic Codes for the Primary Circuit A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. B. Switch the 35 amp circuit breaker ON. C. Attempt to start the engine. Use Cat ET in order to determine if the following codes are active or logged:
• 301-05 Ignition Transformer Primary #1 open circuit through 316-05 Ignition Transformer Primary #16 open circuit
• 1752-05 Ignition Transformer Primary #17 open
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers. 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
circuit through 1755-05 Ignition Transformer Primary #20 open circuit
• 301-06 Ignition Transformer Primary #1 short through 316-06 Ignition Transformer Primary #16 short
• 1752-06 Ignition Transformer Primary #17 short through 1755-06 Ignition Transformer Primary #20 short
Note: If a diagnostic code for the primary circuit is logged but not currently active, attempt to repeat the condition that activated the code. Run the engine to full operating temperature. Expected Result: None of the above diagnostic codes are active. Results:
• Active “open circuit” – There is an open in the primary circuit. Proceed to Test Step 6.
• Active “short” – There is a short in the primary circuit. Proceed to Test Step 3.
• Logged only – There may be an intermittent problem in the ignition harness.
Repair: Perform the following steps:
Illustration 143
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Section view of a cylinder (1) Cover (2) Transformer (3) 3-pin connector
2. Remove cover (1) for the suspect cylinder. Inspect the harness and 3-pin connector (3) of transformer (2). Check for corrosion, for abrasion, and for pinch points. 3. Reconnect the connectors, and reinstall the cover. If the problem persists, refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
311 Troubleshooting Section
Test Step 3. Check the Transformer’s Primary Circuit and the Secondary Circuit
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers. A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
Illustration 145
g01057616
Schematic for the primary circuit and for the secondary circuit (4) 3-pin connector for the transformer (5) Terminal A (6) Terminal B (7) Blocking diode (8) Flyback diode (9) Primary coil of the transformer (10) Secondary coil of the transformer (11) Resistor (12) Spark plug gap
E. Measure the primary circuit by checking the voltage of the blocking diode. Illustration 144
g01057615
Section view of a cylinder (1) Cover (2) Transformer (3) 3-pin connector
B. Remove cover (1) for the suspect cylinder. C. Disconnect 3-pin connector (3). Visually inspect the 3-pin connectors for corrosion and/or for damage. D. Remove transformer (2) from the cylinder head.
312 Troubleshooting Section
Illustration 147
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Resistance versus temperature (Y) Resistance in Ohms (X) Temperature in degrees celsius (degrees fahrenheit)
Illustration 146
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Ignition transformer (A) + Terminal (B) - Terminal (13) Mounting flange (14) Connector for the spark plug
a. Set the multimeter to the diode scale. Connect the multimeter leads to terminals (A) and (B) of the 3-pin connector. The polarity of the leads is not important. Measure the voltage between the terminals. Record the measurement. b. Reverse the multimeter leads. Measure the voltage between the terminals again. Record the measurement. F. Measure the resistance of the secondary circuit. Note: The resistance of the secondary coil will vary with the temperature. Illustration 147 demonstrates the relationship between the secondary coil’s resistance and the temperature. A reading that is within 1000 Ohms is acceptable. For example, if the transformer’s temperature is 60 °C (140 °F), the correct resistance is between 21,000 and 23,000 Ohms.
a. Set the multimeter to the 40,000 Ohm scale. Measure the resistance between mounting flange (13) and the extension’s internal terminal (14) for the spark plug. Expected Result: For the primary circuit, one of the voltage measurements is approximately 0.450 VDC. The other voltage measurement indicates an open circuit. For the secondary circuit, the resistance between the screw for the ground spring and the connector for the spark plug is within the acceptable tolerance. Results:
• OK – All three of the measurements are correct. Repair: Perform the following steps: 1. Install the spark plug according to the instructions in Operation and Maintenance Manual, “Ignition System Spark Plugs Check/Adjust/Replace”. 2. Switch the suspect transformer with a transformer from a different cylinder that is known to be good. Install the transformers. Install the valve covers. 3. Reset the control system. Restart the engine. Clear any logged codes. 4. Operate the engine. Check for a recurrence of the problem.
313 Troubleshooting Section
If the problem stays with the suspect transformer, replace the transformer. If the problem stays with the suspect cylinder, proceed to Test Step 4.
• Not OK – At least one of the three measurements is incorrect.
Repair: Replace the ignition transformer. Make sure that you use the correct transformer for the G3520C Engine. STOP.
Test Step 4. Check for a Short Circuit Between the ECM and the Transformer
Repair: Perform the following procedure: 1. Connect the ignition harness to the transformer. 2. Set the engine control to the START mode and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Look for a “short circuit” code. Replace the transformer if the original “short circuit” code is activated. If the original “short circuit” code does not return, the problem appears to be resolved. Resume normal operation. STOP.
Test Step 5. Disconnect the Wiring From the ECM and Check for a Short Circuit There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. NOTICE The air inlet, the cylinders, and the exhaust system can be filled with fuel when the gas supply is ON, the ignition system is disabled, and the engine is cranked. The unburned fuel can ignite unexpectedly and cause damage. Turn OFF the gas supply before you perform this step.
There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. NOTICE The air inlet, the cylinders, and the exhaust system can be filled with fuel when the gas supply is ON, the ignition system is disabled, and the engine is cranked. The unburned fuel can ignite unexpectedly and cause damage.
A. Shut OFF the fuel supply. Set the engine control to the OFF mode.
Turn OFF the gas supply before you perform this step.
B. Disconnect the 3-pin connector for the suspect transformer.
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
C. Set the engine control to the START mode and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Expected Result: The “short” code is active when the transformer’s connector is disconnected. Results:
• Yes – The “short” code was activated after
the transformer’s connector was disconnected. Proceed to Test Step 5. Illustration 148
• No – The original “short” code was not
activated after the transformer’s connector was disconnected.
P2 or P4 connector
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314 Troubleshooting Section
B. Use a 151-6320 Wire Removal Tool to remove the terminal for the circuit driver of the suspect cylinder from the ECM connector. For identification of the appropriate terminal, refer to Illustration 148 and Table 25. Table 25
Cylinder and Corresponding Terminal of the ECM Connector for the Ignition Harness Cylinder
Terminal for the Circuit Driver
1
P4-1
2
P2-1
3
P4-14
4
P2-14
5
P4-48
6
P2-48
7
P4-24
8
P2-24
9
P4-32
10
P2-32
11
P4-3
12
P2-3
13
P4-50
14
P2-50
15
P4-16
16
P2-16
17
P4-34
18
P2-34
19
P4-26
20
P2-26
Repair: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Repair the harness, when possible. Replace the harness, if necessary. STOP.
• No – The ECM continued to activate a “short
circuit” diagnostic code after the wire was disconnected from the ECM. There is a problem with the ECM. Repair: Replace the ECM that is appropriate for the suspect cylinder. Follow the instructions in Troubleshooting, “Replacing the ECM”. STOP.
Test Step 6. Create a Short Circuit in the Ignition Harness
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers. NOTICE The air inlet, the cylinders, and the exhaust system can be filled with fuel when the gas supply is ON, the ignition system is disabled, and the engine is cranked. The unburned fuel can ignite unexpectedly and cause damage.
C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
Turn OFF the gas supply before you perform this step.
D. Set the engine control to the START mode and observe the “Active Diagnostic” screen of Cat ET while you crank the engine.
A. Shut OFF the fuel supply. Set the engine control to the OFF/RESET mode.
Expected Result: An “open circuit” diagnostic code is activated for the circuit after removal of the wire for the circuit driver. Results:
• Yes – The ECM detected an open circuit after the wire was disconnected from the ECM. There is a short circuit in the wiring.
B. Remove the valve cover for the suspect cylinder. C. Disconnect the 3-pin connector for the transformer. Inspect the connectors. Verify that the connectors do not have damage or corrosion. Inspect the harness. Verify that the harness does not have damage or corrosion. D. Install a jumper wire into terminals A and B of the 3-pin connector on the ignition harness.
315 Troubleshooting Section
E. Set the engine control to the START mode and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Look for the original “open circuit” code. Expected Result: The original “open circuit” code is active. Results:
6. Replace the transformer. Make sure that you use the correct transformer for the G3520C Engine. 7. Clear all of the logged diagnostic codes. STOP.
Test Step 7. Check the Engine Harness for an Open Circuit
• Yes – The original “open circuit” code was
activated after a short circuit was created in the ignition harness. The ECM did not detect the jumper wire. Reconnect the ignition harness to the transformer. Proceed to Test Step 7.
• No – Cat ET displayed an active “short” diagnostic
code after a short circuit was created in the ignition harness. The harness and the ECM are OK. Repair: Perform the following steps:
There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. NOTICE The air inlet, the cylinders, and the exhaust system can be filled with fuel when the gas supply is ON, the ignition system is disabled, and the engine is cranked. The unburned fuel can ignite unexpectedly and cause damage.
There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. NOTICE The air inlet, the cylinders, and the exhaust system can be filled with fuel when the gas supply is ON, the ignition system is disabled, and the engine is cranked. The unburned fuel can ignite unexpectedly and cause damage. Turn OFF the gas supply before you perform this step. A. Shut OFF the fuel supply. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker to the OFF position.
Turn OFF the gas supply before you perform this step. 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Remove the jumper wire from the 3-pin connector of the ignition harness. g01013288
3. Reconnect the ignition harness to the transformer.
Illustration 149
4. Set the engine control to the START mode and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Look for the original “open circuit” code.
B. Use a 151-6320 Wire Removal Tool to remove two terminals for the circuit driver of the suspect cylinder from the ECM connector. For identification of the appropriate terminals, refer to Illustration 149 and Table 26.
5. If the original “open circuit” code is activated, set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
P2 or P4 connector
316 Troubleshooting Section
Results:
Table 26
Cylinders and Corresponding Terminals of the ECM Connectors for the Ignition Harnesses
• Yes – When the jumper wire was installed into the connector, a “short circuit” diagnostic code was activated for the suspect cylinder. The original “open circuit” diagnostic code was not active. There is an open circuit in the wiring harness for the suspect cylinder.
Cylinder
Terminals for the Cylinder
1
P4-1 and P4-2
2
P2-1 and P2-2
3
P4-14 and P4-15
Repair: Perform the following steps:
4
P2-14 and P2-15
5
P4-48 and P4-49
1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
6
P2-48 and P2-49
7
P4-24 and P4-25
8
P2-24 and P2-25
9
P4-32 and P4-33
10
P2-32 and P2-33
11
P4-3 and P4-4
12
P2-3 and P2-4
13
P4-50 and P4-51
14
P2-50 and P2-51
15
P4-16 and P4-17
16
P2-16 and P2-17
17
P4-34 and P4-35
18
P2-34 and P2-35
19
P4-26 and P4-27
20
P2-26 and P2-27
2. Remove the jumper wire and reinstall the terminals that were removed from the connector. Pull on the wires in order to verify that the terminals are fully inserted into the connector. 3. Repair the harness, when possible. Replace the harness, if necessary. STOP.
• No – When the jumper wire was installed into the
connector, a “Short circuit” diagnostic code was not activated. The ECM did not detect the jumper wire. There is a problem with the ECM. Repair: Replace the ECM that is appropriate for the suspect cylinder. Follow the instructions in Troubleshooting, “Replacing the ECM”. STOP. i02089548
C. Install the ends of a jumper wire into the terminals for the removed wires. This will replace the wiring with a short circuit. D. Set the engine control to the START mode. Switch the 35 amp circuit breaker to the ON position. E. Observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Look for a “short circuit” diagnostic code. Expected Result: A “short circuit” diagnostic code is activated for the suspect cylinder. The original “open circuit” diagnostic code is not active.
Ignition Transformers Secondary Circuit and Spark Plugs SMCS Code: 1555-038; 1561-038 System Operation Description: The ignition transformers initiate combustion by providing high voltage to the spark plugs. The positive output from the secondary circuit of the transformer is at the connection for the terminal of the transformer and the terminal of the spark plug. The transformers are located underneath covers at the top of each cylinder. Each transformer is grounded to the cylinder head via a mounting flange.
317 Troubleshooting Section
Note: Ignition transformers from Electronic Ignition Systems (EIS) are not interchangeable with the transformers in this engine. Caterpillar spark plugs are high voltage devices with internal resistors. The spark plugs operate at a voltage that is greater than 5,000 volts. Most ignition systems are not affected by resistance in the secondary circuit. If a measurement of the resistance is desired, a megohmmeter must be used. A low voltage multimeter will not provide a reliable reading of the resistance because oxidation of the spark plug’s internal components will affect the readings of those meters.
Test Step 1. Check the Status Screen of Cat ET for the Output of the Secondary Circuits of the Transformers
Illustration 150
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Ignition transformer and spark plug (1) Mounting flange (2) 3-pin connector (3) Transformer (4) Extension (5) Secondary spark plug terminal (6) O-ring seal (7) Hole in the spark plug’s precombustion chamber
The secondary circuit of the transformer provides an initial 8,000 to 37,000 volts to the spark plug. This voltage ionizes the spark plug gap. This voltage is then reduced to about 1000 volts. The total duration of the spark is approximately 400 microseconds. Each Electronic Control Module (ECM) can diagnose the primary circuit of the ignition transformers for open circuits and/or for short circuits. Secondary open circuits and short circuits will not directly shut down the engine. However, these conditions may lead to misfire which can cause lugging of the engine. Lugging of the engine can cause a shutdown. Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file.
Illustration 151
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Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. B. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. D. Set up two status screens for Cat ET. Use eight of the following labels for parameters on each status screen:
318 Troubleshooting Section
Table 27
Parameters for the Status Screens on Cat ET Screen 1 Group 8
Screen 2 Group 9
“Cylinder #1 Transformer Secondary Output Voltage Percentage”
“Cylinder #2 Transformer Secondary Output Voltage Percentage”
“Cylinder #3 Transformer Secondary Output Voltage Percentage”
“Cylinder #4 Transformer Secondary Output Voltage Percentage”
“Cylinder #5 Transformer Secondary Output Voltage Percentage”
“Cylinder #6 Transformer Secondary Output Voltage Percentage”
“Cylinder #7 Transformer Secondary Output Voltage Percentage”
“Cylinder #8 Transformer Secondary Output Voltage Percentage”
“Cylinder #9 Transformer Secondary Output Voltage Percentage”
“Cylinder #10 Transformer Secondary Output Voltage Percentage”
“Cylinder #11 Transformer Secondary Output Voltage Percentage”
“Cylinder #12 Transformer Secondary Output Voltage Percentage”
“Cylinder #13 Transformer Secondary Output Voltage Percentage”
“Cylinder #14 Transformer Secondary Output Voltage Percentage”
“Cylinder #15 Transformer Secondary Output Voltage Percentage”
“Cylinder #16 Transformer Secondary Output Voltage Percentage”
“Cylinder #17 Transformer Secondary Output Voltage Percentage”
“Cylinder #18 Transformer Secondary Output Voltage Percentage”
“Cylinder #19 Transformer Secondary Output Voltage Percentage”
“Cylinder #20 Transformer Secondary Output Voltage Percentage”
Repair: Investigate other possible root causes of the problem. Troubleshoot the symptom. Refer to Troubleshooting, “Troubleshooting Without A Diagnostic Code”. STOP.
• Not OK – At least one of the outputs displayed a
value of 0 percent or a value that is greater than 90 percent. The ignition system components require maintenance. Proceed to Test Step 2.
Test Step 2. Inspect the Transformer
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers. A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
E. Start the engine. Apply the normal load at rated speed. Allow the engine to warm up to normal operating temperature. F. Observe the value of the output for the secondary circuit of each transformer. Expected Result: The displayed value of the output for the secondary circuit of each transformer is between 1 and 90 percent. Results:
• OK – The displayed value of the output for the
secondary circuit of each transformer is between 1 and 90 percent. The ignition system components are operating properly.
Illustration 152
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Section view of a cylinder (1) Cover (2) Transformer (3) 3-pin connector
B. Remove cover (1) for the suspect cylinder.
319 Troubleshooting Section
NOTICE Pulling on the wiring harness may break the wires. Do not pull on the wiring harness.
NOTICE The extension can be scratched and damaged with a wire brush. Do not use a wire brush on the extension.
C. Disconnect the ignition harness from 3-pin connector (3). Remove transformer (2) from the engine.
G. Clean any deposits from the inside of the extension. Use a 6V-7093 Brush with isopropyl alcohol. Expected Result: The transformer is in good condition. Results:
• OK – The transformer appears to be in good condition. Proceed to Test Step 3.
• Not OK – An inspection found a problem with the transformer.
Repair: Repair the transformer, when possible. Replace the transformer, if necessary. Be sure to use the correct transformer for the G3520C Engine. Reset the control system. Restart the engine. Clear the logged codes. STOP.
Illustration 153
g01057657
Ignition transformer and spark plug (4) (5) (6) (7)
Transformer Extension Secondary terminal for the spark plug O-ring seal
D. Inspect the body of transformer (4) and extension (5) for corrosion and/or for damage. E. Inspect internal O-ring seal (7) for damage. F. The extension has an internal terminal for the spark plug. Inspect the terminal for looseness, for corrosion, and/or for damage. Insert a spark plug into the extension and check the terminal for spring pressure.
320 Troubleshooting Section
Test Step 3. Check the Primary Circuit and the Secondary Circuit
Illustration 155
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Ignition transformer (A) + Terminal (B) - Terminal (10) Mounting flange (11) Connector for the spark plug
Illustration 154
g01057676
Schematic for the primary circuit and for the secondary circuit (1) (2) (3) (4) (5) (6) (7) (8) (9)
3-pin connector for the transformer Terminal A Terminal B Blocking diode Flyback diode Primary coil of the transformer Secondary coil of the transformer Resistor Spark plug gap
A. Measure the primary circuit by checking the voltage of the blocking diode.
a. Set the multimeter to the diode scale. Connect the multimeter leads to the terminal (A) and terminal (B) of the 3-pin connector. The polarity of the leads is not important. Measure the voltage between the terminals. Record the measurement. b. Reverse the multimeter leads. Measure the voltage between the terminals again. Record the measurement. B. Measure the resistance of the secondary circuit. Note: The resistance of the secondary coil will vary with the temperature. Illustration 156 demonstrates the relationship between the secondary coil’s resistance and the temperature. A reading that is within 1000 Ohms is acceptable. For example, if the transformer’s temperature is 60 °C (140 °F), the correct resistance is between 21,000 and 23,000 Ohms.
321 Troubleshooting Section
Illustration 157
g01057662
Spark plug that has a precombustion chamber
B. Perform the following procedures according to the instructions in the engine’s Operation and Maintenance Manual. Illustration 156
g00863850
Resistance versus temperature (Y) Resistance in Ohms (X) Temperature in degrees celsius (degrees fahrenheit)
a. Set the multimeter to the 40,000 Ohm scale. Measure the resistance between mounting flange (10) and the extension’s internal terminal (11) for the spark plug. Expected Result: For the primary circuit, one of the voltage measurements is approximately 0.450 VDC. The other voltage measurement indicates an open circuit. For the secondary circuit, the resistance between the mounting flange and the secondary terminal for the spark plug is within the acceptable tolerance. Results:
• OK – All three of the measurements are correct. Proceed to Test Step 4.
• Not OK – At least one of the measurements is incorrect.
Repair: Make sure that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. Replace the ignition transformer. Make sure that you use the correct transformer for the G3520C Engine. STOP.
Test Step 4. Check the Spark Plug A. Switch the 35 amp circuit breaker OFF.
a. Remove the spark plug from the cylinder head. b. Inspect the spark plug. c. Clean the spark plug. Note: For a spark plug with a precombustion chamber, the resistance cannot be measured. The minimum service life of a spark plug with a precombustion chamber is approximately 3000 service hours. The spark plug may be good for a considerable period beyond 3000 service hours. Experience at the particular site will help to determine the proper interval for replacement of the spark plug. Expected Result: The spark plug is in good condition. Results:
• OK – The spark plug is in good condition. Proceed to Test Step 5.
• Not OK – The spark plug is not in good condition. Repair: Discard the spark plug. Install a new spark plug according to the instructions in the engine’s Operation and Maintenance Manual. Reset the control system. Restart the engine. Clear the logged codes. STOP.
Test Step 5. Operate the Engine A. Install the spark plug according to the instructions in the engine’s Operation and Maintenance Manual. B. Install the transformer and the cover. C. Reset the control system. Clear any logged diagnostic codes. D. Start the engine and operate the engine in order to generate the diagnostic code again.
322 Troubleshooting Section
Expected Result: A diagnostic code is not generated. Results:
• OK – A diagnostic code is not generated. Proceed with normal operation. STOP.
• Not OK – A diagnostic code is generated. Proceed to Test Step 6.
Test Step 6. Isolate the Spark Plug and the Transformer A. Switch the suspect transformer with a transformer from a different cylinder that is known to be good. Install the transformers. Install the covers.
i01811734
Inspecting Electrical Connectors SMCS Code: 7553-040-WW System Operation Description: Many of the troubleshooting procedures direct you to a specific electrical connector. Use the following test steps to help determine whether the connector is the cause of the problem. If a problem is found in a connector, repair the connector and verify that the problem is corrected.
C. Start the engine and operate the engine in order to generate the diagnostic code again.
Intermittent electrical problems are often caused by poor connections. Always check for an active diagnostic code before you open any connection. Immediately after you reconnect the connector, check for codes again. Sometimes, simply disconnecting a connector and then reconnecting the connector can solve a problem. If this occurs, the following conditions are likely causes:
Expected Result:
• Loose terminals
The diagnostic code is generated for the suspect transformer.
• Bent terminals
B. Reset the control system. Clear any logged diagnostic codes.
Results:
• Yes – The diagnostic code is generated for the
• Improperly crimped terminals • Improperly mated connectors
suspect transformer.
• Moisture
Repair: Make sure that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. Replace the faulty transformer. Make sure that you use the correct transformer for the G3520C Engine. Reset the control system. Clear any logged diagnostic codes.
• Corrosion
STOP.
• No – The diagnostic code is generated for the original cylinder.
Repair: Make sure that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. Install a new spark plug according to the instructions in Operation and Maintenance Manual, “Ignition System Spark Plugs - Check/Adjust/Replace”. Reset the control system. Clear any logged diagnostic codes. STOP.
Illustration 158
g00700045
The MS connectors have a metal housing. The pins and the sockets are soldered to the electrical wires. The solder connections are usually protected by a chemical potting which prevents access to the solder point.
323 Troubleshooting Section
Illustration 159
g00700064
Deutsch connectors have a plastic housing. The pins and the sockets are crimped onto the electrical wires. The connector has a locking mechanism in order to hold the pins and the sockets. These connectors are repairable without cutting the wires.
Illustration 160
Use the following test steps in order to thoroughly inspect the connectors and determine if the connectors are the cause of the problem.
Test Step 1. Check the Connectors. A. Always set the engine control to the OFF/RESET mode before you inspect electrical conductors. Switch the 35 amp circuit breaker OFF.
g00928006
B. For the MS connectors, make sure that the receptacle is turned fully in the clockwise direction. Check that the threading is properly aligned and securely mated.
324 Troubleshooting Section
C. For the Deutsch HD connectors, make sure that the plug and the receptacle are aligned properly with the index markings. Make sure that the receptacle is turned fully in the clockwise direction. Verify that the receptacle is clicked into the locked position. Make sure that the two halves cannot be pulled apart. D. For the Deutsch DT style, make sure that the orange wedge is used in order to lock the pins. Check that the receptacle has clicked into the locked position. Make sure that the two halves cannot be pulled apart. Expected Result: All connectors are properly mated and free of damage. Results:
Verify that the repair eliminates the problem. STOP.
Test Step 3. Perform a Pull Test on Each Wire Connection. A. Each terminal and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector. B. The DT connectors use an orange wedge to lock the terminals in place. Ensure that the orange wedge is not missing and that the orange wedge is installed properly on the DT connectors.
• OK – Proceed to Test Step 2.
Note: Terminals should ALWAYS be crimped onto the wires with a crimp tool. Do not solder terminals. Use the 1U-5804 Crimp Tool.
• Not OK
Expected Result:
Repair: Repair the connectors and/or replace the connectors. Reconnect all of the connectors. STOP.
Test Step 2. Check the Allen Head Screw on the Rectangular Connectors A. Ensure that each allen head screw is properly tightened. Be careful not to overtighten the screw and break the screw.
Each terminal and each connector easily withstands 45 N (10 lb) of pull and each wire remains in the connector body. Results:
• OK – Proceed to Test Step 4. • Not OK Repair: Repair the circuit.
B. When you connect a 70-pin connector to an Electronic Control Module (ECM), do not exceed 6 ± 1 N·m (55 ± 9 lb in) of torque on the screw.
Verify that the repair eliminates the problem.
C. When you connect a rectangular connector to the terminal box, do not exceed 2.25 ± 0.25 N·m (20 ± 2 lb in) of torque on the screw.
Test Step 4. Monitor the Electronic Service Tool While the Wiring and the Connectors Are Being Pulled.
STOP.
Expected Result: Each rectangular connector is secure and the allen head screw is properly torqued. Results:
There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch wires that are associated with the ignition transformer circuit when the engine is cranking or running.
• OK – Proceed to Test Step 3. • Not OK Repair: Repair the connector or replace the connector, as required.
A. If there is an active diagnostic code that pertains to the circuit, perform the following steps: a. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
325 Troubleshooting Section
b. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box.
Verify that the repair eliminates the problem.
c. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Then start the engine. Run the engine under normal operating conditions.
Test Step 5. Check Wires for Nicks or Abrasion in the Insulation.
d. Monitor the “Active Diagnostic Code” screen on Cat ET while you pull on all harnesses and connectors for the circuit with the active code. If the harness is being pulled and the active diagnostic code disappears, there is a problem in the wiring or the connector. B. If there are no active diagnostic codes that pertain to the circuit, perform the following test: a. Run the engine under normal operating conditions. b. Monitor the “Display Status” screen on Cat ET while you pull on all harnesses and connectors for the circuit. If the harness is being pulled and the reading changes erratically, there is a problem in the wiring or the connector. C. If there are no active diagnostic codes and there are complaints about intermittent changes in speed or power cutouts, perform the following test:
STOP.
A. Set the engine control to the STOP mode. Allow the engine to coast to a stop. B. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. C. Carefully inspect each wire for signs of abrasion, of nicks, or of cuts. The following areas are likely locations:
• Places with exposed insulation • Points with wiring that rubs against the engine • Places with wiring that rubs against a sharp point
D. Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. Also, check all of the hold down clamps in order to verify that the harness is not compressed by the clamps. Pull back the harness sleeves in order to check for flattening of the wires by the clamps. Expected Result:
a. Run the engine under normal operating conditions.
The wires do not have abrasion, nicks, or cuts and the harness is properly clamped.
b. Listen for speed burps or power cutouts while the wiring and/or the connectors are pulled.
Results:
If the harness is being pulled and the engine has a speed burp or a power cutout, there could be a problem in the wiring or the connector. Expected Result: The problem appears to be external to the harnesses and connectors. Pulling on the harness and on the connectors does not affect the active diagnostic code, component status, or engine performance. Results:
• OK – Proceed to Test Step 5. • Not OK Repair: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Repair the circuit.
• OK – Proceed to Test Step 6. • Not OK Repair: Repair the wires or replace the wires, as required. Verify that the repair eliminates the problem. STOP.
326 Troubleshooting Section
Test Step 6. Check the Connectors for Moisture or Corrosion.
Note: It is normal to see some minor seal abrasion on the ECM connector seals. Minor seal abrasion will not allow the entry of moisture. If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and the source of the moisture entry must be repaired. If the repair is not made, the problem will recur. Simply drying the connector will not fix the problem. The following list includes likely paths for the entrance of moisture:
• Missing seals or plugs • Improperly installed seals or plugs • Nicks in exposed insulation • Improperly mated connectors
Illustration 161
g00690571
A. Ensure that the connector seals and the white sealing plugs are in place. If any of the seals or plugs are missing, replace the seal or plug. If necessary, replace the connector.
Moisture can also wick from one connector through the inside of a wire to an ECM connector. If moisture is found in an ECM connector, thoroughly check all connectors and wires on the harness that connects to the ECM. The ECM is not the source of the moisture. Do not replace an ECM if moisture is found in either ECM connector. Note: If corrosion is evident on the pins, sockets or the connector, use only denatured alcohol to remove the corrosion. Use a cotton swab or a soft brush to remove the corrosion. Do not use any cleaners that contain 1,1,1 trichloro-ethylene because 1,1,1 trichloro-ethylene may damage the connector. Expected Result: All of the connectors are completely coupled and all of the seals are completely inserted. The harness and the wiring does not have corrosion, abrasion, or pinch points. Results:
• OK – Proceed to Test Step 7. • Not OK
Illustration 162
g00690568
B. Check all of the wiring harnesses in order to verify that the harness does not make a sharp bend out of a connector. This will deform the connector seal and this will create a path for the entrance of moisture. Thoroughly inspect each ECM connector for evidence of moisture entry.
Repair: Repair the circuit. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.
327 Troubleshooting Section
Verify that the repair eliminates the problem by running the engine for several minutes and by checking again for moisture. If moisture reappears, the moisture is wicking into the connector. Even if the moisture entry path is repaired, it may be necessary to replace the wires that have moisture. These wires may have moisture that is trapped inside the insulation. Verify that the repair eliminates the problem. STOP.
Test Step 7. Inspect the Connector Terminals. Verify that the terminals are not damaged. Verify that the terminals are properly aligned in the connector and verify that the terminals are properly located in the connector.
Note: This is especially important for intermittent problems. A. One at a time, insert a new pin into each socket. Make sure that the pin is properly gripped by the socket. B. One at a time, insert a new socket onto each pin. Make sure that the pin is properly gripped by the socket. Verify that the socket holds the pin when the connector hangs freely. Expected Result: Each socket firmly grips each pin. Results:
• OK – The pins and sockets mate properly. STOP. • Not OK – The pins and sockets do not mate
Expected Result: The terminals are properly aligned and the terminals appear undamaged.
properly.
Results:
Repair: Repair any bad pins and sockets. Replace the connectors, if necessary. Replace the wiring, if necessary.
• OK – Proceed to Test Step 7.
Verify that the repair eliminates the problem.
• Not OK
STOP.
Repair: Repair the terminals and/or replace the terminals, as required. Verify that the repair eliminates the problem. STOP.
i02089552
Integrated Temperature Sensing Module (ITSM) SMCS Code: 1901-038
Test Step 8. Check the Individual Retention of the Pins and Sockets.
System Operation Description: The Integrated Temperature Sensing Module (ITSM) monitors type K thermocouples at each cylinder exhaust port and at the inlets and outlets for both turbochargers. The ITSM can also calculate the average temperature for each cylinder bank (left and right). Temperature readings of the thermocouples are available over the CAT data link for use by each Electronic Control Module (ECM) and other modules. The temperatures can be viewed on the Caterpillar Electronic Technician (ET). The ITSM generates event codes for each of the following programmable conditions:
• High exhaust temperature • High deviation of an exhaust port temperature • Low deviation of an exhaust port temperature Illustration 163
g00690572
• High inlet temperature to the turbocharger turbine
328 Troubleshooting Section
• High outlet temperature from the turbocharger turbine
A diagnostic code is generated by the ITSM for the circuit of any thermocouple that is shorted to the +Battery side, shorted to ground, or open. Logged diagnostic codes provide a historical record. Before you begin this procedure, use Cat ET to print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
329 Troubleshooting Section
Illustration 164 Schematic for the circuit of the ITSM for 1500 RPM engines
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330 Troubleshooting Section
Illustration 165
g01065626
331 Troubleshooting Section
Schematic for the circuit of the ITSM for 1800 RPM engines
Test Step 1. Inspect the Electrical Connectors and Wiring
B. Thoroughly inspect each of the following connectors:
• Master ECM J1/P1 connectors • J3/P3 connectors for the slave ECM • J7/P7 and J9/P9 connectors on the terminal box a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (53 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 166
g01054206
Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Illustration 168
Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
g01065145
Harness side of the P1 connector (P1-8) CAT data link + (P1-9) CAT data link −
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the ITSM.
Illustration 167 Terminal box (2) J1/P1 connectors for the master EM (3) J7/P7 connectors for the harness from the ITSM (4) J9/P9 connectors for the CAT Data Link (5) J3/P3 connectors for the slave ECM
g01065628
332 Troubleshooting Section
g01065630
Illustration 169 Thermocouples (6) Thermocouple for the temperature of a cylinder exhaust port (7) Thermocouple for the temperature of the exhaust inlet to the turbocharger turbine
(8) Thermocouples for the temperature of the turbocharger exhaust outlets (9) Thermocouple for the temperature of the turbocharger exhaust outlet
d. Carefully inspect the connectors for each of the thermocouples. Check the harnesses and wiring for abrasion and for pinch points from each thermocouple to the ITSM.
333 Troubleshooting Section
Test Step 2. Verify the Active Diagnostic Codes A. Access the “Active Diagnostic” screen for the ITSM on Cat ET. Determine if any of the following diagnostic codes for the thermocouples are active:
• 1489-03 through 1492-03 (“short to +batt”) • 1489-04 through 1492-04 (“short to ground”) • 1489-05 through 1492-05 (“open circuit”) • 1531-03 through 1550-03 (“short to +batt”) • 1531-04 through 1550-04 (“short to ground”) • 1531-05 through 1550-05 (“open circuit”) Expected Result: Illustration 170
g01065631
ITSM (10) 54-pin connectors for the harness to the thermocouples (11) ITSM (12) 14-pin connectors for the harness to the terminal box for the master ECM
e. Thoroughly inspect 54-pin connectors (10) and 14-pin connectors (12) for ITSM (11). Check the harnesses and wiring for abrasion and for pinch points from the ITSM to the master ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. Results:
None of the above diagnostic codes for the thermocouples are active. Results:
• No Active Codes – None of the above diagnostic codes for the thermocouples are active.
Repair: If any of the codes are logged, there may be an intermittent condition that is causing the codes to be generated. If the engine is not running properly, refer to Troubleshooting, “Troubleshooting Without a Diagnostic Code”. STOP.
• Active “short to ground” or “short to +batt” – At
least one “short to ground” or “short to +batt” diagnostic code is active. Proceed to Test Step 3.
• OK – The components are in good condition with
• Active “open circuit” – At least one “open circuit”
• Not OK – The components are not in good
Test Step 3. Create an Open Circuit
proper connections. Proceed to Test Step 2. condition and/or at least one connection is improper.
Repair: Perform the necessary repairs and/or replace parts, if necessary. If the wiring harness from the thermocouples to the ITSM requires repair, replace the harness in order to ensure reliable operation. All of the wiring from the thermocouples to the ITSM must be type K. The polarity of the wires from each thermocouple to the ITSM must be maintained in order for the ITSM to read the correct temperatures. STOP.
diagnostic code is active. Proceed to Test Step 4.
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the connector for the thermocouple with the short circuit diagnostic code. C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. D. Access the “Active Diagnostic” screen for the ITSM on Cat ET. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Expected Result: There is an active “open circuit” diagnostic code for the disconnected thermocouple.
334 Troubleshooting Section
Results:
• Yes – There is an active “open circuit” diagnostic code for the disconnected thermocouple. The ITSM and the harness are OK. Repair: Perform the following procedure: 1. Thoroughly inspect the thermocouple’s connectors. Ensure that the connectors and the seals are in good condition. 2. Reconnect the thermocouple’s connectors and check for an active short circuit diagnostic code. If the short circuit diagnostic code becomes active again, there is a problem with the thermocouple. 3. Disconnect the suspect thermocouple and connect a thermocouple that is known to be good. Do not install the thermocouple into the engine yet. 4. Check for an active short circuit diagnostic code. If the diagnostic code is not generated with the good thermocouple, remove the suspect thermocouple from the engine. Install the good thermocouple. 5. Clear the logged diagnostic codes. STOP.
• No – There is not an active “open circuit” diagnostic code for the disconnected thermocouple. There is a short circuit between the harness for the thermocouple and the ITSM. Proceed to Test Step 5.
Test Step 4. Create a Short Circuit A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the connector for the thermocouple with the open circuit diagnostic code. C. Install a jumper wire into terminals A and B on the harness connector for the suspect thermocouple. D. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. E. Access the “Active Diagnostic” screen for the ITSM on Cat ET. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Observe the “Active Diagnostic” screen.
F. Remove the jumper wire and observe the “Active Diagnostic” screen. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Expected Result: When the jumper wire was installed, a “short circuit” diagnostic code was generated. When the jumper wire was removed, the “open circuit” diagnostic code recurred. Results:
• Yes – When the jumper wire was installed, a
“short circuit” diagnostic code was generated. When the jumper wire was removed, the “open circuit” diagnostic code recurred. The ITSM and the harness are OK. Repair: Perform the following procedure: 1. Thoroughly inspect the thermocouple’s connectors. Ensure that the connectors and the seals are in good condition. 2. Reconnect the thermocouple’s connectors and check for an active open circuit diagnostic code. If the open circuit diagnostic code becomes active again, there is a problem with the thermocouple. 3. Disconnect the suspect thermocouple and connect a thermocouple that is known to be good. Do not install the good thermocouple into the engine yet. 4. Check for an active open circuit diagnostic code. If the diagnostic code is not generated with the good thermocouple, remove the suspect thermocouple from the engine. Install the good thermocouple. 5. Clear the logged diagnostic codes. STOP.
• No – When the jumper wire was installed, the
“open circuit” diagnostic code recurred. There is probably an open circuit in the harness between the ITSM and the connector for the thermocouple. Repair: Remove the jumper wire. Proceed to Test Step 5.
Test Step 5. Check the ITSM A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
335 Troubleshooting Section
B. Disconnect the 54-pin connector from the ITSM. Thoroughly inspect the 54-pin connectors. Ensure that the connectors are in good condition. C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Note: When the 54-pin connectors are disconnected, an active “open circuit” diagnostic code will be generated for all of the thermocouples. This is normal. Only pay attention to the diagnostic codes for the suspect thermocouple. D. Access the “Active Diagnostic” screen for the ITSM on Cat ET. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Observe the “Active Diagnostic” screen. E. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. F. Install a jumper wire into the terminals for the suspect sensor on the 54-pin connector on the ITSM. For identification of the terminals, refer to Illustration 164 or 165. G. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Observe the “Active Diagnostic” screen. Allow a minimum of 30 seconds for any diagnostic codes to be generated.
• No – Either of the following results or both of the
results occurred: When the 54-pin connectors were disconnected, an “open circuit” diagnostic code was not generated for the suspect sensor. When the jumper wire was installed, a “short circuit” diagnostic code was not generated. There may be a problem with the ITSM. Repair: It is unlikely that the ITSM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: 1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Remove the jumper wire from the connector on the ITSM. 3. Temporarily install a new ITSM. Refer to Troubleshooting, “Replacing the ITSM”. 4. If the problem is resolved with the new ITSM, install the original ITSM and verify that the problem returns. If the new ITSM operates correctly and the original ITSM does not operate correctly, replace the original ITSM. Refer to Troubleshooting, “Replacing the ITSM”. STOP.
Expected Result: When the 54-pin connectors were disconnected, an “open circuit” diagnostic code was generated for the suspect sensor. When the jumper wire was installed, a “short circuit” diagnostic code was generated. Results:
• Yes – When the 54-pin connectors were
disconnected, an “open circuit” diagnostic code was generated for the suspect sensor. When the jumper wire was installed, a “short circuit” diagnostic code was generated. The ITSM is OK. There is a problem in the harness between the ITSM and the connector for the suspect thermocouple. Repair: Remove the jumper wire. Replace the harness in order to ensure reliable operation. Clear the logged diagnostic codes and verify that the problem is resolved. All of the wiring from the thermocouples to the ITSM must be K type. The polarity of the wires from each thermocouple to the ITSM must be maintained in order for the ITSM to read the correct temperatures. STOP.
i02089570
PWM Sensor SMCS Code: 5574-038 System Operation Description: The engine contains the following Pulse Width Modulated sensors (PWM):
• Engine coolant pressure (outlet) • Inlet manifold air pressure A PWM sensor produces a digital signal. In a digital signal, the duty cycle varies as the input condition changes. The frequency remains constant. Refer to Illustration 171.
336 Troubleshooting Section
This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 171
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Duty cycles that are low, medium, and high
The master Electronic Control Module (ECM) supplies 8.0 ± 0.8 VDC to each PWM sensor. Note: Excessive pressure can generate false “noisy signal” diagnostic codes. If the actual inlet manifold air pressure is greater than approximately 338 kPa (49 psi), a “106-08 Air Inlet Pressure Sensor noisy signal” diagnostic code will be generated. Although there is not a problem with the sensor, the code will be generated. If the actual engine coolant pressure is greater than approximately 444 kPa (64 psi), a “109-08 Engine Coolant Outlet Pressure Sensor noisy signal” diagnostic code will be generated. Although there is not a problem with the sensor, the code will be generated. If a “106-08” or “109-08” diagnostic code is generated, measure the absolute pressure with a pressure gauge before you troubleshoot the sensor. If the pressure is actually too high, reduce the pressure in order to avoid activation of false diagnostic codes. Logged diagnostic codes provide a historical record. Before you begin this procedure, print the logged codes to a file.
337 Troubleshooting Section
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Illustration 172 Schematic for the PWM sensors
Test Step 1. Inspect the Electrical Connectors and Wiring
Illustration 174
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Terminal box Illustration 173
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Junction box (1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
(2) J2/P2 connectors for the master ECM (3) J1/P1 connectors for the master ECM (4) J7/P7 connectors for the PWM sensors
B. Thoroughly inspect the following connectors:
• J1/P1 connectors • J2/P2 connectors • J7/P7 connectors • The connectors for each PWM sensor
338 Troubleshooting Section
a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 175
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Harness side of the P1 connector (P1-4) 8 volt supply (P1-5) Return (P1-10) Signal for inlet manifold air pressure Illustration 177
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Harness side of the P7 connector (P7-1) Signal for inlet manifold air pressure (P7-2) Signal for engine coolant pressure (outlet) (P7-15) Return for inlet manifold air pressure (P7-16) Return for engine coolant pressure (outlet) (P7-29) Shield (P7-30) Shield (P7-43) 8 volt supply for the inlet manifold air pressure (P7-44) 8 volt supply for the engine coolant pressure (outlet)
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the PWM sensors. Illustration 176 Harness side of the P2 connector (P2-68) Signal for engine coolant pressure (outlet)
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339 Troubleshooting Section
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Illustration 178 Top view (5) Sensor for engine coolant pressure (outlet)
(6) Sensor for inlet manifold air pressure
d. Check the harness and wiring for abrasion and for pinch points from each of the PWM sensors to the master ECM.
C. Observe the “Active Diagnostic” screen on Cat ET. Allow a minimum of thirty seconds for any codes to activate. Look for these codes:
Expected Result:
• 41-03 8 Volt DC Supply short to +batt
The connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.
• 41-04 8 Volt DC Supply short to ground
Results:
• OK – The components are in good condition with proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good condition and/or at least one connection is improper.
Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Test Step 2. Check for Active “8 Volt DC Supply” Diagnostic Codes A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
Expected Result: There are no active “8 Volt DC Supply” diagnostic codes. Results:
• No codes – There are no active diagnostic codes for the power supplies. Proceed to Test Step 3.
• Active code – There is an active diagnostic code
for the 8 volt power supply. This procedure will not work when this type of code is active. Repair: Refer to Troubleshooting, “+8 V Sensor Voltage Supply”. STOP.
Test Step 3. Check for Active Diagnostic Codes for the PWM Sensors A. Turn on the “Active Diagnostic” screen on Cat ET. Determine if any of these diagnostic codes are active:
• 106-03 Air Inlet Pressure Sensor open/short to +batt
340 Troubleshooting Section
• 106-08 Air Inlet Pressure Sensor noisy signal
Results:
• 109-03 Engine Coolant Outlet Pressure
• OK – The voltage is within the specification. The
open/short to +batt
• 109-08 Engine Coolant Outlet Pressure noisy signal
correct voltage is present at the sensor connector. Proceed to Test Step 5.
• Not OK – The voltage is not within the specification. The correct voltage is not present at the sensor connector. The correct voltage must be present at the sensor connector in order to continue this procedure.
Expected Result: One of the above codes is active. Results:
• Yes – At least one of the above diagnostic codes is active. Proceed to Test Step 4.
• No – None of the above codes are active. Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshooting, “Troubleshooting Without a Diagnostic Code”.
Repair: Verify that the wiring and/or connectors are OK. Repair any faulty wiring and/or connectors, when possible. Replace any faulty wiring and/or connectors, if necessary. Refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
Test Step 5. Verify that +Battery Voltage is Not Present in the Signal Wire
If the engine is running properly at this time, there may be an intermittent problem in the harness that is causing the codes to be logged. Refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
Illustration 180
Test Step 4. Verify the Supply Voltage to the Sensor A. Set the engine control to the OFF/RESET mode. B. Disconnect the suspect sensor. C. Set the engine control to the STOP mode.
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Harness connector for the PWM sensors (B) Return (C) Signal
A. At the harness connector for the suspect sensor, measure the voltage between terminal (B) and terminal (C). Expected Result: The voltage is between 7.0 VDC and 8.0 VDC. Results:
• OK – The voltage is between 7.0 VDC and 8.0 Illustration 179
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Harness connector for the PWM sensors (A) 8 volt supply (B) Return
D. At the harness connector for the suspect sensor, measure the voltage between terminals (A) and (B).
VDC. The battery voltage is not present in the signal wire. Proceed to Test Step 6.
• Not OK – The voltage is approximately equal to
the battery voltage. The signal wire is probably shorted to the battery between the sensor and the master ECM.
Expected Result:
Repair: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Repair the harness, when possible. Replace the harness, if necessary.
The voltage is between 7.6 VDC and 8.4 VDC.
STOP.
341 Troubleshooting Section
• Not OK – The voltage is approximately 0 volts. The signal wire is probably shorted to ground between the sensor and the master ECM.
Repair: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Repair the harness, when possible. Replace the harness, if necessary. STOP.
Test Step 6. Check the Signal at the Sensor A. Set the engine control to the OFF/RESET mode. B. Install a 8T-8726 Adapter Cable As (Three-Pin Breakout) at the harness connector for the suspect sensor. C. Use a multimeter that is capable of measuring both the duty cycle and the frequency. Connect the multimeter to terminal B and terminal C of the breakout t. D. Set the engine control to the STOP mode. E. Measure the duty cycle and the frequency of the suspect sensor. Expected Result: The duty cycle is between 5 percent and 95 percent. The frequency is between 400 and 600 Hz.
4. Disconnect the sensor. Connect a sensor that is known to be good. Do not install the new sensor into the engine yet. 5. Set the engine control to the STOP mode. Allow a minimum of 30 seconds for any codes to activate. 6. Check for an active diagnostic code. If the code is not active for the new sensor, install the sensor into the engine. Clear any logged diagnostic codes. STOP.
Test Step 7. Check the Signal at the Master ECM A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Insert two 7X-1710 Multimeter Probes into the terminals that are appropriate for the suspect sensor. The terminals for the connection of the probes are identified in Table 28. Table 28
Terminals for the Connection of the Probes Suspect Sensor
Connector and Terminals
Engine coolant pressure (outlet)
J2-68 and J1-5
Inlet manifold air pressure
J1-10 and J1-5
Results:
• OK – The duty cycle is between 5 percent and
95 percent. The frequency is between 400 and 600 Hz. A valid signal is produced by the sensor. Proceed to Test Step 7.
• Not OK – The duty cycle or the frequency is
incorrect. The sensor is receiving the correct supply voltage but the sensor is not producing a valid signal. Repair: Perform the following steps: 1. Thoroughly inspect the connector for the sensor according to Troubleshooting, “Inspecting Electrical Connectors”. 2. Check the duty cycle and the frequency of the sensor signal again. 3. If the duty cycle and the frequency of the sensor signal are incorrect, set the engine control to the OFF/RESET mode.
C. Use a multimeter that is capable of measuring both the duty cycle and the frequency. Connect the multimeter to the probes. D. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. E. Measure the duty cycle and the frequency of the suspect sensor. Expected Result: The duty cycle is between 5 percent and 95 percent. The frequency is between 400 and 600 Hz. Results:
• OK – The duty cycle is between 5 percent and 95 percent. The frequency is between 400 and 600 Hz. The ECM is receiving a valid signal from the sensor. Repair: Perform the following steps:
342 Troubleshooting Section
1. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 2. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. 3. Check “Status Screen Group 2” on Cat ET. Look for a valid signal. It is possible that the actual air inlet pressure is less than the pressure that can be measured by the sensor during low idle operation (26.7 kPa (3.87 psi)). This causes the master ECM to set the 106-03 diagnostic code although there is no short circuit to the +Battery side. In this case, adjust the derivative gain and the fuel quality in order to make the engine more stable at low idle. Refer to Troubleshooting, “System Configuration Parameters”. Otherwise, verify that the master ECM is receiving the correct voltage. Refer to Troubleshooting, “Electrical Power Supply”. If the condition is not resolved, temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP.
• Not OK – The duty cycle or the frequency is
incorrect. The sensor is producing a valid signal but the signal does not reach the master ECM. There is a problem in the harness between the sensor and the master ECM. Repair: Repair the harness, when possible. Replace the harness, if necessary. STOP. i02089593
Throttle Actuator SMCS Code: 1716-038 System Operation Description: The throttle actuator is an electronic actuator that works with the master Electronic Control Module (ECM) in order to ensure the correct throttle position in all conditions of engine operation.
The master ECM and the throttle actuator communicate via the CAN data link. The master ECM sends a command signal to the actuator. The actuator sends the following information to the master ECM: actuator position, CCM heartbeat, software version, and internal fault diagnosis. If the master ECM cannot communicate with the throttle actuator, the master ECM activates a 1440-09 diagnostic code and the engine is shut down. A 1440-09 diagnostic code is probably caused by a problem with an electrical connector or a harness. The next likely cause is a problem with the actuator. The least likely cause is a problem with the master ECM. Terminating resistors must be connected to each end of the CAN data link. The terminating resistors improve the communication between the devices. If there is an intermittent diagnostic code for any of the devices that are connected to the CAN data link, be sure to check the terminating resistor that is inside the terminal box. Also check the jumper wire that is connected between terminals J and K on the actuator for the bypass valve. Make repairs, when possible. Replace parts, if necessary. Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
343 Troubleshooting Section
Illustration 181 Schematic for the circuit of the throttle actuator
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344 Troubleshooting Section
Test Step 1. Inspect the Electrical Connectors and Wiring
Illustration 183
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Terminal box Illustration 182
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(1) 35 amp circuit breaker
(2) (3) (4) (5)
A. Set the engine control to the OFF/RESET position. Switch 35 amp circuit breaker (1) to the OFF position.
B. Thoroughly inspect each of the following connectors:
Junction box
Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.
Ground strap J1/P1 connectors for the master ECM J9/P9 connectors for the CAN data link J10/P10 connectors for the terminating resistor for the CAN data link
• J1/P1 connectors • J9/P9 connectors • Connectors on the throttle actuator a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
345 Troubleshooting Section
Illustration 184
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Harness side of the P1 connector (P1-34) CAN data link − (P1-42) CAN shield (P1-50) CAN data link + Illustration 186
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Right side view with the throttle actuator
d. Check the wiring for abrasion and for pinch points from the throttle actuator to the master ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. Results:
• OK – The components are in good condition with proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good Illustration 185
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condition and/or at least one connection is improper.
Harness side of the J9 connector (J9-6) CAN data link + (J9-12) CAN data link − (J9-18) CAN shield
c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the throttle actuator.
Repair: Perform the necessary repairs and/or replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
Test Step 2. Check for Diagnostic Codes A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box. B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. C. Use Cat ET in order to determine if a 1440-09 diagnostic code is active.
346 Troubleshooting Section
Expected Result:
Expected Result:
The 1440-09 code is not active.
The continuity of the circuits between the terminals is good.
Results:
• OK – The 1440-09 code is not active. The
communication between the master ECM and the throttle actuator appears to be OK at this time. However, diagnostic codes may be logged. Repair: If you are troubleshooting an intermittent problem, refer to Troubleshooting, “Inspecting Electrical Connectors”. Terminating resistors must be connected to each end of the CAN data link. The terminating resistors improve the communication between the devices. If there is an intermittent diagnostic code for any of the devices that are connected to the CAN data link, be sure to check the terminating resistor that is inside the terminal box. Also check the jumper wire that is connected between terminals J and K on the actuator for the bypass valve. Make repairs, when possible. Replace parts, if necessary. STOP.
Results:
• OK – The continuity of the circuits between the terminals is good. Proceed to Test Step 4.
• Not OK – At least one of the continuity checks
indicates an open circuit. There is an open circuit for the CAN data link between the throttle actuator and the master ECM. Repair: The open circuit could be caused by a poor electrical connection in a connector. Alternatively, the open circuit could be caused by one of the following components:
• The harness inside the terminal box • The harness between the terminal box and the fuel metering valve
• The harness between the fuel metering valve and the throttle actuator
• Not OK (Active 1440-09) – The master ECM
has detected a problem with the communication between the master ECM and the throttle actuator. Proceed to Test Step 3.
Test Step 3. Check the CAN Data Link for Continuity Between the Throttle Actuator and the Master ECM A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the P1 connector. Disconnect the connector for the throttle actuator. C. Use a multimeter to check for continuity between the points that are listed in Table 29. During each measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harness near each of the connectors. Be sure to wiggle the harness near the fuel metering valve. Table 29
Points to Check for Continuity Connector and Terminal
Harness Connector for the Throttle Actuator
P1-34
Terminal B (CAN data link −)
P1-50
Terminal A (CAN data link +)
P1-42
Terminal M (CAN shield)
• The fuel metering valve Make repairs, when possible. Replace parts, if necessary. STOP.
Test Step 4. Check the CAN Data Link for a Short Circuit A. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. B. Use a multimeter to check for continuity between the points that are listed in Table 30. During each measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harness near each of the connectors. Be sure to wiggle the harness near the fuel metering valve.
347 Troubleshooting Section
Expected Result:
Table 30
Points to Check for Continuity Connector and Terminal
Connector and Terminal
P1-34 (CAN Data Link −)
P1-50 (CAN Data Link +) P1-42 (CAN Shield) P1-52 (+ Battery) Ground strap for the ECM
P1-50 (CAN Data Link +)
P1-42 (CAN Shield) P1-52 (+ Battery) Ground strap for the ECM
P1-42 (CAN Shield)
P1-52 (+ Battery) Ground strap for the ECM
Expected Result: All of the measurements indicate an open circuit. Results:
• OK – All of the measurements indicate an open
circuit. The CAN data link does not have a short circuit. Repair: Reconnect the P1 connector. Reconnect the connector for the throttle actuator. Proceed to Test Step 5.
• Not OK – At least one of the measurements indicate a short circuit.
Repair: The short circuit could be caused by a poor electrical connection in a connector. Alternatively, the short circuit could be caused by one of the following components:
• The harness inside the terminal box • The harness between the terminal box and the fuel metering valve
• The harness between the fuel metering valve and the throttle actuator
• The fuel metering valve Make repairs, when possible. Replace parts, if necessary. STOP.
Test Step 5. Check for Diagnostic Codes A. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. B. Use Cat ET in order to determine if a 1440-09 diagnostic code is active.
The 1440-09 code is not active. Results:
• OK – The 1440-09 code is not active. The problem seems to be resolved. The initial diagnostic code was probably caused by a poor electrical connection. Repair: If there is an intermittent problem that is causing the code to be logged, refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
• Not OK – The 1440-09 code is active. Repair: The active 1440-09 code could be caused by one of the following components:
• The master ECM • The throttle actuator • The actuator for the bypass valve • The fuel metering valve It is unlikely that any of the components that are listed above have failed. Exit this procedure and perform this procedure again. If the 1440-09 code remains active, perform the following procedure: 1. Temporarily install a new master ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is not resolved with a new ECM, install the original ECM. Continue with this procedure. 2. Temporarily install a new throttle actuator. If the new throttle actuator operates correctly, the problem is resolved. If the new throttle actuator does not operate correctly, install the original throttle actuator and continue with this procedure. 3. Temporarily install a new actuator for the bypass valve. If the new actuator for the bypass valve operates correctly, the problem is resolved. If the new actuator for the bypass valve does not operate correctly, install the original actuator for the bypass valve and continue with this procedure.
348 Troubleshooting Section
4. Temporarily install a new fuel metering valve. If the new fuel metering valve operates correctly, the problem is resolved. If the new fuel metering valve does not operate correctly, install the original fuel metering valve. Refer to Troubleshooting, “Inspecting Electrical Connectors”. STOP.
349 Troubleshooting Section
Calibration Procedures i02089646
Engine Speed/Timing Sensor Calibrate SMCS Code: 1912-524 System Operation Description: The master Electronic Control Module (ECM) has the ability to calibrate the mechanical differences between the Top Center (TC) of the flywheel and the TC of the timing gear on the left rear camshaft gear. A magnetic transducer signals the TC of the flywheel to the master ECM when the TC hole on the flywheel passes beneath the transducer. The engine speed/timing sensor signals the TC of the timing gear to the master ECM. Any offset between the TC of the flywheel and the TC of the timing gear is stored into memory. The master ECM communicates the information from the calibration to the slave ECM via the CAT data link. Calibration of the timing is required only after the following circumstances:
• The master ECM has been replaced. • The timing gear and/or the rear gear train have been adjusted.
• The timing gear and/or the rear gear train have been replaced.
Note: The “261-13 Engine Timing calibration required” diagnostic code is generated only for a master ECM that has never performed a timing calibration. The calibration procedure is initiated with the Caterpillar Electronic Technician (ET).
350 Troubleshooting Section
Test Step 1. Install the Transducer
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Illustration 187 Right side view (1) 6V-3093 Transducer Adapter (2) 6V-2197 Magnetic Transducer
(3) Connector for the 7X-1695 cable (4) 7X-1695 Cable
A. Set the engine control to the OFF/RESET mode. Remove the timing calibration plug from either the left side or the right side of the flywheel housing. Install 6V-3093 Transducer Adapter (1) into the hole. NOTICE The timing hole in the flywheel must not be aligned with the hole for the transducer. The transducer will be damaged on engine start-up if the transducer is installed through both holes. Rotate the flywheel for more than 10 degrees before or after the TC position in order to move the flywheel hole away from the hole for the transducer. Always confirm that the holes are not aligned. B. Make sure that the hole in the flywheel housing for the transducer is not aligned with the timing hole in the flywheel. Remove the protective end cap from 6V-2197 Magnetic Transducer (2). Insert the transducer into the adapter until the transducer contacts the surface of the flywheel. Move the transducer 1 mm (0.04 inch) away from the surface of the flywheel. Tighten the nut on the adapter in order to secure the transducer in place. C. Connect the one end of 7X-1695 Cable (4) to the transducer. Connect the other end of the cable to connector (3) on the side of the engine. D. Set the engine control to the STOP mode.
E. Connect Cat ET to the service tool connector on the terminal box. For instructions, refer to Troubleshooting, “Electronic Service Tools”. Start Cat ET. Continue to the next test step.
Test Step 2. Calibration Note: A two-step process is used to calibrate the signal for the speed/timing sensor. The new timing reference is calculated first. The reference is based on the signals from the transducer and the speed/timing sensor. Next, the new timing reference is programmed into the permanent memory of the master ECM. A. Start the engine. Operate the engine at the rated speed and load. B. Select “Service” from the main menu on Cat ET. Select “Calibrations” from the menu. Select “Timing Calibration”. C. Use either of the following methods in order to initiate the calculation of the new timing reference:
• Press the space bar on the keyboard of the PC. • Click the left mouse button on the “Continue” button in the lower left corner of the Cat ET screen.
351 Troubleshooting Section
Cat ET will indicate “Please wait...Calculating the new Timing Reference”. After a few moments, Cat ET will display “The ECM has calculated the Timing Reference” and “Choose the Continue button to program the Timing Reference”. D. Use either of the following methods in order to program the new timing reference:
• Press the space bar on the keyboard of the PC. • Click the left mouse button on the “Continue” button in the lower left corner of the Cat ET screen.
Expected Result: After a few moments, Cat ET will display “CALIBRATION SUCCESSFUL”. Results:
• OK – The timing calibration was successful.
Disconnect the transducer and the cable. Remove the adapter and reinstall the timing calibration plug. Replace the protective cover on the transducer. STOP.
• Not OK – Cat ET displayed “COULD NOT
CALIBRATE”. The calibration was unsuccessful. Repair: If the calibration failed in the first step, verify that the engine rpm was stable during the calibration (± 50 rpm). Verify that there are no active diagnostic codes which can prevent the calibration. Repeat the calibration procedure. If the calibration is still unsuccessful, check the installation of the tools and the operation of the tools. Check the 7X-1695 Cable for continuity. Verify that the transducer is not bent, open, or shorted internally. Repeat the calibration procedure. Excessive backlash in the gear train will cause inconsistent timing. Refer to Disassembly and Assembly for identifying and repairing a gear train problem. STOP.
• Not OK – The calibration was completed
successfully. However, the “261-13 Engine Timing calibration required” diagnostic code is still active. Repair: Replace the master ECM according to the instructions in Troubleshooting, “Replacing the ECM”. STOP.
i02089716
Generator Output Power Sensor - Calibrate SMCS Code: 5574-524-PWR System Operation Description: The master Electronic Control Module (ECM) must receive an accurate signal that indicates the power output of the generator. When the generator is stopped, the signal must be less than 0.01 VDC. The offset voltage is the voltage level of the signal when the generator is stopped. An offset voltage above 0.01 VDC can be reduced by adding resistance to the circuit. The following steps describe the procedure for adding the correct amount of resistance to the circuit in order to reduce the offset voltage to an acceptable level.
Test Step 1. Identify the Configuration of the Wiring A. Remove the electrical power from the engine.
352 Troubleshooting Section
g01065858
Illustration 188 Schematic for the wiring between the generator output power sensor and the ECM
B. Carefully inspect the wiring between the generator output power sensor and the ECM. Refer to Illustration 188. Determine if a potentiometer has been connected to the wiring. Expected Result: A potentiometer is connected to the wiring. Results:
• Yes – A potentiometer is connected to the wiring. Proceed to Test Step 3.
• No – A potentiometer is not connected to the wiring. Proceed to Test Step 2.
Test Step 2. Install a Potentiometer The potentiometer must have the following characteristics:
• 5000 Ohms • Linear taper
B. Connect an ohmmeter to the end terminals of the potentiometer. Measure the resistance between the end terminals. C. Adjust the potentiometer in order to create the minimum resistance across the terminals. D. Refer to Illustration 188. Connect the potentiometer to the wiring. Use 16 gauge wire in order to make the connections. You may connect the potentiometer to the positive terminal or to the negative terminal of the generator output power sensor. Expected Result: The potentiometer is connected correctly. Results:
• OK – The potentiometer is connected properly. Proceed to Test Step 4.
• Not OK – The potentiometer is not connected properly.
• 10 turns
Repair: Make repairs to the installation, as needed.
The wattage rating of the potentiometer is not important. 122-9457 Potentiometer meets these specifications.
STOP.
A. Connect the terminal for the wiper to an end terminal. Use a piece of 16 gauge wire in order to make the connection.
Test Step 3. Adjust the Potentiometer to the Minimum Value A. Disconnect one of the wires that is used to connect the potentiometer to the circuit.
353 Troubleshooting Section
B. Connect an ohmmeter to the end terminals of the potentiometer. C. Adjust the potentiometer in order to create the minimum resistance across the terminals. D. Reconnect the wire to the circuit. Expected Result: The potentiometer is set to the minimum value. Results:
• OK – The potentiometer is set to the minimum value. Proceed to Test Step 4.
• Not OK – The potentiometer is not set to the minimum value.
Repair: The potentiometer must be set to the minimum value before you continue with this procedure. Perform this Test Step again. When the potentiometer is set to the minimum value, continue with this procedure. STOP.
Test Step 4. Adjust the Potentiometer Note: The multimeter must be connected to the P1 connector.
Illustration 189
g01066039
Terminal box (P1-19) Return for the input from the generator output power sensor (P1-25) Input from the generator output power sensor
A. Insert 7X-1710 Multimeter Probes into terminals P1-19 and P1-25. Connect a digital voltmeter to the probes. The polarity of the connections is not important. B. Restore the electrical power to the engine. Set the engine control to the STOP position. C. Verify that the probes are making good contact with the terminals inside the connector. Measure the DC voltage at the terminals. D. While you are measuring the voltage at the terminals of the master ECM, slowly adjust the potentiometer. The voltage reading will decrease as you increase the resistance. The adjustment is correct when the voltage reading is between ±0.00 VDC and ±0.01 VDC. A reading of zero VDC is ideal.
354 Troubleshooting Section
Expected Result: The voltage decreases as the potentiometer is adjusted. The final voltage is between ±0.0 VDC and ±0.01 VDC. Results:
• OK – The voltage is between ±0.0 VDC and
±0.01 VDC. The calibration procedure has been completed successfully. Repair: Adjust the “Power Monitoring” parameters. Refer to Systems Operation/Testing and Adjusting, “Electronic Control System Parameters”. STOP.
• Not OK – The potentiometer cannot be adjusted
in order to attain a DC voltage between ±0.0 VDC and ±0.01 VDC.
Repair: Replace the potentiometer and perform this entire procedure again. STOP.
355 Index Section
Index Numerics +5V Sensor Voltage Supply................................. 199 +8V Sensor Voltage Supply................................. 206 A Analog Sensor Signal .......................................... 214 C Calibration Procedures ........................................ 349 CAT Data Link ..................................................... 223 Compressor Bypass ............................................ 229 Customer Passwords ............................................ 27 D Desired Speed Input (4 - 20 mA)......................... 235 Detonation ............................................................. 36 Probable Causes ............................................... 36 Recommended Repairs ..................................... 37 Detonation Sensors ............................................. 239 Diagnostic Codes .................................................. 65 Active Diagnostic Codes .................................... 66 Logged Diagnostic Codes.................................. 66 Diagnostic Functional Tests................................. 199 Driven Equipment .................................................. 38 Probable Causes ............................................... 38 Recommended Repairs ..................................... 38 E E004 Engine Overspeed Shutdown .................... E016 High Engine Coolant Temperature Shutdown........................................................... E017 High Engine Coolant Temperature Warning ............................................................. E019 High Engine Oil Temperature Shutdown .... E020 High Engine Oil Temperature Warning....... E026 High Inlet Air Temperature Shutdown ........ E027 High Inlet Air Temperature Warning ........... E038 Low Engine Coolant Temperature Warning ............................................................. E040 Low Engine Oil Pressure Shutdown........... E042 Low System Voltage Shutdown.................. E043 Low System Voltage Warning .................... E050 High System Voltage Warning ................... E053 Low Fuel Pressure Warning....................... E096 High Fuel Pressure .................................... E100 Low Engine Oil Pressure Warning ............. E127 Engine Oil Filter Diff Pressure Low Warning ............................................................. E128 Engine Oil Filter Diff Pressure Low Shutdown...........................................................
152 152 153 153 153 153 154 154 154 155 155 155 155 156 156 156 156
E129 Engine Oil Filter Diff Pressure High Warning ............................................................. E130 Engine Oil Filter Diff Pressure High Shutdown........................................................... E135 Low Jacket Water Pressure Shutdown ...... E223 High Gas Temperature ............................... E224 High Jacket Water Inlet Pressure............... E225 Engine Overcrank ...................................... E226 Driven Equipment Not Ready..................... E229 Fuel Energy Content Setting Low .............. E230 Fuel Energy Content Setting High.............. E231 Fuel Quality Out of Range.......................... E243 High Left Turbo Turbine Outlet Temperature....................................................... E244 High Right Turbo Turbine Outlet Temperature....................................................... E245 High Right Turbo Turbine Inlet Temperature....................................................... E246 High Left Turbo Turbine Inlet Temperature.. E264 Emergency Stop Activated......................... E268 Unexpected Engine Shutdown................... E269 Customer Shutdown Requested ................ E270 Driven Equipment Shutdown Requested ... E337 High Engine Oil to Engine Coolant Diff Temp .................................................................. E401 Cylinder #1 Detonation............................... E402 Cylinder #2 Detonation............................... E403 Cylinder #3 Detonation............................... E404 Cylinder #4 Detonation............................... E405 Cylinder #5 Detonation............................... E406 Cylinder #6 Detonation............................... E407 Cylinder #7 Detonation............................... E408 Cylinder #8 Detonation............................... E409 Cylinder #9 Detonation............................... E410 Cylinder #10 Detonation............................. E411 Cylinder #11 Detonation ............................. E412 Cylinder #12 Detonation............................. E413 Cylinder #13 Detonation............................. E414 Cylinder #14 Detonation............................. E415 Cylinder #15 Detonation............................. E416 Cylinder #16 Detonation............................. E417 Cylinder #17 Detonation............................. E418 Cylinder #18 Detonation............................. E419 Cylinder #19 Detonation............................. E420 Cylinder #20 Detonation............................. E421 Cylinder #1 Detonation Shutdown.............. E422 Cylinder #2 Detonation Shutdown.............. E423 Cylinder #3 Detonation Shutdown.............. E424 Cylinder #4 Detonation Shutdown.............. E425 Cylinder #5 Detonation Shutdown.............. E426 Cylinder #6 Detonation Shutdown.............. E427 Cylinder #7 Detonation Shutdown.............. E428 Cylinder #8 Detonation Shutdown.............. E429 Cylinder #9 Detonation Shutdown.............. E430 Cylinder #10 Detonation Shutdown............ E431 Cylinder #11 Detonation Shutdown............ E432 Cylinder #12 Detonation Shutdown............ E433 Cylinder #13 Detonation Shutdown............ E434 Cylinder #14 Detonation Shutdown............ E435 Cylinder #15 Detonation Shutdown............
157 157 157 158 158 158 158 159 159 159 159 160 160 161 161 161 161 162 162 163 163 163 163 164 164 164 164 165 165 165 165 166 166 166 166 167 167 167 167 168 168 168 168 169 169 169 169 170 170 170 171 171 171 171
356 Index Section
E436 Cylinder #16 Detonation Shutdown............ E437 Cylinder #17 Detonation Shutdown............ E438 Cylinder #18 Detonation Shutdown............ E439 Cylinder #19 Detonation Shutdown............ E440 Cylinder #20 Detonation Shutdown............ E801 Cylinder #1 High Exhaust Port Temp ......... E802 Cylinder #2 High Exhaust Port Temp ......... E803 Cylinder #3 High Exhaust Port Temp ......... E804 Cylinder #4 High Exhaust Port Temp ......... E805 Cylinder #5 High Exhaust Port Temp ......... E806 Cylinder #6 High Exhaust Port Temp ......... E807 Cylinder #7 High Exhaust Port Temp ......... E808 Cylinder #8 High Exhaust Port Temp ......... E809 Cylinder #9 High Exhaust Port Temp ......... E810 Cylinder #10 High Exhaust Port Temp ....... E811 Cylinder #11 High Exhaust Port Temp........ E812 Cylinder #12 High Exhaust Port Temp ....... E813 Cylinder #13 High Exhaust Port Temp ....... E814 Cylinder #14 High Exhaust Port Temp ....... E815 Cylinder #15 High Exhaust Port Temp ....... E816 Cylinder #16 High Exhaust Port Temp ....... E817 Cylinder #17 High Exhaust Port Temp ....... E818 Cylinder #18 High Exhaust Port Temp ....... E819 Cylinder #19 High Exhaust Port Temp ....... E820 Cylinder #20 High Exhaust Port Temp ....... E821 Cyl #1 Exhaust Port Temp Deviating High.. E822 Cyl #2 Exhaust Port Temp Deviating High.. E823 Cyl #3 Exhaust Port Temp Deviating High.. E824 Cyl #4 Exhaust Port Temp Deviating High.. E825 Cyl #5 Exhaust Port Temp Deviating High.. E826 Cyl #6 Exhaust Port Temp Deviating High.. E827 Cyl #7 Exhaust Port Temp Deviating High.. E828 Cyl #8 Exhaust Port Temp Deviating High.. E829 Cyl #9 Exhaust Port Temp Deviating High.. E830 Cyl #10 Exhaust Port Temp Deviating High ................................................................... E831 Cyl #11 Exhaust Port Temp Deviating High ................................................................... E832 Cyl #12 Exhaust Port Temp Deviating High ................................................................... E833 Cyl #13 Exhaust Port Temp Deviating High ................................................................... E834 Cyl #14 Exhaust Port Temp Deviating High ................................................................... E835 Cyl #15 Exhaust Port Temp Deviating High ................................................................... E836 Cyl #16 Exhaust Port Temp Deviating High ................................................................... E837 Cyl #17 Exhaust Port Temp Deviating High ................................................................... E838 Cyl #18 Exhaust Port Temp Deviating High ................................................................... E839 Cyl #19 Exhaust Port Temp Deviating High ................................................................... E840 Cyl #20 Exhaust Port Temp Deviating High ................................................................... E841 Cyl #1 Exhaust Port Temp Deviating Low .. E842 Cyl #2 Exhaust Port Temp Deviating Low .. E843 Cyl #3 Exhaust Port Temp Deviating Low .. E844 Cyl #4 Exhaust Port Temp Deviating Low .. E845 Cyl #5 Exhaust Port Temp Deviating Low ..
172 172 172 173 173 173 173 174 174 175 175 175 176 176 177 177 177 178 178 179 179 179 180 180 180 181 181 182 182 183 183 183 184 184 185 185 185 186 186 187 187 187 188 188 189 189 189 190 190 191
E846 Cyl #6 Exhaust Port Temp Deviating Low .. 191 E847 Cyl #7 Exhaust Port Temp Deviating Low .. 191 E848 Cyl #8 Exhaust Port Temp Deviating Low .. 192 E849 Cyl #9 Exhaust Port Temp Deviating Low .. 192 E850 Cyl #10 Exhaust Port Temp Deviating Low .................................................................... 193 E851 Cyl #11 Exhaust Port Temp Deviating Low.. 193 E852 Cyl #12 Exhaust Port Temp Deviating Low .................................................................... 193 E853 Cyl #13 Exhaust Port Temp Deviating Low .................................................................... 194 E854 Cyl #14 Exhaust Port Temp Deviating Low .................................................................... 194 E855 Cyl #15 Exhaust Port Temp Deviating Low .................................................................... 195 E856 Cyl #16 Exhaust Port Temp Deviating Low .................................................................... 195 E857 Cyl #17 Exhaust Port Temp Deviating Low .................................................................... 195 E858 Cyl #18 Exhaust Port Temp Deviating Low .................................................................... 196 E859 Cyl #19 Exhaust Port Temp Deviating Low .................................................................... 196 E860 Cyl #20 Exhaust Port Temp Deviating Low .................................................................... 197 E864 Low Gas Fuel Differential Pressure ........... 197 E865 High Gas Fuel Differential Pressure........... 197 E866 Low Gas Fuel Flow Rate............................ 197 E867 Improper Gas Flow Control Valve Response........................................................... 198 E868 Gas Flow Control Valve Malfunction .......... 198 ECM Output Circuit (Fuel Control)....................... 248 ECM Output Circuit (Starting Motor).................... 257 ECM Status Indicator Output............................... 269 ECM Will Not Accept Factory Passwords.............. 38 Probable Causes ............................................... 38 Recommended Repairs ..................................... 38 Electrical Connectors and Functions ..................... 16 Harness Wire Identification ................................ 16 Junction Box ...................................................... 18 Terminal Box ...................................................... 16 Electrical Power Supply....................................... 275 Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With an Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM))...................................... 38 Probable Causes ............................................... 38 Recommended Repairs ..................................... 39 Electronic Service Tools ........................................ 18 Caterpillar Electronic Technician (ET)................ 19 Electronic Troubleshooting .................................... 10 Engine Coolant Temperature (High) ...................... 39 Probable Causes ............................................... 39 Recommended Repairs ..................................... 39 Engine Coolant Temperature (Low)....................... 41 Probable Causes ............................................... 41 Recommended Repairs ..................................... 41 Engine Cranks but Will Not Start ........................... 41 Probable Causes ............................................... 41 Recommended Repairs ..................................... 41
357 Index Section
Engine Misfires, Runs Rough or Is Unstable......... 42 Probable Causes ............................................... 42 Recommended Repairs ..................................... 42 Engine Monitoring System..................................... 20 Changing the Settings of the Monitoring System ............................................................. 21 Default Settings of the Monitoring System......... 22 Monitoring Parameters....................................... 21 Programmable Parameters of the Integrated Temperature Sensing Module .......................... 25 Engine Oil Filter Differential Pressure ................... 44 Probable Causes ............................................... 44 Recommended Repairs ..................................... 44 Engine Oil Pressure (Low)..................................... 44 Probable Causes ............................................... 44 Recommended Repairs ..................................... 44 Engine Oil Temperature (High) .............................. 45 Probable Causes ............................................... 45 Recommended Repairs ..................................... 45 Engine Overcrank.................................................. 46 Probable Causes ............................................... 46 Recommended Repairs ..................................... 46 Engine Overload.................................................... 47 Probable Causes ............................................... 47 Recommended Repairs ..................................... 47 Engine Overspeed................................................. 47 Probable Causes ............................................... 47 Recommended Repairs ..................................... 47 Engine Shutdown .................................................. 48 Probable Causes ............................................... 48 Recommended Repairs ..................................... 48 Engine Shutdown (Unexpected)............................ 48 Probable Causes ............................................... 48 Recommended Repair ....................................... 48 Engine Shutdown without a Diagnostic Code........ 50 Probable Causes ............................................... 50 Recommended Repairs ..................................... 50 Engine Speed/Timing Sensor .............................. 282 Engine Speed/Timing Sensor - Calibrate ............ 349 Engine Starts but Stalls Immediately..................... 51 Probable Causes ............................................... 51 Recommended Repairs ..................................... 51 Engine Timing Does Not Match Programmed Timing .................................................................. 51 Probable Causes ............................................... 51 Recommended Repairs ..................................... 51 Engine Will Not Crank ........................................... 52 Probable Causes ............................................... 52 Recommended Repairs ..................................... 52 Event Codes ........................................................ 150 Active Event Codes.......................................... 151 Diagnostic Codes and Event Codes ................ 151 Logged Event Codes ....................................... 152 Operator Information........................................ 151 Other Symptoms .............................................. 151 Troubleshooting ............................................... 151 Exhaust Port Temperature (High) .......................... 53 Probable Causes ............................................... 53 Recommended Repairs ..................................... 53 Exhaust Port Temperature (Low)........................... 54 Probable Causes ............................................... 54 Recommended Repairs ..................................... 54
F Factory Passwords ................................................ 27 Factory Passwords Worksheet.............................. 28 Flash Programming ............................................... 29 Flash Programming............................................ 29 Fuel Energy Content.............................................. 55 Probable Causes ............................................... 55 Recommended Repairs ..................................... 55 Fuel Metering Valve....................................... 55, 289 Probable Causes ............................................... 55 Recommended Repairs ..................................... 55 Fuel Pressure ........................................................ 55 Probable Causes ............................................... 55 Recommended Repairs ..................................... 55 G Gas Fuel Differential Pressure (High).................... 55 Probable Causes ............................................... 55 Recommended Repairs ..................................... 56 Gas Fuel Differential Pressure (Low) .................... 56 Probable Causes ............................................... 56 Recommended repairs....................................... 56 Gas Fuel Flow Rate (Low)..................................... 56 Probable Causes ............................................... 56 Recommended Repairs ..................................... 57 Gas Temperature (High) ........................................ 57 Probable Causes ............................................... 57 Recommended Repairs ..................................... 57 Generator Output Power Readings Do Not Match ................................................................... 58 Probable Causes ............................................... 58 Recommended Repairs ..................................... 58 Generator Output Power Sensor ......................... 298 Generator Output Power Sensor - Calibrate ....... 351 I Ignition Transformers Primary Circuit .................. 305 Ignition Transformers Secondary Circuit and Spark Plugs.................................................................. 316 Important Safety Information ................................... 2 Inlet Air Temperature (High) .................................. 59 Probable Causes ............................................... 59 Recommended Repairs ..................................... 59 Inspecting Electrical Connectors ......................... 322 Integrated Temperature Sensing Module (ITSM)................................................................ 327 Intermittent Engine Shutdown ............................... 60 Probable Causes ............................................... 60 Recommended Repairs ..................................... 60 J Jacket Water Inlet Pressure (High)........................ 60 Probable Causes ............................................... 60 Recommended Repairs ..................................... 61
358 Index Section
Jacket Water Pressure (Low) ................................ 61 Probable Causes ............................................... 61 Recommended Repairs ..................................... 61 Jacket Water to Engine Oil Differential Temperature (Low).................................................................... 61 Probable Causes ............................................... 61 Recommended Repairs ..................................... 62 L Location of Components........................................ Actuators............................................................ Fuel Metering Valve ........................................... Integrated Temperature Sensing Module........... Sensors.............................................................. Thermocouples ..................................................
12 12 12 15 12 14
M MID 033 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt................................................................. 66 MID 033 - CID 0041 - FMI 04 8 Volt DC Supply short to ground.............................................................. 67 MID 033 - CID 0168 - FMI 02 System Voltage intermittent/erratic ................................................ 67 MID 033 - CID 0301 - FMI 05 Ignition Transformer Primary #1 open circuit ........................................ 67 MID 033 - CID 0301 - FMI 06 Ignition Transformer Primary #1 short .................................................. 68 MID 033 - CID 0303 - FMI 05 Ignition Transformer Primary #3 open circuit ........................................ 68 MID 033 - CID 0303 - FMI 06 Ignition Transformer Primary #3 short .................................................. 68 MID 033 - CID 0305 - FMI 05 Ignition Transformer Primary #5 open circuit ........................................ 69 MID 033 - CID 0305 - FMI 06 Ignition Transformer Primary #5 short .................................................. 69 MID 033 - CID 0307 - FMI 05 Ignition Transformer Primary #7 open circuit ........................................ 69 MID 033 - CID 0307 - FMI 06 Ignition Transformer Primary #7 short .................................................. 70 MID 033 - CID 0309 - FMI 05 Ignition Transformer Primary #9 open circuit ........................................ 70 MID 033 - CID 0309 - FMI 06 Ignition Transformer Primary #9 short .................................................. 71 MID 033 - CID 0311 - FMI 05 Ignition Transformer Primary #11 open circuit ...................................... 71 MID 033 - CID 0311 - FMI 06 Ignition Transformer Primary #11 short................................................. 71 MID 033 - CID 0313 - FMI 05 Ignition Transformer Primary #13 open circuit ...................................... 72 MID 033 - CID 0313 - FMI 06 Ignition Transformer Primary #13 short ................................................ 72 MID 033 - CID 0315 - FMI 05 Ignition Transformer Primary #15 open circuit ...................................... 72 MID 033 - CID 0315 - FMI 06 Ignition Transformer Primary #15 short ................................................ 73 MID 033 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt........................................................ 73
MID 033 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal ................................................... 74 MID 033 - CID 0401 - FMI 05 Ignition Transformer Secondary #1 open circuit ................................... 74 MID 033 - CID 0401 - FMI 06 Ignition Transformer Secondary #1 short to ground ............................. 74 MID 033 - CID 0403 - FMI 05 Ignition Transformer Secondary #3 open circuit ................................... 75 MID 033 - CID 0403 - FMI 06 Ignition Transformer Secondary #3 short to ground ............................. 75 MID 033 - CID 0405 - FMI 05 Ignition Transformer Secondary #5 open circuit ................................... 75 MID 033 - CID 0405 - FMI 06 Ignition Transformer Secondary #5 short to ground ............................. 76 MID 033 - CID 0407 - FMI 05 Ignition Transformer Secondary #7 open circuit ................................... 76 MID 033 - CID 0407 - FMI 06 Ignition Transformer Secondary #7 short to ground ............................. 77 MID 033 - CID 0409 - FMI 05 Ignition Transformer Secondary #9 open circuit ................................... 77 MID 033 - CID 0409 - FMI 06 Ignition Transformer Secondary #9 short to ground ............................. 77 MID 033 - CID 0411 - FMI 05 Ignition Transformer Secondary #11 open circuit ................................. 78 MID 033 - CID 0411 - FMI 06 Ignition Transformer Secondary #11 short to ground............................ 78 MID 033 - CID 0413 - FMI 05 Ignition Transformer Secondary #13 open circuit ................................. 79 MID 033 - CID 0413 - FMI 06 Ignition Transformer Secondary #13 short to ground ........................... 79 MID 033 - CID 0415 - FMI 05 Ignition Transformer Secondary #15 open circuit ................................. 79 MID 033 - CID 0415 - FMI 06 Ignition Transformer Secondary #15 short to ground ........................... 80 MID 033 - CID 0590 - FMI 09 Unable to communicate with Engine ECM ................................................. 80 MID 033 - CID 1501 - FMI 03 Cylinder #1 Detonation Sensor open/short to +batt .................................. 81 MID 033 - CID 1501 - FMI 04 Cylinder #1 Detonation Sensor short to ground ........................................ 81 MID 033 - CID 1505 - FMI 03 Cylinder #5 Detonation Sensor open/short to +batt .................................. 81 MID 033 - CID 1505 - FMI 04 Cylinder #5 Detonation Sensor short to ground ........................................ 82 MID 033 - CID 1509 - FMI 03 Cylinder #9 Detonation Sensor open/short to +batt .................................. 82 MID 033 - CID 1509 - FMI 04 Cylinder #9 Detonation Sensor short to ground ........................................ 82 MID 033 - CID 1513 - FMI 03 Cylinder #13 Detonation Sensor open/short to +batt .................................. 83 MID 033 - CID 1513 - FMI 04 Cylinder #13 Detonation Sensor short to ground ........................................ 83 MID 033 - CID 1517 - FMI 03 Cylinder #17 Detonation Sensor open/short to +batt .................................. 83 MID 033 - CID 1517 - FMI 04 Cylinder #17 Detonation Sensor short to ground ........................................ 84 MID 033 - CID 1748 - FMI 05 Ignition Transformer Secondary #17 open circuit ................................. 84 MID 033 - CID 1748 - FMI 06 Ignition Transformer Secondary #17 short to ground ........................... 84
359 Index Section
MID 033 - CID 1750 - FMI 05 Ignition Transformer Secondary #19 open circuit ................................. 85 MID 033 - CID 1750 - FMI 06 Ignition Transformer Secondary #19 short to ground ........................... 85 MID 033 - CID 1752 - FMI 05 Ignition Transformer Primary #17 open circuit ...................................... 85 MID 033 - CID 1752 - FMI 06 Ignition Transformer Primary #17 short to ground ................................ 86 MID 033 - CID 1754 - FMI 05 Ignition Transformer Primary #19 open circuit ...................................... 86 MID 033 - CID 1754 - FMI 06 Ignition Transformer Primary #19 short to ground ................................ 87 MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open circuit ................................................................... 87 MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short to ground.............................................................. 87 MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve malfunction .......................................................... 88 MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt................................................................. 88 MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short to ground.............................................................. 88 MID 036 - CID 0100 - FMI 03 Engine Oil Pressure open/short to +batt............................................... 89 MID 036 - CID 0100 - FMI 04 Engine Oil Pressure short to ground..................................................... 89 MID 036 - CID 0106 - FMI 03 Air Inlet Pressure Sensor short to +batt ........................................... 90 MID 036 - CID 0106 - FMI 08 Air Inlet Pressure Sensor noisy signal.............................................. 90 MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure open/short to +batt............................................... 90 MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal .............................. 91 MID 036 - CID 0110 - FMI 03 Engine Coolant Temperature open/short to +batt ......................... 91 MID 036 - CID 0110 - FMI 04 Engine Coolant Temperature short to ground ............................... 91 MID 036 - CID 0145 - FMI 03 12 Volt DC Power Supply short to +batt............................................ 92 MID 036 - CID 0145 - FMI 04 12 Volt DC Power Supply short to ground......................................... 92 MID 036 - CID 0168 - FMI 02 System Voltage intermittent/erratic ................................................ 92 MID 036 - CID 0172 - FMI 03 Intake Manifold Air Temp open/short to +batt..................................... 93 MID 036 - CID 0172 - FMI 04 Intake Manifold Air Temp short to ground........................................... 93 MID 036 - CID 0175 - FMI 03 Engine Oil Temperature open/short to +batt............................................... 93 MID 036 - CID 0175 - FMI 04 Engine Oil Temperature short to ground..................................................... 94 MID 036 - CID 0261 - FMI 13 Engine Timing calibration required .............................................. 94 MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power Supply short to +batt ................................ 95 MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power Supply short to ground ............................. 95 MID 036 - CID 0302 - FMI 05 Ignition Transformer Primary #2 open circuit ........................................ 96 MID 036 - CID 0302 - FMI 06 Ignition Transformer Primary #2 short .................................................. 96
MID 036 - CID 0304 - FMI 05 Ignition Transformer Primary #4 open circuit ........................................ 96 MID 036 - CID 0304 - FMI 06 Ignition Transformer Primary #4 short .................................................. 97 MID 036 - CID 0306 - FMI 05 Ignition Transformer Primary #6 open circuit ........................................ 97 MID 036 - CID 0306 - FMI 06 Ignition Transformer Primary #6 short .................................................. 97 MID 036 - CID 0308 - FMI 05 Ignition Transformer Primary #8 open circuit ........................................ 98 MID 036 - CID 0308 - FMI 06 Ignition Transformer Primary #8 short .................................................. 98 MID 036 - CID 0310 - FMI 05 Ignition Transformer Primary #10 open circuit ...................................... 98 MID 036 - CID 0310 - FMI 06 Ignition Transformer Primary #10 short ................................................ 99 MID 036 - CID 0312 - FMI 05 Ignition Transformer Primary #12 open circuit ...................................... 99 MID 036 - CID 0312 - FMI 06 Ignition Transformer Primary #12 short .............................................. 100 MID 036 - CID 0314 - FMI 05 Ignition Transformer Primary #14 open circuit .................................... 100 MID 036 - CID 0314 - FMI 06 Ignition Transformer Primary #14 short .............................................. 100 MID 036 - CID 0316 - FMI 05 Ignition Transformer Primary #16 open circuit .................................... 101 MID 036 - CID 0316 - FMI 06 Ignition Transformer Primary #16 short .............................................. 101 MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt...................................................... 101 MID 036 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal ................................................. 102 MID 036 - CID 0323 - FMI 03 Shutdown Lamp short to +batt............................................................... 102 MID 036 - CID 0324 - FMI 03 Warning Lamp short to +batt................................................................... 102 MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch inputs ................................................................. 103 MID 036 - CID 0402 - FMI 05 Ignition Transformer Secondary #2 open circuit ................................. 103 MID 036 - CID 0402 - FMI 06 Ignition Transformer Secondary #2 short to ground ........................... 103 MID 036 - CID 0404 - FMI 05 Ignition Transformer Secondary #4 open circuit ................................. 104 MID 036 - CID 0404 - FMI 06 Ignition Transformer Secondary #4 short to ground ........................... 104 MID 036 - CID 0406 - FMI 05 Ignition Transformer Secondary #6 open circuit ................................. 105 MID 036 - CID 0406 - FMI 06 Ignition Transformer Secondary #6 short to ground ........................... 105 MID 036 - CID 0408 - FMI 05 Ignition Transformer Secondary #8 open circuit ................................. 105 MID 036 - CID 0408 - FMI 06 Ignition Transformer Secondary #8 short to ground ........................... 106 MID 036 - CID 0410 - FMI 05 Ignition Transformer Secondary #10 open circuit ............................... 106 MID 036 - CID 0410 - FMI 06 Ignition Transformer Secondary #10 short to ground ......................... 107 MID 036 - CID 0412 - FMI 05 Ignition Transformer Secondary #12 open circuit ............................... 107 MID 036 - CID 0412 - FMI 06 Ignition Transformer Secondary #12 short to ground ......................... 107
360 Index Section
MID 036 - CID 0414 - FMI 05 Ignition Transformer Secondary #14 open circuit ............................... 108 MID 036 - CID 0414 - FMI 06 Ignition Transformer Secondary #14 short to ground ......................... 108 MID 036 - CID 0416 - FMI 05 Ignition Transformer Secondary #16 open circuit ............................... 108 MID 036 - CID 0416 - FMI 06 Ignition Transformer Secondary #16 short to ground ......................... 109 MID 036 - CID 0443 - FMI 03 Crank Terminate Relay short to +batt...................................................... 109 MID 036 - CID 0444 - FMI 05 Start Relay open circuit .................................................................. 110 MID 036 - CID 0444 - FMI 06 Start Relay short to ground................................................................. 110 MID 036 - CID 0445 - FMI 03 Run Relay short to +batt.................................................................... 110 MID 036 - CID 0524 - FMI 03 Desired Engine Speed Sensor short to +batt .......................................... 111 MID 036 - CID 0524 - FMI 04 Desired Engine Speed Sensor short to ground ....................................... 111 MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil Pressure open/short to +batt .............................. 111 MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil Pressure short to ground .................................... 112 MID 036 - CID 1042 - FMI 09 Unable to communicate with ITSM............................................................ 112 MID 036 - CID 1440 - FMI 09 Unable to communicate with Throttle Actuator Drv ................................... 113 MID 036 - CID 1446 - FMI 05 Fuel Metering Module open circuit ......................................................... 113 MID 036 - CID 1446 - FMI 09 Unable to communicate with Fuel Metering Module.................................. 113 MID 036 - CID 1446 - FMI 12 Fuel Metering Module malfunction ......................................................... 114 MID 036 - CID 1446 - FMI 13 Fuel Metering Module calibration required ............................................. 114 MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor Module malfunction............................................. 114 MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation Sensor open/short to +batt ................................. 114 MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation Sensor short to ground ....................................... 115 MID 036 - CID 1506 - FMI 03 Cylinder #6 Detonation Sensor open/short to +batt ................................. 115 MID 036 - CID 1506 - FMI 04 Cylinder #6 Detonation Sensor short to ground ....................................... 115 MID 036 - CID 1510 - FMI 03 Cylinder #10 Detonation Sensor open/short to +batt ................................. 116 MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation Sensor short to ground ....................................... 116 MID 036 - CID 1514 - FMI 03 Cylinder #14 Detonation Sensor open/short to +batt ................................. 116 MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation Sensor short to ground ....................................... 117 MID 036 - CID 1518 - FMI 03 Cylinder #18 Detonation Sensor open/short to +batt ................................. 117 MID 036 - CID 1518 - FMI 04 Cylinder #18 Detonation Sensor short to ground ....................................... 117 MID 036 - CID 1636 - FMI 09 Loss of Communication with Engine #2 (Slave)........................................ 118
MID 036 - CID 1719 - FMI 03 Generator Output Power Sensor open/short to +batt ...................... 118 MID 036 - CID 1719 - FMI 04 Generator Output Power Sensor short to ground ............................ 118 MID 036 - CID 1719 - FMI 12 Generator Output Power Sensor malfunction.................................. 119 MID 036 - CID 1720 - FMI 09 Turbocharger Compressor Bypass Valve Actuator not communicating on link ........................................ 119 MID 036 - CID 1749 - FMI 05 Ignition Transformer Secondary #18 open circuit ................................ 119 MID 036 - CID 1749 - FMI 06 Ignition Transformer Secondary #18 short to ground ......................... 120 MID 036 - CID 1751 - FMI 05 Ignition Transformer Secondary #20 open circuit ............................... 120 MID 036 - CID 1751 - FMI 06 Ignition Transformer Secondary #20 short to ground ......................... 120 MID 036 - CID 1753 - FMI 05 Ignition Transformer Primary #18 open circuit .................................... 121 MID 036 - CID 1753 - FMI 06 Ignition Transformer Primary #18 short to ground .............................. 121 MID 036 - CID 1755 - FMI 05 Ignition Transformer Primary #20 open circuit .................................... 121 MID 036 - CID 1755 - FMI 06 Ignition Transformer Primary #20 short to ground .............................. 122 MID 111 - CID 0591 - FMI 12 EEPROM checksum fault or ECM not programmed ........................... 122 MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out Temp Sens short to +batt................................... 122 MID 111 - CID 1489 - FMI 04 Left Turbo Turbine Out Temp Sens short to ground................................ 123 MID 111 - CID 1489 - FMI 05 Left Turbo Turbine Out Temp Sens open circuit ..................................... 123 MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out Temp Sens short to +batt................................... 123 MID 111 - CID 1490 - FMI 04 Rt Turbo Turbine Out Temp Sens short to ground................................ 124 MID 111 - CID 1490 - FMI 05 Rt Turbo Turbine Out Temp Sens open circuit ..................................... 124 MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In Temp Sens short to +batt................................... 124 MID 111 - CID 1491 - FMI 04 Rt Turbo Turbine In Temp Sens short to ground................................ 125 MID 111 - CID 1491 - FMI 05 Rt Turbo Turbine In Temp Sens open circuit ..................................... 125 MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In Temp Sens short to +batt................................... 125 MID 111 - CID 1492 - FMI 04 Left Turbo Turbine In Temp Sens short to ground................................ 126 MID 111 - CID 1492 - FMI 05 Left Turbo Turbine In Temp Sens open circuit ..................................... 126 MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port Temp Sensor short to +batt ............................... 126 MID 111 - CID 1531 - FMI 04 Cyl #1 Exhaust Port Temp Sensor short to ground ............................ 127 MID 111 - CID 1531 - FMI 05 Cyl #1 Exhaust Port Temp Sensor open circuit .................................. 127 MID 111 - CID 1532 - FMI 03 Cyl #2 Exhaust Port Temp Sensor short to +batt ............................... 127 MID 111 - CID 1532 - FMI 04 Cyl #2 Exhaust Port Temp Sensor short to ground ............................ 128
361 Index Section
MID 111 - CID 1532 - FMI 05 Cyl #2 Exhaust Port Temp Sensor open circuit .................................. 128 MID 111 - CID 1533 - FMI 03 Cyl #3 Exhaust Port Temp Sensor short to +batt ............................... 129 MID 111 - CID 1533 - FMI 04 Cyl #3 Exhaust Port Temp Sensor short to ground ............................ 129 MID 111 - CID 1533 - FMI 05 Cyl #3 Exhaust Port Temp Sensor open circuit .................................. 129 MID 111 - CID 1534 - FMI 03 Cyl #4 Exhaust Port Temp Sensor short to +batt ............................... 130 MID 111 - CID 1534 - FMI 04 Cyl #4 Exhaust Port Temp Sensor short to ground ............................ 130 MID 111 - CID 1534 - FMI 05 Cyl #4 Exhaust Port Temp Sensor open circuit .................................. 130 MID 111 - CID 1535 - FMI 03 Cyl #5 Exhaust Port Temp Sensor short to +batt ............................... 131 MID 111 - CID 1535 - FMI 04 Cyl #5 Exhaust Port Temp Sensor short to ground ............................ 131 MID 111 - CID 1535 - FMI 05 Cyl #5 Exhaust Port Temp Sensor open circuit .................................. 132 MID 111 - CID 1536 - FMI 03 Cyl #6 Exhaust Port Temp Sensor short to +batt ............................... 132 MID 111 - CID 1536 - FMI 04 Cyl #6 Exhaust Port Temp Sensor short to ground ............................ 132 MID 111 - CID 1536 - FMI 05 Cyl #6 Exhaust Port Temp Sensor open circuit .................................. 133 MID 111 - CID 1537 - FMI 03 Cyl #7 Exhaust Port Temp Sensor short to +batt ............................... 133 MID 111 - CID 1537 - FMI 04 Cyl #7 Exhaust Port Temp Sensor short to ground ............................ 133 MID 111 - CID 1537 - FMI 05 Cyl #7 Exhaust Port Temp Sensor open circuit .................................. 134 MID 111 - CID 1538 - FMI 03 Cyl #8 Exhaust Port Temp Sensor short to +batt ............................... 134 MID 111 - CID 1538 - FMI 04 Cyl #8 Exhaust Port Temp Sensor short to ground ............................ 135 MID 111 - CID 1538 - FMI 05 Cyl #8 Exhaust Port Temp Sensor open circuit .................................. 135 MID 111 - CID 1539 - FMI 03 Cyl #9 Exhaust Port Temp Sensor short to +batt ............................... 135 MID 111 - CID 1539 - FMI 04 Cyl #9 Exhaust Port Temp Sensor short to ground ............................ 136 MID 111 - CID 1539 - FMI 05 Cyl #9 Exhaust Port Temp Sensor open circuit .................................. 136 MID 111 - CID 1540 - FMI 03 Cyl #10 Exhaust Port Temp Sensor short to +batt ............................... 136 MID 111 - CID 1540 - FMI 04 Cyl #10 Exhaust Port Temp Sensor short to ground ............................ 137 MID 111 - CID 1540 - FMI 05 Cyl #10 Exhaust Port Temp Sensor open circuit .................................. 137 MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port Temp Sensor short to +batt ............................... 138 MID 111 - CID 1541 - FMI 04 Cyl #11 Exhaust Port Temp Sensor short to ground ............................ 138 MID 111 - CID 1541 - FMI 05 Cyl #11 Exhaust Port Temp Sensor open circuit .................................. 138 MID 111 - CID 1542 - FMI 03 Cyl #12 Exhaust Port Temp Sensor short to +batt ............................... 139 MID 111 - CID 1542 - FMI 04 Cyl #12 Exhaust Port Temp Sensor short to ground ............................ 139 MID 111 - CID 1542 - FMI 05 Cyl #12 Exhaust Port Temp Sensor open circuit .................................. 139
MID 111 - CID 1543 - FMI 03 Cyl #13 Exhaust Port Temp Sensor short to +batt ............................... 140 MID 111 - CID 1543 - FMI 04 Cyl #13 Exhaust Port Temp Sensor short to ground ............................ 140 MID 111 - CID 1543 - FMI 05 Cyl #13 Exhaust Port Temp Sensor open circuit .................................. 141 MID 111 - CID 1544 - FMI 03 Cyl #14 Exhaust Port Temp Sensor short to +batt ............................... 141 MID 111 - CID 1544 - FMI 04 Cyl #14 Exhaust Port Temp Sensor short to ground ............................ 141 MID 111 - CID 1544 - FMI 05 Cyl #14 Exhaust Port Temp Sensor open circuit .................................. 142 MID 111 - CID 1545 - FMI 03 Cyl #15 Exhaust Port Temp Sensor short to +batt ............................... 142 MID 111 - CID 1545 - FMI 04 Cyl #15 Exhaust Port Temp Sensor short to ground ............................ 142 MID 111 - CID 1545 - FMI 05 Cyl #15 Exhaust Port Temp Sensor open circuit .................................. 143 MID 111 - CID 1546 - FMI 03 Cyl #16 Exhaust Port Temp Sensor short to +batt ............................... 143 MID 111 - CID 1546 - FMI 04 Cyl #16 Exhaust Port Temp Sensor short to ground ............................ 144 MID 111 - CID 1546 - FMI 05 Cyl #16 Exhaust Port Temp Sensor open circuit .................................. 144 MID 111 - CID 1547 - FMI 03 Cyl #17 Exhaust Port Temp Sensor short to +batt ............................... 144 MID 111 - CID 1547 - FMI 04 Cyl #17 Exhaust Port Temp Sensor short to ground ............................ 145 MID 111 - CID 1547 - FMI 05 Cyl #17 Exhaust Port Temp Sensor open circuit .................................. 145 MID 111 - CID 1548 - FMI 03 Cyl #18 Exhaust Port Temp Sensor short to +batt ............................... 145 MID 111 - CID 1548 - FMI 04 Cyl #18 Exhaust Port Temp Sensor short to ground ............................ 146 MID 111 - CID 1548 - FMI 05 Cyl #18 Exhaust Port Temp Sensor open circuit .................................. 146 MID 111 - CID 1549 - FMI 03 Cyl #19 Exhaust Port Temp Sensor short to +batt ............................... 147 MID 111 - CID 1549 - FMI 04 Cyl #19 Exhaust Port Temp Sensor short to ground ............................ 147 MID 111 - CID 1549 - FMI 05 Cyl #19 Exhaust Port Temp Sensor open circuit .................................. 147 MID 111 - CID 1550 - FMI 03 Cyl #20 Exhaust Port Temp Sensor short to +batt ............................... 148 MID 111 - CID 1550 - FMI 04 Cyl #20 Exhaust Port Temp Sensor short to ground ............................ 148 MID 111 - CID 1550 - FMI 05 Cyl #20 Exhaust Port Temp Sensor open circuit .................................. 148 P Programming Parameters ..................................... 27 PWM Sensor ....................................................... 335 R Replacing the ECM................................................ 30 Replacing the ITSM ............................................... 32
362 Index Section
S Self-Diagnostics...................................................... 11 Symptoms.............................................................. 36 Diagnostic Codes and Event Codes .................. 36 Operator Information.......................................... 36 Other Symptoms ................................................ 36 System Configuration Parameters......................... 29 System Overview................................................... 10 Air/Fuel Ratio Control......................................... 10 Engine Monitoring and Protection....................... 11 Engine Speed Governing................................... 10 Ignition Control.................................................... 11 Introduction ........................................................ 10 Start/Stop Sequencing ....................................... 10 System Voltage...................................................... 62 Probable Causes ............................................... 62 Recommended Repairs ..................................... 62 T Table of Contents..................................................... 3 Throttle Actuator .................................................. 342 Troubleshooting Data Sheet.................................. 34 Report the Service Information .......................... 35 Troubleshooting Section........................................ 10 Troubleshooting with a Diagnostic Code ............... 65 Troubleshooting with an Event Code................... 150 Troubleshooting without a Diagnostic Code .......... 36 Turbocharger Turbine Temperature (High) ............ 62 Probable Causes ............................................... 62 Recommended Repairs ..................................... 62 Turbocharger Turbine Temperature (Low)............. 63 Probable Causes ............................................... 63 Recommended Repairs ..................................... 63
363 Index Section
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