SENR6477-06

November 2010

Troubleshooting
3412, 3412C, and 3412E Generator Set
Engines
TGC1-Up (Generator Set)
2WJ1-Up (Engine)
BAK1-Up (Engine)
DJN1-Up (Generator Set)
9EP1-Up (Generator Set)
TFT1-Up (Generator Set)
BCW1-Up (Generator Set)
RTY1-Up (Generator Set)
4BZ1-Up (Generator Set)

SAFETY.CAT.COM
 i03991620

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are 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.
A non-exhaustive list of 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. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. 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 become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
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. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SENR6477-06 3
Table of Contents

Table of Contents ECM Will Not Accept Factory Passwords ...........

Electronic Service Tool Does Not Communicate ..
101
101
ECM Software - Install ........................................ 104
ECM - Replace ................................................... 104
Troubleshooting Section Electrical Connectors - Inspect ........................... 105
Crank Terminate - Calibrate ................................ 107
Introduction
Fuel Rack Position Sensor - Calibrate ................ 108
General Information (System Operation) ................ 4
Overspeed - Calibrate ......................................... 109
Welding Precaution ................................................. 5
Electronic Service Tools .......................................... 6
Index Section
Electronic System Overview
System Overview .................................................. 12 Index .................................................................... 111
Component Location ............................................. 15
Diagnostic Capabilities ......................................... 17
Programmable Parameters ................................... 17
Electrical Connectors ............................................ 17

Diagnostic Trouble Codes

Diagnostic Trouble Codes ..................................... 21

Symptom Troubleshooting
Symptom Troubleshooting .................................... 26
Acceleration Is Poor or Throttle Response Is
Poor .................................................................... 26
Boost Pressure Is High ......................................... 28
Boost Pressure Is Low .......................................... 28
Coolant Temperature Is High ................................ 29
Coolant Temperature Is Low ................................. 31
Engine Cranks but Does Not Start ........................ 31
Engine Does Not Crank ........................................ 32
Engine Misfires, Runs Rough or Is Unstable ........ 33
Engine Overspeeds .............................................. 35
Engine Shutdown Is Intermittent ........................... 36
Engine Stalls Immediately After Starting .............. 37
Engine Top Speed Is Not Obtained ...................... 38
Oil Pressure Is Low ............................................... 40
Power Is Intermittently Low or Power Cutout Is
Intermittent .......................................................... 41
Service Meter Problem ......................................... 42

Circuit Tests
Atmospheric Pressure - Test ................................. 43
Coolant Level - Test .............................................. 46
Coolant Temperature - Test .................................. 50
ECM/Personality Module - Test ............................ 53
Electrical Power Supply - Test .............................. 55
Engine Speed - Test ............................................. 58
Fuel Control - Test ................................................ 61
Fuel Rack Solenoid - Test ..................................... 64
Fuel Shutoff - Test ................................................. 67
Indicator Lamp - Test ............................................ 71
Inlet Manifold Pressure - Test ............................... 75
Sensor Signal (Analog, Active) - Test ................... 79
Sensor Supply - Test ............................................. 85
Shutdown - Test .................................................... 88
Speed Control (Auxiliary) - Test ............................ 91
Speed Control (PWM) - Test ................................. 93
Speed Control - Test ............................................. 97

Service
Customer Passwords .......................................... 100
Factory Passwords ............................................. 100
4 SENR6477-06
Troubleshooting Section

Troubleshooting Section

Introduction
i03160481

General Information
(System Operation)
SMCS Code: 1000

The 3412Generator Set Engine is equipped with

an electronic control system. The electronic control
system is used to control the fuel. The electronic
control system also replaces the mechanical fuel
ratio control, the torque control group, and various
adjustment screws.

The Electronic Control Module (ECM) uses the input Illustration 1

g01621681
signals from the rack position sensor to calculate the
desired rack position. The signals are also used to The throttle inputs allow the ECM to determine the
control the rack movement. The rack position sensor desired engine speed. Also, the customer specified
indicates the actual rack position to the ECM. The parameters will determine the speed. The ECM
ECM then varies the voltage to a brushless torque maintains the desired engine speed by sensing the
motor until the desired position is reached. actual engine speed with the engine speed sensor.
The ECM controls the rack solenoid in order to
Electronic Controls achieve the desired speed.

The electronic control system consists of the ECM The ECM sets limits on the amount of fuel that can
and the personality module. The ECM is the hardware be injected. The rack of the fuel ratio control operates
which controls the engine. The personality module is in the same manner as the fuel and air control on
the software that controls the ECM. a mechanically governed engine. When the ECM
senses a higher inlet manifold pressure, the limit of
the rack for the fuel ratio control is increased in order
Rack Controls to allow more fuel. The rated rack is a limit which
is based on the power rating of the engine. The
The ECM adjusts the voltage to the rack solenoid in rated rack determines maximum power values and
order to increase the rack position. The ECM also torque values of a specific engine family and rating.
adjusts the voltage in order to decrease the rack The rack of the fuel ratio control and the rated rack
position. An increase in voltage to the rack solenoid are programmed by the factory into the personality
will increase the fuel rate. The rack solenoid moves module.
a spool valve to control oil pressure to a servo that
controls the rack position.
Programmable Parameters
Programmable parameters will affect engine
operation. These parameters may be changed
with an electronic service tool. The parameters are
stored in the ECM. These parameters are system
configuration parameters or customer parameters.
System configuration parameters are parameters that
affect the power rating or the emissions. Customer
parameters affect settings such as low idle and high
idle.
SENR6477-06 5
Troubleshooting Section

Passwords Note: If the overspeed switch is faulty, a jumper can

be used to bypass relay “SR1” to allow the engine
System configuration parameters are protected to operate normally.
from unauthorized changes by factory passwords.
Customer parameters are protected by customer Crank Termination
passwords that are programmed by the customer.
The programmable crank termination speed is the
Self-Diagnostics engine rpm that is achieved prior to disengagement
of the starting motor. The engine hour meter activates
The ECM has a limited ability to make a after the engine speed of the crank termination is
self-diagnosis. A diagnostic code is generated when reached and a set of contacts opens.
the ECM detects a problem. The diagnostic code
is indicated on the diagnostic lamp as a series Load Share Module
of flashes. In most cases, the code is stored in
the permanent memory of the ECM. Active codes The load share module allows the connection of one
represent a current problem. Service an active code generator set in parallel with another generator set.
first. The load share module senses the power output of
the generator set engine. The load share module
Diagnostic codes that are stored in memory are provides a pulse width modulated signal. The signal
called logged codes. Logged diagnostic codes do is used to adjust the power output of the other
not always require repair. The problem could have generator set.
been temporary. Logged diagnostic codes may be
an indicator of intermittent problems. Some logged
diagnostic codes record events rather than failures. Warning Lamps
Diagnostic codes will automatically reset after 100
hours if the code does not require a factory password The ECM provides outputs in order to drive six
to clear the code. different warning lamps. The warning lamps alert the
operator of certain operating conditions.
Engine Speed Switch The following output lamps are used.
The engine speed switch is designed to monitor
several functions at the same time. Primary functions • Low oil pressure
of the engine speed switch are engine overspeed
and crank termination. • High coolant temperature
• Low coolant level
Engine Overspeed
• Low boost pressure
This is an adjustable engine speed setting that
prevents the engine from running at a speed that • Derate from atmospheric pressure
could cause damage. An overspeed condition causes
a relay to open and the relay will de-energize the • Diagnostic
shutoff solenoid. This will stop the fuel flow to the
engine. Also, this will shut down the engine. The The diagnostic lamp displays diagnostic conditions.
engine speed switch may activate the emergency The conditions are detected by the ECM. Flash
air shutoff system by de-energizing the air shutoff codes are used to detect these conditions.
solenoid.
i03160388

Welding Precaution
SMCS Code: 1000

The connection of any electrical equipment and

the disconnection of any electrical equipment may
cause an explosion hazard which may result in in-
jury or death. Do not connect any electrical equip-
ment or disconnect any electrical equipment in an
explosive atmosphere.
g01621694
Illustration 2
6 SENR6477-06
Troubleshooting Section

Proper welding procedures are necessary in order 5. Weld the materials by using standard welding
to avoid damage to the engine's electronic control methods.
module, to sensors, and to associated components.
Remove the component that requires welding.
i04020509
When welding on a engine that is equipped with
an Electronic Control Module (ECM) and removal
of the component is not possible, the following
Electronic Service Tools
procedure must be followed. This procedure provides SMCS Code: 0785
the minimum amount of risk to the electronic
components.
Service Tools
NOTICE Most of the tools that are listed in Table 1 are required
Do not ground the welder to electrical components to enable a service technician to perform the test
such as the ECM or sensors. Improper grounding can procedures in this manual. Some of the devices are
cause damage to the drive train bearings, hydraulic specific to the type of Electronic Control Module
components, electrical components, and other com- (ECM) that is being used.
ponents.

Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.

1. Stop the engine. Remove the electrical power

from the ECM.

2. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is installed,
open the switch.

g01143634
Illustration 3
Service welding guide (typical diagram)

3. Connect the welding ground cable as close

as possible to the area that will be welded.
Components which may be damaged by welding
include bearings, hydraulic components, and
electrical/electronic components.

4. Protect the wiring harness from welding debris

and from spatter.
SENR6477-06 7
Troubleshooting Section

Table 1 Optional Service Tools

Service Tools
Table 2 lists the optional service tools that may be
Pt. No. Description needed during testing or repair.
N/A 4 mm Allen Wrench
Table 2
151-6320 Wire Removal Tool (14-GA TO 18-GA, Optional Service Tools
RED)
Pt. No. Description
1U-5804 Crimp Tool (12−AWG TO 18−AWG)
198-4240 Digital Pressure Indicator
6V-2197 Transducer or or
7X-1171 Transducer Adapter 1U-5470 Engine Pressure Group

7X-1695 Cable As 4C-4075 Crimp Tool (4−AWG TO 10−AWG)

146-4080 Digital Multimeter Gp (RS232) 4C-4911(1) Battery Load Tester

7X-1710 Multimeter Probes 5P-7277 Voltage Tester

326-4904 Adapter Cable As (3-PIN BREAKOUT) 6V-9130(2) Temperature Adapter (MULTIMETER)

7X-1715 Adapter Cable As (40-PIN BREAKOUT) 8T-5319 Connector Tool Group

134-5195 Harness (40-PIN) 349-4199 AC/DC Current Probe
For ADEM 2 ECM (two 40-pin
connectors) 348-5430 Multi-Tool Gp
208-0059 Adapter Cable As (70-PIN BREAKOUT) (1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911
For ADEM 3 ECM (two 70-pin Battery Load Tester for 6, 8, and 12 v Lead Acid Batteries” and
connectors) and for ADEM 4 ECM Special Instructions, SEHS7633, “Battery Test Procedure”.
(2) Refer to Special Instructions, SEHS8382, “Use of the 6V-9130
(one 70-pin connector and one 120-pin
Temperature Adapter Group”.
connector)
257-8718 Adapter Cable As (120-PIN BREAKOUT)
For ADEM 4 ECM (one 70-pin connector Caterpillar Electronic Technician
and one 120-pin connector) (ET)
N/A Torque Wrench (capable of applying
1.5 N·m (13.3 lb in)) Cat ET can be used by the technician to help perform
the following procedures:
Repair Kits for Connectors
270-5051 Connector Repair Kit (AMPSEAL) • Diagnostic tests
175-3700 Connector Repair Kit (DEUTSCH DT) • Calibrations
Bypass Harnesses for the ECM
• Flash programming
129-2018 Power Cable
Stand alone cable for ADEM 2 ECM
• Configuration of the ECM
217-0113 Wiring Harness (ECM BYPASS)
The bypass harness connects to the Cat ET can display the following information:
battery. The bypass harness is used
with the following harnesses for different • Parameters
types of electronic control modules.
328-2292 Harness (ENGINE ECM BYPASS) • Event codes
For ADEM 3 ECM and ADEM 4 ECM
• Diagnostic codes
277-4734 Harness (ENGINE ECM BYPASS)
For A4:E2 ECM (Two 64-pin connectors)
• Engine configuration
Two short jumper wires are needed to check the Always use the latest revision of Cat ET. The media
continuity of some wiring harness circuits by shorting is available on CD and the media can also be
two adjacent terminals together in a connector. A downloaded from various Caterpillar web sites.
long extension wire may also be needed to check the
continuity of some wiring harness circuits. Table 3
Software, JEBD3003, “CATERPILLAR
ELECTRONIC TECHNICIAN”
8 SENR6477-06
Troubleshooting Section

Once you have downloaded Cat ET onto your

PC, you will need a license from your Caterpillar
dealer in order to use the software. Various licenses
are available for different users with different
requirements. Consult your Caterpillar dealer.

Note: For more information regarding the use of

Cat ET and the PC requirements for Cat ET, refer to
the documentation that accompanies your Cat ET
software.

Connecting Cat ET
Connecting the Communication Adapter

Table 4 lists the standard hardware that is required in

order to connect Cat ET.

Note: The 275-5120 Communication Adapter

Gp was canceled and replaced by the 317-7484
Communication Adapter Gp. However, the 275-5120
g02051513
Communication Adapter Gp can still be used. Illustration 4
(1) PC
Table 4 (2) 353-5083 Cable As (USB)
(3) 317-7485 Communication Adapter (3)
Standard Hardware for the Use of Cat ET (4) 327-8981 Cable As (DATA LINK)
Part Number Description
2. Connect cables (2) and (4) to communication
N/A Personal Computer (PC) adapter (3).
Communication Adapter Note: The communication adapter will power up
317-7484
Gp
when the adapter is connected to a PC or to an ECM
Components of the 317-7484 Communication that is powered up.
Adapter Gp
3. Connect cable (2) to the USB port of the PC.
Communication Adapter
317-7485
(3)
4. Connect cable (4) to a service tool connector.
353-5083 Cable As (USB)
327-8981 Cable As (DATA LINK)
5. Restore electrical power to the ECM. Verify that
the “POWER” indicator on the communication
Tool Operating Manual & Software CD ROM, adapter is illuminated. Make sure that the PC is
NETG5057, “Communication Adapter 3” powered up.

Follow the instructions for the communication 6. Establish communication between Cat ET and the
adapter. Use the following procedure in order to ECM. If Cat ET indicates that there is more than
connect Cat ET and the communication adapter to one ECM, select the engine ECM.
a PC.
7. If Cat ET and the communication adapter
1. Remove the electrical power from the ECM. do not communicate with the ECM, refer to
Troubleshooting, “Electronic Service Tool Will Not
Communicate with ECM”.

Refer to Troubleshooting, “Electronic Service Tool

Does Not Communicate” if any of the following
conditions exist:

• Cat ET displays a message that refers to a

communication problem.

• Cat ET displays “Error #142 The interface

hardware is not responding”.
SENR6477-06 9
Troubleshooting Section

• Cat ET displays a message that indicates that Note: Items (7), (8), and (9) are part of the 261-3363
the firmware in the communications adapter is Wireless Communication Adapter Gp.
old.
Use the following procedure in order to connect the
Dual Data Links wireless communication adapter for use with Cat ET.

When the connection of the communication adapter 1. Remove the electrical power from the ECM.
is complete, observe the communication adapter
and Cat ET. If the “J1939” and the “Cat Data Link” 2. Ensure that the computer has been correctly
indicators are flashing and Cat ET does not display configured for the 261-4867 Card. Verify that
a message that indicates “Service tool support is the PC card is installed in the computer PCMCIA
limited”, Cat ET is communicating with the ECM on expansion slot.
both data links.
3. Connect cable (9) between communication radio
Refer to Troubleshooting, “Electronic Service Tool (8) and the service tool connector.
Does Not Communicate” if the “J1939” indicator and
the “Cat Data Link” indicator are not flashing. Both 4. Restore the electrical power to the ECM. If Cat ET
indicators must be flashing. and the communication radio do not communicate
with the ECM, refer to Troubleshooting, “Electronic
Communicating with the Wireless Communication Service Tool Will Not Communicate with ECM”.
Adapter

Table 5 lists the optional hardware that is needed

in order to connect Cat ET by using a wireless
connection.

Note: Some applications cannot use a wireless

connection. Also, a dual data link cannot be used
with a wireless connection.

Table 5

Optional Hardware for the Use of Cat ET

Part Number Description

N/A Personal Computer (PC)

g01297379
Illustration 5
(1) Personal computer (PC)
(7) 261-4867 Card (PCMCIA)
(8) 239-9955 Communication Radio Gp
(9) 259-3183 Data Link Cable As
10 SENR6477-06
Troubleshooting Section

PL1000E Communication ECM (If

Equipped)

g01163897
Illustration 6

The “PL1000E” is an ECM that provides the

customer with the ability to integrate Caterpillar
engines into specific applications. The “PL1000E”
enables communication from a “J1939” data link
to a “Modbus”. A PC with Cat ET installed can be
connected to the “PL1000E” through the RS232
serial port of the PC. The “PL1000E” contains an
embedded communications adapter that will allow
Cat ET to communicate with the engine over the
“J1939” data link.

Refer to System Operation/Troubleshooting/Test and

Adjust, RENR8091, “PL1000E Communication ECM”
for additional information.
SENR6477-06 11
Troubleshooting Section

Electronic System
Overview
i03162445

System Overview
SMCS Code: 1000; 1900
12 SENR6477-06
Troubleshooting Section

System Component Diagram

g01622007
Illustration 7
SENR6477-06 13
Troubleshooting Section

Electrical Connectors and (Table 7, contd)

Functions 20 Coolant Temperature

21 -Battery
Table 6
Connector Function 22 Solenoid Ground

J5/P5 Fuel Shutoff Solenoid (3-Pin Connector) 23 Rack Solenoid

J6/P6 Rack Solenoid (3-Pin Connector) 24 Spare Switch Input

J7/P7 Coolant Level Sensor (3-Pin Connector) 25 Boost Pressure

J8/P8 Boost Pressure Sensor (3-Pin Connector) 26 Coolant Level Switch

J9/P9 Oil Pressure Sensor (3-Pin Connector) 27 Engine Oil Pressure

J10/P10 Engine Speed Sensor (3-Pin Connector) 28 Spare Frequency Input

J11/P11 Rack Position Sensor Connector (3-Pin) 29 ATA Data Link

J12/P12 Coolant Temperature Sensor (3-Pin 30 +5 VDC

Connector) 31 Engine Shutdown
J13 ATA Data Link (9-Pin Connector) 32 Spare Driver
J14/P14 ECM (40-Pin Connector) 33 Fuel Shutoff Solenoid
J15/P15 Atmospheric Pressure Sensor 34 Atmospheric Pressure
(3-Pin Connector)
35 Analog Return
J17/P17 Customer Connector (24-Pin Connector)
36 Spare Switch Input
37 Droop
Pin Descriptions
38 ATA Data Link
Table 7
39 Spare Analog Input
J14/P14 40-Pin ECM Connector
40 Rack Position
Pin Name
1 +Battery
2 Auxiliary Circuit
3 Low Oil Pressure
4 Diagnostic Lamp
5 Derate from Atmospheric Pressure
6 Spare
7 Spare Switch Input
8 Primary Throttle
9 CatData Link +
10 +8 VDC
11 Spare
12 Crank
13 Low Boost Pressure
14 Low Coolant Level
15 High Coolant Temperature
16 Spare Switch Input
17 Idle/Rated Switch
18 Engine Speed
19 Cat Data Link -
(continued)
14 SENR6477-06
Troubleshooting Section

Table 8
J17/P17“ 24-Pin Customer Connector”
Pin Name
1 Fuel Shutoff Solenoid
2 Auxiliary Circuit
3 Droop
4 High Coolant Temperature Lamp
5 Low Boost Pressure
6 Shutoff
7 Idle/Rated Switch
8 Derate From Atmospheric Pressure
9 Throttle
10 Diagnostic Lamp
11 Low Oil Pressure Lamp
12 Low Coolant Level Lamp
13 +Battery
14 Engine Shutdown
15 Auxiliary Circuit
16 Auxiliary Circuit
17 Auxiliary Circuit
18 Cat Data Link +
19 -Battery
20 Auxiliary Circuit
21 Auxiliary Circuit
22 Auxiliary Circuit
23 Auxiliary Circuit
24 Cat Data Link -
SENR6477-06 15
Troubleshooting Section

i03170740

Component Location
SMCS Code: 1000; 1900

g01623331
Illustration 8
16 SENR6477-06
Troubleshooting Section

g01622123
Illustration 9
SENR6477-06 17
Troubleshooting Section

i03170621 Logged codes may not indicate that a repair is

needed. The problem may have been temporary.
Diagnostic Capabilities Logged codes may be useful to help troubleshoot
intermittent problems. Logged codes can also be
SMCS Code: 1900 used to review the performance of the engine and
of the electronic system.
Diagnostic Codes
i03496620
The engine's Electronic Control Module (ECM) has
the ability to monitor the circuitry between the ECM Programmable Parameters
and the engine's components. The ECM also has the
ability to monitor the engine's operating conditions. If SMCS Code: 1900
the ECM detects a problem, a code is generated.
The Caterpillar Electronic Technician (ET) can be
There are two categories of codes: used to view certain parameters that can affect
the operation of the engine. Cat ET can also be
• Diagnostic code used to change certain parameters. There are
some parameters that cannot be changed and
• Event code there are some applications that do not allow any
changes to the programmable monitoring system.
Diagnostic Code – A diagnostic code indicates an The parameters are stored in the Electronic Control
electrical problem such as a short or an open in the Module (ECM). Some of the parameters are
engine's wiring or in an electrical component. protected from unauthorized changes by passwords.
Parameters that can be changed have a tattletale
Event Code – An event code is generated by the number. The tattletale number shows if a parameter
detection of an abnormal engine operating condition. has been changed.
For example, an event code will be generated if the
oil pressure is too low. In this case, the event code
indicates the symptom of a problem. Event codes i03168980
indicate mechanical problems rather than electrical
problems. Electrical Connectors
Codes can have two different states: SMCS Code: 7553-WW

Many of the procedures in this guide will direct you to

• Active a specific electrical connector. The connectors have
a locking feature that holds the pins. The connectors
• Logged have a locking feature that holds the sockets. The
connectors are repairable without cutting the wires.
Active Codes Do not solder sockets and pins to the wires. Always
crimp sockets and pins onto the wires with the
An active code indicates that a problem is present. 1U-5804 Crimp Tool.
Service the active code first. For the appropriate
troubleshooting procedure for a particular code, refer
to the following troubleshooting procedure:

• Troubleshooting, “Diagnostic Trouble Codes ”

Logged Codes
The codes are logged and stored in the ECM
memory. The problem may have been repaired
and/or the problem may no longer exist. If the
system is powered, it is possible to generate an
active diagnostic code whenever a component is
disconnected. If the component is reconnected, the
code is no longer active but the code may become
logged.
18 SENR6477-06
Troubleshooting Section

g00738352
Illustration 10
Terminal connections
The 8T-8729 Connector Pin and the 8T-8730 Connector Socket
are designed to accept only one 16/18 AWG wire. Do not insert
multiple wires of a smaller wire size. The 9W-0852 Connector
Pin and the 9W-0844 Connector Socket are designed to accept
only one 14 AWG wire. Do not insert multiple wires of a smaller
wire size.

ECM Connector

g01655753
Illustration 11
(40-pin connector)

Service Tool Connector for Cat ET

g01158896
Illustration 12
(9-pin connector)
SENR6477-06 19
Troubleshooting Section

Harness Connectors

g01317390
Illustration 13
20 SENR6477-06
Troubleshooting Section

HD-10 Connectors
Ensure that the plug and the receptacle are aligned
with the index marking. Rotate the plug until the plug
slips into the receptacle. Rotate the coupling for
one quarter of a turn. A click will be heard. Ensure
that the two halves cannot be pulled apart. The
acceptable range for the outside diameter of the wire
is 2.50 to 3.75 mm (0.100 to 0.150 inch).

DT Connectors
The DT connectors use a wedge to lock the pins in
place. Check that the seals are in place and check
that the seals are properly seated. Check pins and
sockets before the connectors are joined. Verify
proper alignment and locations of pins and sockets
in each connector. Check the locking tab for the DT
connector for damage. Replace the connector if the
tab is damaged. Ensure that the connector is properly
locked. An audible click will be heard. Ensure that the
two mating connectors can not be pulled apart. The
acceptable range for the outside diameter of the wire
is 2.20 to 3.68 mm (0.088 to 0.145 inch).
SENR6477-06 21
Troubleshooting Section

Diagnostic Trouble Codes

i03171802

Diagnostic Trouble Codes

SMCS Code: 1900

Cross-Reference Information for

Diagnostic Codes
Table 9 is a list of the diagnostic codes for the
engine. The diagnostic codes are cross-referenced
with the appropriate procedure that can be used to
troubleshoot the code.

Further explanations of diagnostic codes are

explained after Table 9.

Table 9

Cross-Reference from CID-FMI Code on Cat Data Link to Troubleshooting Procedure

Code Description Flash Code Procedure
17-05 Shut Off Solenoid current low 45 Troubleshooting, “Fuel Shutoff - Test”
17-06 Shut Off Solenoid current high 45 Troubleshooting, “Fuel Shutoff - Test”
23-02 Engine Power Excessive 48 Troubleshooting, “Fuel Rack
Solenoid - Test”
23-05 Rack BTM current low 43 Troubleshooting, “Fuel Rack
Solenoid - Test”
23-06 Rack BTM current high 43 Troubleshooting, “Fuel Rack
Solenoid - Test”
24-03 Rack Sensor voltage high 22 Troubleshooting, “Sensor Signal
(Analog, Active) - Test”
24-04 Rack Sensor voltage low 22 Troubleshooting, “Sensor Signal
(Analog, Active) - Test”
24-07 Rack System Fault 43 Troubleshooting, “Sensor Signal
(Analog, Active) - Test”
24-10 Rack signal rate of change 22 Troubleshooting, “Sensor Signal
(Analog, Active) - Test”
91-08 Throttle Position Invalid 32 Troubleshooting, “Speed Control
(PWM) - Test”
91-10 Throttle signal rate of change 32 Troubleshooting, “Speed Control
(PWM) - Test”
100-01 Low Oil Pressure Warning 46 Troubleshooting, “Oil Pressure Is Low”
100-03 Oil Pressure voltage high 24 Troubleshooting, “Sensor Signal
(Analog, Active) - Test”
100-04 Oil Pressure voltage low 24 Troubleshooting, “Sensor Signal
(Analog, Active) - Test”
100-10 Oil Pressure signal rate of change 24 Troubleshooting, “Sensor Signal
(Analog, Active) - Test”
102-00 Excessive Boost Pressure 25 Troubleshooting, “Boost Pressure
Is High”
(continued)
22 SENR6477-06
Troubleshooting Section

(Table 9, contd)
Cross-Reference from CID-FMI Code on Cat Data Link to Troubleshooting Procedure
Code Description Flash Code Procedure
102-01 Low Boost Pressure 25 Troubleshooting, “Boost Pressure
Is Low”
102-03 Boost Pressure voltage high 25 Troubleshooting, “Inlet Manifold
Pressure - Test”
102-04 Boost Pressure voltage low 25 Troubleshooting, “Inlet Manifold
Pressure - Test”
102-13 Boost Pressure out of calibration 42 Troubleshooting, “Inlet Manifold
Pressure - Test”
106-01 Low Atmospheric Pressure 26 The engine derates
106-03 Atmospheric Pressure voltage high 26 Troubleshooting, “Atmospheric
Pressure - Test”
106-04 Atmospheric Pressure voltage low 26 Troubleshooting, “Atmospheric
Pressure - Test”
106-10 Atmospheric Pressure signal rate of change 26 Troubleshooting, “Atmospheric
Pressure - Test”
110-00 High Coolant Temperature Warning 61 Troubleshooting, “High Coolant
Temperature”
110-03 Coolant Temperature voltage high 27 Troubleshooting, “Coolant Temperature
- Test”
110-04 Coolant Temperature voltage low 27 Troubleshooting, “Coolant Temperature
- Test”
111-01 Low Coolant Level Warning 62 Add coolant and check for leaks.
168-02 ECM Battery Power Intermittent 51 Troubleshooting, “Electrical Power
Supply - Test”
190-00 Engine Overspeed Warning 35 Troubleshooting, “Engine Overspeeds”
190-02 Primary Engine Speed loss of signal 34 Troubleshooting, “Engine Speed - Test”
190-08 Primary Engine Speed loss of signal 33 Troubleshooting, “Engine Speed - Test”
190-10 Engine Speed rate of change 34 Troubleshooting, “Engine Speed - Test”
241-00 5 Volt Open Circuit 21 Troubleshooting, “Sensor Supply - Test”
241-01 5 Volt Short Circuit 21 Troubleshooting, “Sensor Supply - Test”
241-02 8 Volt Open Circuit 21 Troubleshooting, “Sensor Supply - Test”
241-03 8 Volt Short Circuit 21 Troubleshooting, “Sensor Supply - Test”
252-11 Engine Software Incorrect 50 Troubleshooting, “ECM/Personality
Module - Test”
252-12 Personality Module Fault 52 Troubleshooting, “ECM/Personality
Module - Test”
253-02 Check Customer or System Parameters 56 Troubleshooting, “ECM/Personality
Module - Test”
254-12 ECM Fault 53 Troubleshooting, “ECM/Personality
Module - Test”
SENR6477-06 23
Troubleshooting Section

Diagnostic Codes
Diagnostic codes alert the operator that a problem in
the electronic system has been detected. Diagnostic
codes are also used by the service technician
to identify the nature of the problem. Caterpillar
Electronic Technician (ET) is a software program
that is designed to run on a personal computer.
The software can be used by the service technician
in order to view the diagnostic code information
for an ECM. Diagnostic codes may consist of the
component identifier (CID), and the failure mode
identifier (FMI).

Component Identifier (CID) – The CID indicates the

component that generated the code. For example,
the CID number 1 identifies the fuel injector for the
number one cylinder.

Failure Mode Identifier (FMI) – The FMI indicates

the type of failure. Refer to Table 10 for a complete
list of the two digit codes.

Table 10
FMI Failure
00 Data is above the normal
range.
01 Data is below the normal
range.
02 Incorrect signal
03 Voltage is above the
normal range.
g01365757
04 Voltage is below the normal Illustration 14
range. Example of the typical operating range of a sensor
05 Current is below the normal (1) This area represents the normal operating range of the engine
range. parameter.
(2) In these areas, the engine is operating in an unsafe operating
06 Current is above the range of the monitored parameter. An event code will be
normal range. generated for the monitored parameter. The sensor circuit does
not have an electronic problem.
08 Abnormal signal (3) In these areas, the signal from the sensor is outside of the
operating range of the sensor. The sensor circuit has an
09 Abnormal update electronic problem. A diagnostic code will be generated for
the sensor circuit.
12 A device or a component
failed.
13 A component is out of
Active Diagnostic Codes
calibration.
An active diagnostic code represents a problem with
the electronic control system. Correct the problem
Refer to Table 9 for a complete list of the diagnostic as soon as possible.
codes and the appropriate troubleshooting procedure.
When the engine's ECM generates an active
Illustration 14 is an example of the operating range diagnostic code, the “Active Alarm” indicator (“Engine
of a sensor. 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.
24 SENR6477-06
Troubleshooting Section

Logged Diagnostic Codes

When the ECM generates a diagnostic code, the
ECM logs the code in permanent memory. The
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 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 100 hours.
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is
cleared.

Some diagnostic codes may be easily triggered.

Some diagnostic codes may log occurrences that
did not result in complaints. The most likely cause
of an intermittent problem is a faulty connection
or damaged wiring. The next likely cause is a
component failure. The least likely cause is the failure
of an electronic module. Diagnostic codes that are
logged repeatedly may indicate a problem that needs
special investigation.

Note: Always clear logged diagnostic codes after

investigating and correcting the problem which
generated the code.

Flash Codes
Flash codes are used to represent diagnostic codes
in the electronic system in order to alert the operator
that a problem exists. The flash codes are a two digit
number. A series of flashes represents the flash code
on the diagnostic lamp.

EXAMPLE

Note: Flash Code 27 would flash on the diagnostic

lamp in the following manner:

• Two short flashes

• Hesitation
• Seven short flashes
SENR6477-06 25
Troubleshooting Section

Table 11
Flash Code Description Procedure
21 Sensor Supply Voltage Fault Troubleshooting, “Sensor Supply - Test”
22 Rack Position Sensor Fault Troubleshooting, “Sensor Signal (Analog,
Active) - Test”
24 Engine Oil Pressure Fault Troubleshooting, “Sensor Signal (Analog,
Active) - Test”
25 Boost Pressure Sensor Fault Troubleshooting, “Inlet Manifold
Pressure - Test”
26 Atmospheric Pressure Sensor Fault Troubleshooting, “Atmospheric Pressure - Test”
27 Coolant Temperature Sensor Fault Troubleshooting, “Coolant Temperature - Test”
32 Throttle Position Sensor Fault Troubleshooting, “Speed Control - Test”
33 Engine RPM Signal Fault Troubleshooting, “Speed Control - Test”
34 Loss of Engine RPM Signal Troubleshooting, “Speed Control - Test”
35 Engine Overspeed Warning Troubleshooting, “Speed Overspeeds”
42 Boost Pressure Sensor Calibration Troubleshooting, “Inlet Manifold
Pressure - Test”
43 Fault for the Fuel Rack Troubleshooting, “Sensor Signal (Analog,
Active) - Test”
45 Fault of the Fuel Shutoff Solenoid Troubleshooting, “Fuel Shutoff - Test”
46 Low Oil Pressure Warning Troubleshooting, “Oil Pressure Is Low”
48 Excessive Engine Power Troubleshooting, “Fuel Rack Solenoid - Test”
51 Intermittent Battery Power to the ECM Troubleshooting, “Electrical Power
Supply - Test”
52 Personality Module Fault Troubleshooting, “ECM/Personality
Module - Test”
53 ECM Fault Troubleshooting, “ECM/Personality
Module - Test”
56 Check the Parameters for the System Troubleshooting, “ECM/Personality
Configuration and Customer Parameters. Module - Test”
61 High Coolant Temperature Warning Troubleshooting, “High Coolant Temperature”
62 Low Coolant Level Warning Troubleshooting, “Coolant Level - Test”
26 SENR6477-06
Troubleshooting Section

Symptom Troubleshooting • Determine if the logged diagnostic codes occur

at the same time as the symptoms.

i03174660 • Determine if the logged diagnostic codes are

logged repeatedly.
Symptom Troubleshooting
If these inspections do not reveal any problems, use
SMCS Code: 7569 the procedure that best describes the symptoms.

Some engine symptoms can be unrelated to the

electronic control system. Gather information about i03175920
the complaint that describes the symptoms. Verify
that the complaint is not due to normal engine Acceleration Is Poor or Throttle
operation. Response Is Poor
Perform the following steps in order to determine the SMCS Code: 1000-035
problem.

1. Repair all active diagnostic codes. Probable Causes

2. Gather operator information. • Fuel supply

3. Verify that the complaint is not due to normal • Engine derate or active codes
engine operation.
• Cold mode
4. Perform a visual inspection of the engine. Inspect
the following items: • Flash file

• Wiring • Throttle position signal

• Connectors • Electrical connectors

• Fuel level • Air inlet and exhaust system

• Fuel supply • Rack controls

• Engine oil level Recommended Actions

• Engine oil supply Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
• Coolant level Examples of certain conditions are high engine
speed, full load and engine operating temperature.
• Intake air system Troubleshooting the symptoms under other
conditions can give misleading results.
• Air exhaust system
Fuel Supply
5. Check the wiring and the connectors for the
following problems: 1. Visually check the fuel level in the fuel tank. Do not
rely on the fuel gauge only. If necessary, add fuel
• Damage to the fuel tank. If the engine has been run out of
fuel, it will be necessary to purge the air from the
• Abrasion fuel system. Refer to Operation and Maintenance
Manual for the correct procedure.
• Corrosion
2. Check the fuel lines for the following problems:
• Incorrect attachment restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
6. Check for any logged diagnostic codes. lines and/or replace the lines.

• Determine if the logged diagnostic codes 3. Check the fuel tank for debris or foreign objects
correlate to probable causes. which may block the fuel supply.
SENR6477-06 27
Troubleshooting Section

Cold Mode
NOTICE
Do not crank the engine continuously for more than The Electronic Control Module (ECM) limits engine
30 seconds. Allow the starting motor to cool for two power during cold mode operation. The ECM may
minutes before cranking the engine again. cut out certain engine cylinders. This will increase
startability and this will reduce warm up time. Cold
mode is activated whenever the engine coolant
4. Prime the fuel system if any of the following temperature falls below a predetermined value. Cold
procedures have been performed: mode remains active until the engine has warmed or
a time limit is exceeded.
• Replacement of the fuel filters
Flash File
• Service on the low pressure fuel supply circuit
Verify that the latest flash file is installed in the ECM.
Note: Check the fuel system for air. Refer to Systems
Operation/Testing and Adjusting for information that
is related to checking the fuel system for air. Throttle Signal

5. Check fuel quality. Cold weather adversely Monitor the status for “Throttle Position” on Cat ET.
affects the characteristics of the fuel. Refer to the Verify that the status for “Throttle Position” is stable
engine's Operation and Maintenance Manual for and that the engine is able to reach high idle speed.
information on improving the characteristics of the If a problem is suspected with the throttle, refer
fuel during cold weather operation. to the appropriate troubleshooting procedure for
troubleshooting the throttle signal.
6. Check the filtered fuel pressure while the
engine is being cranked. Refer to Systems Electrical Connectors
Operation/Testing and Adjusting for the test
procedure and for the correct pressure values. Check for correct installation of the J14/P14 ECM
connector. Refer to Troubleshooting, “Electrical
If the fuel pressure is low, replace the fuel filters. Connectors - Inspect”.
Clean the primary filter/water separator of debris.
Refer to the Operation and Maintenance Manual Air Inlet and Exhaust System
for details.
1. Check for an air filter restriction. Clean plugged air
If the fuel pressure is still low, check the operation filters or replace plugged air filters. Refer to the
of the fuel pressure regulating valve. Also, check Operation and Maintenance Manual.
for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting 2. Check the air inlet and exhaust system for
for test information. restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting for information on
Engine Derate or Active Codes inspecting the air inlet and exhaust system.

Some engine monitoring parameters that are capable Rack Controls

of triggering an engine derate do not produce an
event code. Connect Caterpillar Electronic Technician 1. Check the rack solenoid for proper operation.
(ET) in order to check for a derate of the engine. Refer to Troubleshooting, “Fuel Rack Solenoid
- Test” for troubleshooting procedures. Refer to
Certain diagnostic codes and may cause poor Troubleshooting, “Fuel Control - Test” in order
performance. Use Cat ET to check for active codes to troubleshoot the dynamic rack controls. Also,
and for logged codes. Troubleshoot any codes that refer to Troubleshooting, “Sensor Signal (Analog,
are present before continuing with this procedure. Active) - Test” for procedures to troubleshoot the
rack position sensor.
Note: Although a sensor's signal may be in the
operational range of the sensor, the signal may
not represent the actual reading. Use Cat ET to
check that the pressures and the temperatures are
fluctuating. Also check that the values are reasonable
for the conditions that are present.
28 SENR6477-06
Troubleshooting Section

i03266701

Boost Pressure Is High

SMCS Code: 1050-035; 1052-035

Use this procedure in order to troubleshoot a high

boost pressure or use this procedure if the following
diagnostic code is active. You must access the
monitoring system on the Caterpillar Electronic
Technician (ET) in order to view the current trip points
for this code.

Table 12
Diagnostic Code
Code and Description Flash Codes Default Conditions which System Response
Generate this Code
102-00 Boost Pressure 25 The boost pressure is above The code is logged.
Sensor : High the trip point for high boost
pressure.

Probable Causes
• Excessive engine load

Recommended Actions
Excessive Engine Load
Reduce the load on the engine.

i03266714

Boost Pressure Is Low

SMCS Code: 1050-035; 1052-035

Use this procedure in order to troubleshoot a

low boost pressure or use this procedure if the
following diagnostic code is active. You must access
the monitoring system on Caterpillar Electronic
Technician (ET) in order to view the current trip points
for this code.

Table 13
Diagnostic Code
Code and Description Flash Codes Default Conditions which System Response
Generate this Code
102-01 Boost Pressure 25 The boost pressure is below The code is logged. Also, the
Sensor : Low the trip point for high boost engine is derated.
pressure.

Probable Causes • Fuel supply

• Derate mode • Engine speed/timing sensors
• Air inlet and exhaust system • Electrical connectors
SENR6477-06 29
Troubleshooting Section

Derate Mode Engine Speed/Timing Sensors

Connect Caterpillar Electronic Technician (ET) and Use Cat ET to monitor the following status
check for logged derate events. A status indicator parameters while you crank the engine:
for an active engine derate will appear on Cat ET
if a derate is occurring. The engine speed might • “Engine Speed Primary Sensor”
be limited due to one of the following possible
causes: altitude, high exhaust temperatures, air filter Ensure that the engine speed sensor is indicating an
restriction, high coolant temperature, aftercooler engine rpm during cranking. Also, ensure that the
water temperature, and crankcase pressure. status of signal pattern for the engine speed/timing
sensor is “Detected”.
Air Inlet and Exhaust System
Electrical Connectors
1. Check for an air filter restriction. Clean plugged air
filters or replace plugged air filters. Refer to the Check for the correct installation of the J14/P14 ECM
Operation and Maintenance Manual. connector. Check for correct installation of the fuel
Injector connectors. Check the wiring harnesses
2. If air shutoff valves are installed, verify that the air for damage. Refer to Troubleshooting, “Electrical
shutoff valves are fully opened. Connectors - Inspect”.

3. Check the air inlet and exhaust system for

i03266582
restrictions and/or leaks. Refer to the Systems
Operation/Testing and Adjusting for information on
the air inlet and exhaust system.
Coolant Temperature Is High
SMCS Code: 1395-035
Fuel Supply
Use this procedure in order to troubleshoot a high
Check the fuel level in the fuel tank. Ensure that coolant temperature or use this procedure if the
adequate fuel is available for the application. following diagnostic code is active.

Check fuel lines for the following problems:

restrictions, collapse, and pinched line. Repair the
lines and/or replace the lines.

1. Check the fuel tank for foreign objects which may

block the fuel supply. Check for air leaks in the
suction line of the fuel pump. Prime the fuel system
after you perform the following procedures:

• Replacing the fuel filters

• Working on the low pressure fuel supply circuit
• Replacing fuel injectors
2. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.

3. Check the fuel pressure during engine operation.

Check the fuel pressure after the fuel filter. Refer
to the Systems Operation/Testing and Adjusting
manual for the correct pressure values. If the fuel
pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items: fuel
transfer pump and fuel pressure regulating valve.
30 SENR6477-06
Troubleshooting Section

Table 14
Diagnostic Code
Description Flash Code Conditions which Generate System Response
this Code
110-00 High Coolant 61 The coolant temperature is The code is active and the
Temperature Warning above the trip point. code is logged.

Probable Causes If the flow of coolant through the engine is not

sufficient, determine the cause of the obstruction.
• Low coolant level and/or coolant leakage Make necessary repairs.

• Insufficient flow of coolant through the engine Radiator (if equipped)

• Radiator (if equipped) Check the cooling fins on the radiator for dirt and/or
for debris. Remove the dirt and/or debris.
• Faulty radiator cooling fan (if equipped)
1. Check the cooling fins on the radiator for damage.
• Heat exchanger (if equipped) Refer to the Systems Operation/Testing and
Adjusting manual for instructions for testing and
• Faulty pressure relief valve inspecting the cooling system.

• Faulty temperature regulator 2. Check the radiator for internal blockage. Check
the temperature difference between the inlet and
• Faulty water pump the outlet of the radiator.

• Load on the system Faulty Engine Cooling Fan (if equipped)

Recommended Actions Check for proper operation of the cooling fan.

Check for a Low Coolant Level and/or Check for Insufficient Flow of Air and
Coolant Leakage Coolant Through the Heat Exchanger (if
equipped)
Note: Low coolant level can be the effect of
overheating rather than the cause. Measure the coolant temperature at the inlet for the
coolant.
Check the coolant level.
Check for sufficient flow and temperature of the
Run the engine to operating temperature. Inspect the cooling water through the heat exchanger. If the
cooling system for leaks. flow of cooling water through the heat exchanger is
insufficient, determine the location of the obstruction.
Determine whether the leak occurs before the engine
overheats.
Faulty Pressure Relief Valve
Add coolant, if necessary. If leaking is found, make
the necessary repairs. Check operation of the pressure relief valve and the
radiator cap. If necessary, clean the pressure relief
valve and/or the radiator cap. Check that the seating
Check the Flow of Coolant Through the surface of the valve is clean and undamaged. If
Engine necessary, install new parts.

During normal operation, check the inlet pressure Faulty Temperature Regulator
of the engine coolant and the outlet pressure of the
engine coolant. Check the water temperature regulators for correct
operation.
Measure temperatures and pressures at various
points in the cooling system in order to identify
possible locations of restrictions.

If a buildup of deposits restricts the coolant flow,

clean the cooling system.
SENR6477-06 31
Troubleshooting Section

Faulty Water Pump • Electrical power supply to the Electronic Control

Module (ECM)
Measure the coolant pressure at the outlet of the
water pump. Make sure that the water pump is in • Electrical connectors
good condition. Inspect the impeller vanes at the
jacket water pump for damage and/or for erosion. • Personality module or incorrect engine software
Repair impeller vanes and/or replace the impeller
vanes. • Flash file

Load on the system • Engine speed signal

Check that the engine is not loaded beyond design. • Air inlet and exhaust system
• Fuel supply
i03266544

Coolant Temperature Is Low • Engine shutdown switches (if applicable)

• Rack controls
SMCS Code: 1395-035
• Combustion
Use this procedure in order to troubleshoot a low
coolant temperature.
• Overspeed protection
Probable Causes Recommended Actions
• Faulty water temperature regulator Diagnostic Codes, and Electrical Power
• Long idle periods Supply to the ECM

• Very light loads Certain diagnostic codes may prevent the engine
from starting. Connect Caterpillar Electronic
Technician (ET) and check for active codes and/or
Recommended Actions for logged codes. Troubleshoot any codes that are
present before continuing with this procedure.
Water Temperature Regulator
Note: If Cat ET will not communicate with the
A regulator that is stuck open can cause overcooling. ECM, the problem is most likely with the electrical
Overcooling also occurs when the water temperature power supply to the ECM. Refer to Troubleshooting,
regulator is stuck between the following positions: “Electrical Power Supply - Test”.
open position and closed position. Coolant leaks
that are around the water temperature regulator can Electrical Connectors
cause overcooling. An example would be a leak in
the vent line. Disconnect the J14/P14 ECM connector. Inspect
each connector for moisture and corrosion. Also,
Very Light Loads inspect the harness from the ECM to the sensors.
Refer to Troubleshooting, “Electrical Connectors -
Very light loads or a very slow engine speed can Inspect”.
cause overcooling. This overcooling is caused by the
low heat input of the engine. Personality Module or Incorrect Engine
Software
i03174921
Check for a active 252-11 diagnostic code. Also,
Engine Cranks but Does Not check for a active 252-12 diagnostic code. Refer to
Start Troubleshooting, “ECM/Personality Module - Test” if
the code is present.
SMCS Code: 1000-035; 1450-035
Flash File
Probable Causes Verify that the latest flash file has been installed into
the ECM.
• Diagnostic codes
32 SENR6477-06
Troubleshooting Section

Engine Speed Signal 5. Cold weather adversely affects the characteristics

of the fuel. Refer to the Operation and
1. Crank the engine and observe the engine speed Maintenance Manual for information on improving
on the Cat ET status screen. If Cat ET indicates the characteristics of the fuel during cold weather
zero rpm, refer to Troubleshooting, “Engine Speed operation.
- Test”.
Engine Shutdown Switches (if applicable)
Note: Upon initial cranking, the status for engine
speed may indicate that the engine speed signal is The engine shutdown switches should be in the
abnormal. This message will be replaced with an OFF position. Use Cat ET to verify the status of the
engine speed once the ECM is able to calculate a shutdown switches. When a shutdown occurs, the
speed from the signal. keyswitch must be turned to the OFF position for at
least 15 seconds before restarting the engine.
2. Ensure that the timing reference gear is installed
correctly. The engine will not start if the gear was
installed backward. Check for proper orientation
Rack Controls
between the crankshaft and camshaft drive gears.
Correct the orientation and/or replace the drive Refer to Troubleshooting, “Fuel Rack Solenoid -
Test”. Also, refer to Troubleshooting, “Sensor Signal
gear, if necessary. Refer to the Disassembly and
(Analog, Active) - Test”.
Assembly manual.

Air Inlet and Exhaust System Combustion

1. Check the air filter restriction indicator for a Check for mechanical problems in the combustion
system.
plugged filter. If necessary, service the engine.
Refer to the Operation and Maintenance Manual.
Overspeed Protection
2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems If equipped, the air shutoff solenoids must be
Operation/Testing and Adjusting. manually reset. Use Cat ET to verify the status of
the shutdown switches. Refer to Troubleshooting,
“Shutdown - Test” .
Fuel Supply
1. Visually check the fuel level. Do not rely on the fuel i03174820
gauge only. If necessary, add fuel. If the engine
has been run out of fuel, it will be necessary to Engine Does Not Crank
prime the fuel system. Refer to Operation and
Maintenance Manual for the correct procedure. SMCS Code: 1000-035; 1450-035

2. Check the fuel lines for the following problems: Probable Causes
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
• Batteries

3. Check the fuel tank for foreign objects which may

• Battery cables
block the fuel supply.
• Starting circuit
4. Prime the fuel supply system if any of the following
procedures have been performed:
• Starting motor solenoid
• Starting motor
• Replacement of the fuel filters
• Timing pin
• Service on the low pressure fuel supply circuit
Note: A sight glass in the supply line is helpful in
• Flywheel ring gear
diagnosing air in the fuel. Refer to the Systems
Operation/Testing and Adjusting manual for more
• Transmission (if applicable)
information.
• Engine accessories
• Hydraulic cylinder lock
• Internal engine problem
SENR6477-06 33
Troubleshooting Section

Recommended Actions Hydraulic Cylinder Lock

Batteries and/or Battery Cables Check for fluid in the cylinders (hydraulic cylinder
lock) by removing the individual unit injectors.
1. Inspect the main power switch, battery posts,
and battery cables for loose connections and Note: Drain the fuel from the cylinder head. Fuel will
for corrosion. If the battery cables are corroded, flow from the cylinder head into the cylinders when
remove the battery cables and clean the battery the unit injector is removed.
cables. Tighten any loose connections.
Internal Engine Problem
2. Inspect the batteries.
Disassemble the engine. Refer to the Disassembly
a. Charge the batteries. Refer to Special and Assembly manual. Inspect the internal
Instruction, SEHS7633, “Battery Test components for the following conditions:
Procedure”.
• Seizure
b. Load test the batteries. Refer to Special
Instruction, SEHS9249, “Use of 4C-4911 • Broken components
Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries”. • Bent components

Starting Motor Solenoid or Starting i03176721

Circuit
Engine Misfires, Runs Rough
• Test the operation of the starting motor solenoid. or Is Unstable
• Check the wiring to the starting motor solenoid. SMCS Code: 1000-035

Starting Motor or Flywheel Ring Gear Note: If the symptom is intermittent and the symptom
cannot be repeated, refer to Troubleshooting,
• Test the operation of the starting motor. “Intermittent Low Power or Power Cutout is
Intermittent”. If the symptom is consistent and
• Inspect the pinion for the starting motor and the the symptom can be repeated, continue with this
flywheel ring gear for damage. procedure.

Timing Pin Probable Causes

• Verify that the timing pin was not left in the flywheel • Engine derate or active codes
housing.
• Cold mode
Transmission (if applicable) or Engine
Accessories • Electrical connectors

• Ensure free movement of the driveline. • Low compression (cylinder pressure)

• Remove any engine accessories that may lock up • Individual malfunctioning cylinder
the engine and inspect any engine accessories
that may lock up the engine. • Valve lash

The following list illustrates examples of engine • Faulty fuel injector nozzle
accessories that may lock up the engine:
• Throttle signal
• Hydraulic pump that is driven from the rear gear
group • Fuel supply

• Air compressor • Air inlet and exhaust system

• Engine oil pump

• Other components that are driven by the engine
34 SENR6477-06
Troubleshooting Section

Engine Derate or Active Codes 3. Perform all necessary repairs.

Some engine monitoring parameters that are capable 4. Ensure that the repairs have eliminated the faults.
of triggering an engine derate do not produce an
event code. Connect Caterpillar Electronic Technician Individual Malfunctioning Cylinders
(ET) in order to check for a derate of the engine.
1. With the engine speed at a fast idle, loosen
Certain diagnostic codes and may cause poor the high pressure fuel line to the fuel injector of
performance. Use Cat ET to check for active codes number one cylinder. Note if there is any reduction
and for logged codes. Troubleshoot any codes that in engine speed. Tighten the high pressure fuel
are present before you continue with this procedure. line to the fuel injector.
Note: Although a sensor's signal may be in the 2. Individually repeat this procedure for each fuel
operational range of the sensor, the signal may injector. If there is no reduction in the engine
not represent the actual reading. Use Cat ET to speed, investigate the cause of the malfunction.
check that the pressures and the temperatures are
fluctuating. Also check that the values are reasonable
for the conditions that are present. Valve Lash
Check valve lash on misfiring cylinder. Refer
Cold Mode to Testing and Adjusting, “Engine Valve Lash -
Inspect/Adjust” for the correct procedure.
The Electronic Control Module (ECM) limits engine
power during cold mode operation. The ECM may
cut out certain engine cylinders. This will increase Faulty Fuel Injector Nozzle
startability and this will reduce warm up time. Cold
Remove the suspect fuel injection nozzle. Test the
mode is activated whenever the engine coolant
temperature falls below a predetermined value. Cold nozzle by using the 5P-4150 Nozzle Testing Group.
Refer to Systems Operation, Testing and Adjusting,
mode remains active until the engine has warmed or
“Fuel System” for the proper testing procedure.
a time limit is exceeded.
Replace the fuel injector nozzles, as needed.
Electrical Connectors
Throttle Signal
Check for correct installation of the J14/P14 ECM
Monitor the status for “Throttle Position” on Cat ET.
connector. Refer to Troubleshooting, “Electrical
Verify that the status for “Throttle Position” is stable
Connectors - Inspect”.
and that the engine is able to reach high idle speed.
If a problem is suspected with the throttle, refer
Low Compression (Cylinder Pressure) to the appropriate troubleshooting procedure for
troubleshooting the throttle signal.
1. Perform a compression test. Refer to Systems
Operation, Testing and Adjusting, “Compression
- Test ”.
Fuel Supply
1. Visually check the fuel level in the fuel tank. Do not
2. If low compression is noted on any cylinders,
rely on the fuel gauge only. If necessary, add fuel
investigate the cause and rectify the cause.
to the fuel tank. If the engine has been run out of
fuel, it will be necessary to purge the air from the
Possible causes of low compression are shown
fuel system. Refer to Operation and Maintenance
in the following list:
Manual for the correct procedure.
• Loose glow plugs (if equipped) 2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
• Faulty piston problems are found with the fuel lines, repair the
lines and/or replace the lines.
• Faulty piston rings
3. Check the fuel tank for debris or foreign objects
• Worn cylinder bores which may block the fuel supply.
• Worn valves
NOTICE
• Faulty cylinder head gasket Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
• Damaged cylinder head minutes before cranking the engine again.
SENR6477-06 35
Troubleshooting Section

4. Prime the fuel system if any of the following

procedures have been performed:

• Replacement of the fuel filters

• Service on the low pressure fuel supply circuit
Note: Check the fuel system for air. Refer to Systems
Operation/Testing and Adjusting for information that
is related to checking the fuel system for air.

5. Check fuel quality. Cold weather adversely

affects the characteristics of the fuel. Refer to the
engine's Operation and Maintenance Manual for
information on improving the characteristics of the
fuel during cold weather operation.

6. Check the filtered fuel pressure while the

engine is being cranked. Refer to Systems
Operation/Testing and Adjusting for the test
procedure and for the correct pressure values.

If the fuel pressure is low, replace the fuel filters.

Clean the primary filter/water separator of debris.
Refer to the Operation and Maintenance Manual
for details.

If the fuel pressure is still low, check the operation

of the fuel pressure regulating valve. Also, check
for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting
for test information.

Air Inlet and Exhaust System

1. Check for an air filter restriction. Clean plugged air
filters or replace plugged air filters. Refer to the
Operation and Maintenance Manual.

2. Check the air inlet and exhaust system for

restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting for information on
inspecting the air inlet and exhaust system.

i03266761

Engine Overspeeds
SMCS Code: 1915-035

Use this procedure in order to troubleshoot an engine

overspeed or use this procedure if the following
diagnostic code is active.
36 SENR6477-06
Troubleshooting Section

Table 15
Diagnostic Code
Description Flash Code Default Conditions which System Response
Generate this Code
190-00 Engine Speed Sensor 35 The engine has exceeded The code is logged. Also,
: High the trip point for engine the shutdown solenoid will
overspeed for the delay time. de-energize until the engine
speed is below 2420 rpm.

Probable Causes Diagnostic Codes and/or Event Codes

• Intake air is combustible. Certain diagnostic codes and/or event codes may
cause an engine shutdown. Connect Caterpillar
• Sudden drop of load Electronic Technician (ET) and check for active codes
and for logged codes. Troubleshoot any codes that
are present prior to continuing with this procedure.
Recommended Actions
Intake Air is Combustible Electrical Connectors

Check for hydrocarbons in the surrounding 1. Check for correct installation of the J14/P14
connector for the Electronic Control Module
atmosphere. Do not operate the engine in an
(ECM). Also, thoroughly inspect the connectors
environment with hydrocarbons in the surrounding
atmosphere. for the engine speed/timing sensors. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
Sudden Drop of Load 2. Inspect the battery wires from the ECM to the
battery compartment. Refer to the Schematic for
Decrease the load on the engine gradually. specific wiring information. Inspect the wires and
connectors to all circuit protection for the engine.
i03177440
Check the power and ground connections to
the ECM. Check any engine shutdown switches
Engine Shutdown Is and associated wiring. Refer to Troubleshooting,
“Electrical Power Supply - Test”.
Intermittent
SMCS Code: 1900-035 Aftermarket Engine Protection Devices
Check any aftermarket engine protection devices for
Probable Causes proper operation. These devices usually interrupt
power to the ECM.
• Diagnostic codes
Fuel Supply
• Electrical connectors
1. Visually check the fuel level in the fuel tank. Do not
• Aftermarket engine protection devices rely on the fuel gauge only. If necessary, add fuel
to the fuel tank. If the engine has been run out of
• Fuel supply fuel, it will be necessary to purge the air from the
fuel system. Refer to Operation and Maintenance
• Fuel shutoff solenoid Manual for the correct procedure.
• Sensor supply voltage 2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
• Rack controls problems are found with the fuel lines, repair the
lines and/or replace the lines.
• Engine speed sensor
3. Check the fuel tank for debris or foreign objects
• ECM or personality module which may block the fuel supply.
• Overspeed protection
SENR6477-06 37
Troubleshooting Section

Rack Controls
NOTICE
Do not crank the engine continuously for more than Check the rack solenoid for proper operation.
30 seconds. Allow the starting motor to cool for two Refer to Troubleshooting, “Fuel Rack Solenoid
minutes before cranking the engine again. - Test” for troubleshooting procedures. Refer to
Troubleshooting, “Fuel Control - Test” in order to
troubleshoot the dynamic rack controls. Also, refer to
4. Prime the fuel system if any of the following Troubleshooting, “Sensor Signal (Analog, Active) -
procedures have been performed: Test” for procedures to troubleshoot the rack position
sensor.
• Replacement of the fuel filters
Engine Speed Sensor
• Service on the low pressure fuel supply circuit
Make sure that the engine speed sensor is installed
Note: Check the fuel system for air. Refer to Systems
correctly. Refer to Troubleshooting, “Engine Speed -
Operation/Testing and Adjusting for information that
Test”.
is related to checking the fuel system for air.
Make sure that the timing wheel is correctly installed.
5. Check fuel quality. Cold weather adversely
affects the characteristics of the fuel. Refer to the
engine's Operation and Maintenance Manual for ECM or Personality Module
information on improving the characteristics of the
fuel during cold weather operation. Check for proper operation of the ECM and the
personality module. Refer to Troubleshooting, “ECM
6. Check the filtered fuel pressure while the - Replace” for the troubleshooting procedures. Also,
engine is being cranked. Refer to Systems refer to Troubleshooting, “ECM Software - Install” in
Operation/Testing and Adjusting for the test order to troubleshoot the personality module.
procedure and for the correct pressure values.
Overspeed Protection
If the fuel pressure is low, replace the fuel filters.
Clean the primary filter/water separator of debris. Make sure that the engine speed switch is operating
Refer to the Operation and Maintenance Manual correctly. Refer to Troubleshooting, “Overspeed -
for details. Calibrate” for the troubleshooting procedures.

If the fuel pressure is still low, check the operation

i03177143
of the fuel pressure regulating valve. Also, check
for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting
Engine Stalls Immediately
for test information. After Starting
Fuel Shutoff Solenoid SMCS Code: 1000-035; 1900-035

Check the fuel shutoff solenoid for proper operation. Probable Causes
Refer to Troubleshooting, “Fuel Shutoff - Test” .
• Fuel shutoff solenoid
Sensor Supply Voltage
• Electrical connectors
1. Check for logged diagnostic codes.
• Fuel supply
2. Check the following components for damage and
for abrasion to the power supply wires. • Rack controls
• Rack position sensor • Engine speed sensor
• Engine speed sensor • Throttle signal
• ECM • Overspeed protection
• Excessive load
38 SENR6477-06
Troubleshooting Section

Fuel Shutoff Solenoid Rack Controls

Check the fuel shutoff solenoid for proper operation. Check the rack solenoid for proper operation.
Refer to Troubleshooting, “Fuel Shutoff - Test” . Refer to Troubleshooting, “Fuel Rack Solenoid
- Test” for troubleshooting procedures. Refer to
Electrical Connectors Troubleshooting, “Fuel Control - Test” in order to
troubleshoot the Dynamic Rack Controls. Also, refer
Check for correct installation of the J14/P14 ECM to Troubleshooting, “Sensor Signal (Analog, Active) -
connector. Refer to Troubleshooting, “Electrical Test” for procedures to troubleshoot the rack position
Connectors - Inspect”. sensor.

Fuel Supply Engine Speed Sensor

1. Visually check the fuel level in the fuel tank. Do not Make sure that the engine speed sensor is installed
rely on the fuel gauge only. If necessary, add fuel correctly. Refer to Troubleshooting, “Engine Speed -
to the fuel tank. If the engine has been run out of Test”.
fuel, it will be necessary to purge the air from the
fuel system. Refer to Operation and Maintenance Make sure that the timing wheel is correctly installed.
Manual for the correct procedure.
Throttle Signal
2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If Monitor the status for “Throttle Position” on Cat ET.
problems are found with the fuel lines, repair the Verify that the status for “Throttle Position” is stable
lines and/or replace the lines. and that the engine is able to reach high idle speed.
If a problem is suspected with the throttle, refer
3. Check the fuel tank for debris or foreign objects to the appropriate troubleshooting procedure for
which may block the fuel supply. troubleshooting the throttle signal.

4. Prime the fuel system if any of the following Overspeed Protection

procedures have been performed:
Make sure that the engine speed switch is operating
• Replacement of the fuel filters correctly. Refer to Troubleshooting, “Overspeed -
Calibrate” for the troubleshooting procedures.
• Service on the low pressure fuel supply circuit
Note: Check the fuel system for air. Refer to Systems Excessive Load
Operation/Testing and Adjusting for information that
Make sure that the load is not excessive. Reduce the
is related to checking the fuel system for air.
load. If necessary, disengage the driven equipment
and test the engine.
5. Check fuel quality. Cold weather adversely
affects the characteristics of the fuel. Refer to the
engine's Operation and Maintenance Manual for i03176562
information on improving the characteristics of the
fuel during cold weather operation. Engine Top Speed Is Not
6. Check the filtered fuel pressure while the
Obtained
engine is being cranked. Refer to Systems
SMCS Code: 1915-035
Operation/Testing and Adjusting for the test
procedure and for the correct pressure values.
Probable Causes
If the fuel pressure is low, replace the fuel filters.
Clean the primary filter/water separator of debris. • Cold mode
Refer to the Operation and Maintenance Manual
for details. • Engine derate or active codes
If the fuel pressure is still low, check the operation • Programmable parameters
of the fuel pressure regulating valve. Also, check
for the proper operation of the fuel transfer pump. • Throttle position signal
Refer to Systems Operation/Testing and Adjusting
for test information. • Fuel supply
• Air inlet and exhaust system
SENR6477-06 39
Troubleshooting Section

• Inlet manifold pressure Fuel Supply

• Rack controls 1. Visually check the fuel level in the fuel tank. Do not
rely on the fuel gauge only. If necessary, add fuel
• Electrical connectors to the fuel tank. If the engine has been run out of
fuel, it will be necessary to purge the air from the
fuel system. Refer to Operation and Maintenance
Recommended Actions Manual for the correct procedure.
Note: If the problem only occurs under certain
2. Check the fuel lines for the following problems:
conditions, test the engine under those conditions.
Examples of certain conditions are high engine restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
speed, full load, and engine operating temperature.
lines and/or replace the lines.
Troubleshooting the symptoms under other
conditions can give misleading results.
NOTICE
Cold Mode Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
The Electronic Control Module (ECM) limits engine minutes before cranking the engine again.
power during cold mode operation. The ECM may
cut out certain engine cylinders. This will increase 3. Check the fuel tank for debris or foreign objects
startability, and this will reduce warm-up time. Cold which may block the fuel supply.
mode is activated whenever the engine coolant
temperature falls below a predetermined value. Cold 4. Prime the fuel system if any of the following
mode remains active until the engine has warmed, or procedures have been performed:
a time limit is exceeded.
• Replacement of the fuel filters
Engine Derate or Active Codes
• Service on the low pressure fuel supply circuit
Some engine monitoring parameters that are capable
of triggering an engine derate do not produce an Note: Check the fuel system for air. Refer to Systems
event code. Connect Caterpillar Electronic Technician Operation/Testing and Adjusting for information that
(ET) in order to check for a derate of the engine. is related to checking the fuel system for air.

Certain diagnostic codes may cause poor 5. Check fuel quality. Cold weather adversely
performance. Use Cat ET to check for active codes affects the characteristics of the fuel. Refer to the
and for logged codes. Troubleshoot any codes that engine's Operation and Maintenance Manual for
are present before you continue with this procedure. information on improving the characteristics of the
fuel during cold weather operation.
Note: Although a sensor's signal may be in the
operational range of the sensor, the signal may 6. Check the filtered fuel pressure while the
not represent the actual reading. Use Cat ET to engine is being cranked. Refer to Systems
check that the pressures and the temperatures Operation/Testing and Adjusting for the test
are fluctuating. Also, check that the values are procedure and for the correct pressure values.
reasonable for the conditions that are present.
If the fuel pressure is low, replace the fuel filters.
Programmable Parameters Clean the primary filter/water separator of debris.
Refer to the Operation and Maintenance Manual
Record the full load settings and the full torque for details.
settings. The settings should be programmed to
the values on the engine information plate. Refer to If the fuel pressure is still low, check the operation
Troubleshooting, “Programmable Parameters” for of the fuel pressure regulating valve. Also, check
more information. for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting
for test information.
Throttle Position Signal
Monitor the status for “Throttle Position” on Cat ET. Air Inlet and Exhaust System
Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed. 1. Check for an air filter restriction. Clean plugged air
If a problem is suspected with the throttle, refer filters or replace plugged air filters. Refer to the
to the appropriate troubleshooting procedure for Operation and Maintenance Manual.
troubleshooting the throttle signal.
40 SENR6477-06
Troubleshooting Section

2. Check the air inlet and exhaust system for

restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting for information on
inspecting the air inlet and exhaust system.

Inlet Manifold Pressure

Check the inlet manifold pressure sensor for proper
operation. The calibration should also be checked.
Refer to Troubleshooting, “Inlet Manifold Pressure -
Test” for troubleshooting procedures.

Rack Controls
Check the rack solenoid for proper operation.
Refer to Troubleshooting, “Fuel Rack Solenoid
- Test” for troubleshooting procedures. Refer to
Troubleshooting, “Fuel Control - Test” in order to
troubleshoot the dynamic rack controls. Also, refer to
Troubleshooting, “Sensor Signal (Analog, Active) -
Test” for procedures to troubleshoot the rack position
sensor.

Electrical Connectors
Check for correct installation of the J14/P14 ECM
connector. Refer to Troubleshooting, “Electrical
Connectors - Inspect”.

i03266811

Oil Pressure Is Low

SMCS Code: 1348-035-PX

NOTICE
Do not operate the engine with low oil pressure. En-
gine damage will result. If the measured engine oil
pressure is low, discontinue engine operation until the
problem is corrected.

Use this procedure in order to troubleshoot low

engine oil pressure or use this procedure if the
below diagnostic code is active. You must access
the monitoring system on the Caterpillar Electronic
Technician (ET) in order to view the current trip points
for these codes.

Table 16
Event Code
Code and Description Flash Code Conditions which Generate System Response
this Code
100-01 Low Oil Pressure 46 The engine oil pressure is The engine will be derated.
Warning below a map dependent The code is logged.
value for one second. The
engine has been running for
15 seconds.
SENR6477-06 41
Troubleshooting Section

Probable Causes i03177660

• Low engine oil level Power Is Intermittently Low or

Power Cutout Is Intermittent
• Dirty engine oil filters
SMCS Code: 1000-035-PWR
• Restriction at engine oil pump
• Restriction in engine oil cooler(s) Probable Causes
• Fuel dilution of engine oil • Diagnostic codes

• Camshaft and/or camshaft bearings • Electrical connectors

• Crankshaft bearings • Aftermarket engine protection devices

• Fuel supply
Recommended Actions
• Throttle position sensor
Engine Oil Level
• Rack controls
Inspect the engine oil level. If the engine oil level is
low, add engine oil. • ECM or personality module

Oil Filter Diagnostic Codes and/or Event Codes

Inspect the engine oil filter. If the engine oil filter Certain diagnostic codes and/or event codes may
is dirty, install a new engine oil filter. Check the cause an engine shutdown. Connect Caterpillar
operation of the bypass valve for the filter. Clean the Electronic Technician (ET) and check for active codes
bypass valve and the housing. If necessary, install and for logged codes. Troubleshoot any codes that
new parts. are present prior to continuing with this procedure.

Engine Oil Pump Electrical Connectors

Check for blockage of the inlet screen in the engine 1. Check for correct installation of the J14/P14
oil pump. Examine the engine oil pump for excessive connector for the Electronic Control Module
wear. (ECM). Also, thoroughly inspect the connectors
for the engine speed/timing sensors. Refer to
Oil Cooler Troubleshooting, “Electrical Connectors - Inspect”.

Inspect the engine's oil cooler. Clean the engine oil 2. Inspect the battery wires from the ECM to the
cooler core(s) and/or install new engine oil cooler battery compartment. Refer to the Schematic for
core(s). specific wiring information. Inspect the wires and
connectors to all circuit protection for the engine.
Check the power and ground connections to
Fuel Dilution of Engine Oil the ECM. Check any engine shutdown switches
and associated wiring. Refer to Troubleshooting,
Check for the presence of fuel in lubricating oil. “Electrical Power Supply - Test”.

Camshaft and/or Crankshaft Aftermarket Engine Protection Devices

Inspect the camshaft and/or camshaft bearings. Check any aftermarket engine protection devices for
Check the components for excessive wear. Excessive proper operation. These devices usually interrupt
wear is an indication of a blocked oil passage. Inspect power to the ECM.
the crankshaft and/or crankshaft bearings. Check the
components for excessive wear.
42 SENR6477-06
Troubleshooting Section

Fuel Supply Throttle Signal

1. Visually check the fuel level in the fuel tank. Do not Monitor the status of the “Throttle Position” on Cat
rely on the fuel gauge only. If necessary, add fuel ET. Verify that the status of the “Throttle Position” is
to the fuel tank. If the engine has been run out of stable and that the engine is able to reach high idle
fuel, it will be necessary to purge the air from the speed. If a problem is suspected with the throttle,
fuel system. Refer to Operation and Maintenance refer to the appropriate troubleshooting procedure for
Manual for the correct procedure. troubleshooting the throttle signal.

2. Check the fuel lines for the following problems: Rack Controls
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the Check the rack solenoid for proper operation.
lines and/or replace the lines. Refer to Troubleshooting, “Fuel Rack Solenoid
- Test” for troubleshooting procedures. Refer to
3. Check the fuel tank for debris or foreign objects Troubleshooting, “Fuel Control - Test” in order to
which may block the fuel supply. troubleshoot the dynamic rack controls. Also, refer
to Troubleshooting, “Sensor Signal (Analog, Active)
NOTICE - Test” for procedures to troubleshoot the Rack
Do not crank the engine continuously for more than Position Sensor.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. ECM or Personality Module
Check for proper operation of the ECM and the
4. Prime the fuel system if any of the following
personality module. Refer to Troubleshooting, “ECM
procedures have been performed:
- Replace” for the troubleshooting procedures. Also,
refer to Troubleshooting, “ECM Software - Install” in
• Replacement of the fuel filters order to troubleshoot the personality module.
• Service on the low pressure fuel supply circuit
i03175180
Note: Check the fuel system for air. Refer to Systems
Operation/Testing and Adjusting for information that Service Meter Problem
is related to checking the fuel system for air.
SMCS Code: 7478-035
5. Check fuel quality. Cold weather adversely
affects the characteristics of the fuel. Refer to the Probable Causes
engine's Operation and Maintenance Manual for
information on improving the characteristics of the
fuel during cold weather operation.
• Overspeed protection system

6. Check the filtered fuel pressure while the Recommended Actions

engine is being cranked. Refer to Systems
Operation/Testing and Adjusting for the test If the Electronic Modular Control Panel (EMCP) is not
procedure and for the correct pressure values. installed, refer to Troubleshooting, “Speed Control -
Test”.
If the fuel pressure is low, replace the fuel filters.
Clean the primary filter/water separator of debris.
Refer to the Operation and Maintenance Manual
for details.

If the fuel pressure is still low, check the operation

of the fuel pressure regulating valve. Also, check
for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting
for test information.
SENR6477-06 43
Troubleshooting Section

Circuit Tests
i03182967

Atmospheric Pressure - Test

SMCS Code: 1923-038

System Operation Description:

The atmospheric pressure sensor provides the ECM

with an atmospheric pressure signal. The ECM uses
the signal to calibrate the inlet manifold pressure
sensor. The information is also used to protect the
engine. The ECM limits the fuel rate during high
altitude conditions.

Table 17
Diagnostic Code

Code and Description Flash Default Conditions which Generate System Response
Code this Code

106-01 Low 26 The atmospheric pressure is valid, but The diagnostic code is logged. Also, the
Atmospheric Pressure the pressure is below 0.68 VDC. This low oil pressure lamp is illuminated. The
is a normal occurrence at altitudes low atmospheric pressure or the high
above 1500 m (4921 ft). altitude derate is active.
106-03 Atmospheric 26 Voltage is above 4.8 VDC for one The diagnostic code is active and logged.
Pressure voltage high second. Also, there are no sensor The ECM will use a default value of 100 kPa
supply diagnostic codes. (14.5 psi). This value will also be displayed
on an electronic service tool.
106-04 Atmospheric 26 The atmospheric pressure signal The diagnostic code is active and logged.
Pressure voltage low voltage is less than 0.2 VDC for at The ECM will use a default value of 100 kPa
least one second. Also, there are no (14.5 psi). This value will also be displayed
sensor supply diagnostic codes. on an electronic service tool.

106-10Atmospheric 26 The Atmospheric pressure is The diagnostic code is logged if the engine
Pressure signal rate changing abnormally. has been running for 15 seconds.
of change

g01625935
Illustration 15
44 SENR6477-06
Troubleshooting Section

g01635455
Illustration 16
(30) +5 VDC (34) Atmospheric pressure (35) Analog return

Test Step 1. Inspect the Electrical Test Step 2. Check for Active Open or
Connectors and the Wiring Harness Short Diagnostic Codes
A. Remove electrical power from the ECM. A. Connect Caterpillar Electronic Technician
(ET) to the service tool connector. Refer to
B. Thoroughly inspect the connector for the Troubleshooting, “Electronic Service Tools”.
atmospheric pressure sensor and the P15
connector. Inspect the ECM connector J14/P14. B. Turn the engine control switch to the ON position.
Refer to Troubleshooting, “Electrical Connectors - The engine should remain off.
Inspect” for details.
C. Check for active diagnostic codes 106-03 or
C. Perform a 45 N (10 lb) pull test on each of the 106-04.
wires that are associated with the circuit for the
atmospheric pressure sensor. Expected Result:

D. Check the allen head screw on the ECM connector There are no active diagnostic codes.
for the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct Results:
torque values.
• OK – There are no active diagnostic codes.
Expected Result: Proceed to Test Step 5.

All connectors, pins, and sockets are completely • Not OK – The service tool shows a short circuit.
coupled and/or inserted, and the harness and wiring Proceed to Test Step 4.
are free of corrosion, of abrasion and of pinch points.
• Not OK – The service tool shows a open circuit.
Results: Proceed to Test Step 3.

• OK – The connectors and wiring are OK. Proceed Test Step 3. Check for Opens in the
to Test Step 2. Wiring
• Not OK – There is a problem with the connectors A. Remove electrical power from the ECM.
and/or the wiring.
B. Disconnect the J14/P14 ECM connector and the
Repair: Repair the wiring and connectors or connector for the atmospheric pressure sensor.
replace the wiring or the connectors. Ensure that
all of the seals are properly connected. C. Measure the resistance between the following
terminals:
Verify that the repair eliminates the problem.
• P14-30 (ECM connector) to pin J15-A on the
STOP. connector for the atmospheric pressure sensor

• P14-35 (ECM connector) to pin J15-B on the

connector for the atmospheric pressure sensor
SENR6477-06 45
Troubleshooting Section

• P14-34 (ECM connector) to pin J15-C on the Test Step 5. Check the Supply Voltage at
connector for the atmospheric pressure sensor the Sensor Connector
Results: A. Disconnect the atmospheric pressure sensor.

• OK – The resistance indicates a short circuit. B. Restore electrical power to the ECM.
There are no opens in the wiring. Proceed to Test
Step 4.

• Not OK – The resistance indicates an open circuit.

There is an open circuit or excessive resistance in
the harness or the connectors.

Repair: Repair the circuit.

Verify that the repair eliminates the problem.

STOP.

Test Step 4. Check the Wiring for a Short

Circuit
g01356605
Illustration 17
A. Measure the resistance between the following Harness connector for the atmospheric pressure sensor
terminals: (A) +5 VDC
(B) Return
Note: Wiggle the harness during the following (C) Signal
measurements in order to reveal an intermittent
condition. C. Measure the voltage between terminals (A) and (
B) at the harness connector for the atmospheric
• P14-30 (ECM connector) to pin J15-B and pressure sensor.
pinP14-30 (ECM connector) to J15-C on the
connector for the atmospheric pressure sensor D. Remove electrical power from the ECM.

• P14-35 (ECM connector) to pin J15-C and Expected Result:

P14-35 (ECM connector) to pin J15-A on the
connector for the atmospheric pressure sensor The voltage measurement is +5.0 ± 0.25 VDC.

• P14-34 (ECM connector) to pin J15-B and Results:

P14-34 (ECM connector) to pin J15-A on the
connector for the atmospheric pressure sensor • OK – The voltage measurement is +5.0 ± 0.25
VDC. The supply voltage is reaching the sensor.
Expected Result: Proceed to Test Step 7.

Each check of the resistance indicates an open • Not OK – The voltage measurement is not +5.0 ±
circuit. 0.25 VDC. The digital sensor supply voltage is not
reaching the sensor. Proceed to Test Step 6.
Results:
Test Step 6. Check the +5 Volt Supply
• OK – Each check of the resistance indicates an Voltage at the ECM
open circuit. Proceed to Test Step 5.
A. Remove electrical power from the ECM.
• Not OK – At least one check of the resistance
does not indicate an open circuit. There is a B. Disconnect the J14/P14 ECM connector.
problem in the harness. There may be a problem
in a connector. C. Fabricate a wire jumper that is long enough to be
used to measure the supply voltage at the ECM
Repair: Repair the wire and/or the connector, connector. Crimp a connector socket to one end
when possible. Replace parts, if necessary. Verify of the wire.
that the problem is resolved.
D. Remove the wire from terminal location P14-30
STOP. (+5 V sensor supply). Install a wire jumper into
the socket P14-30.
46 SENR6477-06
Troubleshooting Section

E. Connect the J14/P14 ECM connector. i03178200

F. Restore electrical power to the engine ECM. Coolant Level - Test

G. Measure the voltage between the wire jumper SMCS Code: 1395-038; 1439-038-CLT;
in P14-30 (+5 VDC sensor supply) and engine 7422-038-CLT
ground.
System Operation Description:
H. Remove electrical power from the ECM.
Use this procedure to troubleshoot any suspect
I. Remove the wire jumper and replace all wires. problems with the circuit for the coolant level sensor.

Expected Result: The coolant level sensor monitors the engine coolant
level in order to warn the operator in the event that
The voltage measurement is +5.0 ± 0.25 VDC. the coolant level is low.

Results: The coolant level sensor contains no moving

parts. The sensor provides the same function as a
• OK – The voltage measurement is +5.0 ± 0.25 switch. The state of the switch is dependent on the
VDC. The ECM is operating correctly. Proceed to capacitance value that is detected at the probe of the
Test Step 7. sensor. The sensor contains a probe that is covered
with plastic.
• Not OK – The voltage measurement is not +5.0 ±
0.25 VDC. When the sensor's probe is immersed in coolant, the
sensor senses a particular capacitance. The sensor's
Repair: Replace the ECM. Refer to electronics react by sinking the signal to the sensor
Troubleshooting, “ECM - Replace”. return (ground).

STOP. The coolant level sensor requires +8 VDC to operate.

This voltage is supplied to the sensor by the ECM.
Test Step 7. Check for Signal Voltage at The voltage is supplied to terminal ( A) of the sensor.
the Sensor This supply voltage is also used by the coolant
temperature sensor and the rack position sensor.
A. Measure the voltage between P15/B and P15/C. A malfunction with the coolant level sensor or the
wiring of the sensor can cause problems with these
Expected Result: sensors. When the probe is not immersed in coolant,
approximately +5 VDC is sourced to the signal wire.
The measurement should be between 1.6 VDC and When this condition is detected by the Electronic
4.8 VDC. Control Module (ECM), a code is activated.

Results:

• OK – The voltage is between 1.6 VDC and 4.8

VDC.

Repair: Check the voltage between P14/35 and

P14/34. The voltage should be between 1.6 VDC
and 4.8 VDC. Repair the signal wire if the voltage
is not present.

STOP.

• NOT OK – The voltage is not present between

P15/B and P15/C.

Repair: Replace the sensor.

STOP.
SENR6477-06 47
Troubleshooting Section

g01624976
Illustration 18
Schematic for coolant level sensor

g01635514
Illustration 19
(10) +8 VDC (26) Coolant level (35) Analog return

The activation of the following code and/or a warning

lamp is probably caused by a low coolant level. The
next likely cause is a problem with the wiring harness,
a connector, or the sensor. The least likely cause is
a problem with the ECM.

Table 18
Diagnostic Code

Code and Flash Default Conditions which System Response

Description Code Generate this Code

111-01 Low Coolant 62 The coolant level sensor sends a The code is logged. Also, the diagnostic
Level Warning signal to the engines' Electronic lamp is illuminated.
Control Module (ECM) that indicates
a low coolant level.

Note: In order to log a fault, the sensor must detect B. Thoroughly inspect the connector for the
low coolant for ten seconds. coolant level sensor and the P7 connector.
Inspect the ECM connector J14/P14. Refer to
Use this procedure in order to troubleshoot any Troubleshooting, “Electrical Connectors - Inspect”
suspect problems with the coolant level sensor(s) for details.
or with the wiring circuit.
C. Perform a 45 N (10 lb) pull test on each of the
Test Step 1. Inspect the Electrical wires that are associated with the circuit for the
Connectors and the Wiring coolant level sensor.

A. Remove electrical power from the ECM. D. Check the allen head screw on the ECM connector
for the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct
torque values.
48 SENR6477-06
Troubleshooting Section

Expected Result: Results:

All connectors, pins, and sockets are completely • OK – The voltage measurement is +8.0 ± 0.4
coupled and/or inserted, and the harness and wiring VDC. The supply voltage is reaching the sensor.
are free of corrosion, of abrasion and of pinch points. Proceed to Test Step 3.

Results: • Not OK – The voltage measurement is not +8.0 ±

0.4 VDC. The digital sensor supply voltage is not
• OK – The connectors and wiring are OK. Proceed reaching the sensor. Proceed to Test Step 6.
to Test Step 2.
Test Step 3. Disconnect the Coolant
• Not OK – There is a problem with the connectors Level Sensor and Monitor the Status of
and/or the wiring. “Coolant Level”
Repair: Repair the wiring and connectors or A. Connect Caterpillar Electronic Technician
replace the wiring or the connectors. Ensure that (ET) to the service tool connector. Refer to
all of the seals are properly connected. Verify that Troubleshooting, “Electronic Service Tools”.
the repair eliminates the problem.
B. Disconnect the connector for the coolant level
Verify that the repair eliminates the problem. sensor.

STOP. C. Restore electrical power to the ECM.

Test Step 2. Check the Supply Voltage at D. Monitor the status of “Coolant Level” on Cat ET.
the Sensor Connector
Expected Result:
A. Disconnect the coolant level sensor.
The status changes from “OK” to “Low” when the
B. Restore electrical power to the ECM. sensor is disconnected.

Results:

• OK – The status is “Low” when the sensor is

disconnected.

Repair: The sensor is operating properly.

STOP.

• Not OK – The status is “OK” when the sensor is

disconnected. Proceed to Test Step 5.

Test Step 4. Short the Harness and

Monitor the Status of “Coolant Level”
g01356605
Illustration 20
Harness connector for the coolant level sensor A. Install a jumper wire between terminals (B) and
(A) +8 VDC (C) on the harness connector for the coolant level
(B) Return sensor.
(C) Signal
B. Monitor the status of “Coolant Level” on Cat ET
C. Measure the voltage between terminal (A) and while the jumper wire is installed.
terminal (B) at the harness connector for the
coolant level sensor. C. Remove the jumper wire.

D. Remove electrical power from the ECM. D. Remove electrical power from the ECM.

Expected Result: Expected Result:

The voltage measurement is +8.0 ± 0.4 VDC. The status changes from “Low” to “OK” when the
jumper wire is installed.
SENR6477-06 49
Troubleshooting Section

Results: Results:

• OK – The status changes from “Low” to “OK” • OK – The status is “Low” when the jumper wire is
when the jumper wire is installed. The ECM and not connected. The status is “OK” when the jumper
the wiring to the coolant level sensor are OK. wire is connected to engine ground. The ECM is
properly reading the sensor input.
Repair: Perform the following procedure:
Repair: Repair the signal wire between the ECM
and the connector for the sensor.

STOP.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
• Not OK – The ECM is not reading the sensor input.
components are cool. Loosen the cooling system Repair: Temporarily install a new ECM. Refer to
pressure cap slowly in order to relieve the pres- Troubleshooting, “ECM - Replace”.
sure.
If the new ECM works correctly, verify that the
1. Drain the coolant below the level of the coolant problem is resolved.
level sensor.
STOP.
2. Replace the sensor.
Test Step 6. Check the +8 Volt Supply
3. Fill the cooling system according to the Voltage at the ECM
procedure in the Operation and Maintenance
Manual. Verify that the problem is resolved. A. Disconnect the J14/P14 ECM connector.

STOP. B. Fabricate a wire jumper that is long enough to be

used to measure the supply voltage at the ECM
• Not OK – Shorting the harness does not affect the connector. Crimp a connector socket to one end
status on Cat ET. Proceed to Test Step 5. of the wire.

Test Step 5. Check the Operation of the C. Remove the wire from terminal location P14-10
ECM (+8 V sensor supply). Install a wire jumper into
the socket P14-10.
A. Fabricate a jumper wire that is long enough to
provide a test circuit across the ECM connector. D. Connect the J14/P14 ECM connector.
Crimp the connector sockets to each end of the
jumper wire. E. Restore electrical power to the engine ECM.

B. Remove the P14/26 signal wire from the P14 ECM F. Measure the voltage between the wire jumper in
connector. P14-10 (+8 V sensor supply) and engine ground.

C. Install one end of a jumper wire into the location G. Remove electrical power from the ECM.
for the signal wire. Ensure that the jumper wire is
isolated from other wires and from engine ground. H. Remove the wire jumper and replace all wires.

D. Restore electrical power to the ECM and monitor Expected Result:

the status of “Coolant Level” on Cat ET.
The voltage measurement is +8.0 ± 0.4 VDC.
E. Connect the other end of the jumper wire to
engine ground. Monitor the status of “Coolant Results:
Level” on Cat ET.
• OK – The voltage measurement is +8.0 ± 0.4
Expected Result: VDC. The ECM is operating correctly.

The status is “Low” when the jumper wire is not Repair: Repair the wiring harness or replace the
connected to engine ground. The status is “OK” when wiring harness.
the jumper wire is connected to engine ground.
STOP.

• Not OK – The voltage measurement is not +8.0

± 0.4 VDC.
50 SENR6477-06
Troubleshooting Section

Repair: Replace the ECM. Refer to

Troubleshooting, “ECM - Replace”.

STOP.

i03181154

Coolant Temperature - Test

SMCS Code: 1395-038; 1906-038

System Operation Description:

The coolant temperature sensor measures engine

coolant temperature. The Electronic Control Module
(ECM) uses the information to modify the engine
operation for cold operation. The ECM also uses this
information to alert the operator of a high coolant
temperature.

The following cold start strategy is activated when

the coolant temperature is below 60 °C (140 °F).

• Cold mode is deactivated if the engine has been

running for five minutes.

• Cold mode is deactivated when the engine speed

increases above 1200 rpm.

• The rack position is limited to 5 mm (0.20 inch)

during engine start-up (0 - 500 rpm).

The coolant temperature sensor requires +8 VDC

to operate. This supply voltage is also used by the
coolant level sensor and the rack position sensor.
A malfunction with the coolant temperature sensor
or the wiring of the sensor can cause problems with
these sensors.

Table 19
Diagnostic Code

Code and Flash Default Conditions which System Response

Description Code Generate this Code

110-03 Coolant 27 Voltage is above 4.7 VDC. Also, there The diagnostic code is logged. Also, the
Temperature voltage are no sensor supply diagnostic codes. coolant temperature is set to a default
high value of 0 °C (32 °F).
110-04 Coolant 27 Voltage is less than 0.3 VDC. The code is logged. Also, the alarm
Temperature voltage Also, there are no sensor supply lamp is illuminated.
low diagnostic codes.

g01625463
Illustration 21
SENR6477-06 51
Troubleshooting Section

g01635493
Illustration 22
(10) +8 VDC (20) Coolant temperature (35) Analog return

Use this procedure to troubleshoot any suspect Test Step 2. Check for Active Open or
problems with the circuit for the coolant temperature Short Diagnostic Codes
sensor.
A. Connect Caterpillar Electronic Technician
Test Step 1. Inspect the Electrical (ET) to the service tool connector. Refer to
Connectors and the Wiring Harness Troubleshooting, “Electronic Service Tools”.

A. Remove electrical power from the ECM. B. Turn the engine control switch to the ON position.
The engine should remain off.
B. Thoroughly inspect the connector for the coolant
temperature sensor and the P12 connector. C. Check for active diagnostic codes 110-03 or
Inspect the ECM connector J14/P14. Refer to 110-04.
Troubleshooting, “Electrical Connectors - Inspect”
for details. Expected Result:

C. Perform a 45 N (10 lb) pull test on each of the There are no active diagnostic codes.
wires that are associated with the circuit for the
coolant level sensor. Results:

D. Check the allen head screw on the ECM connector • OK – There are no active diagnostic codes.
for the proper torque. Refer to Troubleshooting, Proceed to Test Step 3.
“Electrical Connectors - Inspect” for the correct
torque values. • Not OK – The service tool shows an active 110-03
or 110-04 code.
Expected Result:
Repair: Refer to Troubleshooting, “Sensor Signal
All connectors, pins, and sockets are completely (Analog, Active) - Test ”.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points. STOP.

Results: Test Step 3. Check the Supply Voltage at

the Sensor Connector
• OK – The connectors and wiring are OK. Proceed
to Test Step 2. A. Disconnect the coolant temperature sensor.

• Not OK – There is a problem with the connectors B. Restore electrical power to the ECM.
and/or the wiring.

Repair: Repair the wiring and connectors or

replace the wiring or the connectors. Ensure that
all of the seals are properly connected. Verify that
the repair eliminates the problem.

STOP.
52 SENR6477-06
Troubleshooting Section

H. Remove the wire jumper and replace all wires.

Expected Result:

The voltage measurement is +8.0 ± 0.4 VDC.

Results:

• OK – The voltage measurement is +8.0 ± 0.4

VDC. The ECM is operating correctly.

Repair: Repair the wiring harness or replace the

wiring harness.

g01356605
STOP.
Illustration 23
Harness connector for the coolant level sensor • Not OK – The voltage measurement is not +8.0
(A) +8 VDC ± 0.4 VDC.
(B) Return
(C) Signal Repair: Replace the ECM. Refer to
Troubleshooting, “ECM - Replace”.
C. Measure the voltage between terminals (A) and
(B) at the harness connector for the coolant STOP.
temperature sensor.
Test Step 5. Check for Signal Voltage at
D. Remove electrical power from the ECM. the Sensor
Expected Result: A. Restore electrical power from the ECM.
The voltage measurement is +8.0 ± 0.4 VDC. B. Measure the voltage between J12/B and J12/C.
Results: C. Remove electrical power from the ECM.
• OK – The voltage measurement is +8.0 ± 0.4 Expected Result:
VDC. The supply voltage is reaching the sensor.
Proceed to Test Step 5. The measurement should be between 0.6 VDC and
3.9 VDC.
• Not OK – The voltage measurement is not +8.0 ±
0.4 VDC. The digital sensor supply voltage is not Results:
reaching the sensor. Proceed to Test Step 4.
• OK – The voltage is between 0.6 VDC and 3.9
Test Step 4. Check the +8 Volt Supply VDC. Proceed to Test Step 6.
Voltage at the ECM
• NOT OK – The voltage is not present between
A. Disconnect the J14/P14 ECM connector. J12/B and J12/C.
B. Fabricate a wire jumper that is long enough to be Repair: Replace the sensor.
used to measure the supply voltage at the ECM
connector. Crimp a connector socket to one end STOP.
of the wire.
Test Step 6. Check For Signal Voltage At
C. Remove the wire from terminal location P14-10 the ECM
(+8 V sensor supply). Install a wire jumper into
the socket P14-10. A. Remove electrical power from the ECM.
D. Connect the J14/P14 ECM connector. B. Remove the wires from P14/35 and P14/20.
E. Restore electrical power to the engine ECM. C. Restore electrical power to the engine ECM.
F. Measure the voltage between the wire jumper in D. Measure the voltage between wires P14/35 and
P14-10 (+8 V sensor supply) and engine ground. P14/20.
G. Remove electrical power from the ECM. E. Remove electrical power from the ECM.
SENR6477-06 53
Troubleshooting Section

F. Replace all wires.

Expected Result:

The measurement is between 0.6 VDC and 3.9 VDC.

Results:

• OK – The measurement is between 0.6 VDC and

3.9 VDC.

Repair: Replace the ECM. Refer to

Troubleshooting, “ECM - Replace”.

STOP.

• NOT OK – The measurement is not between 0.6

VDC and 3.9 VDC.

Repair: Repair the wiring harness or replace the

wiring harness.

STOP.

i03199347

ECM/Personality Module - Test

SMCS Code: 1901-038

System Operation Description:

Use this procedure to troubleshoot the electrical

system if a problem is suspected with the Electronic
Control Module (ECM) and/or if any one of the
diagnostic codes in Table 20 is active or easily
repeated.

Note: Also, use this procedure if the integrity of the

configuration parameters or the engine lifetime totals
is questionable.
54 SENR6477-06
Troubleshooting Section

Table 20
Diagnostic Codes Table
Code and Description Flash Code Conditions which System Response
Generate this Code
252-12 Calibration Module : 52 The engine will not start.
Failure The flash file is for a
Clearing this diagnostic code
different engine family
requires factory passwords.
or for a different engine
The personality module code
application.
must be reset to zero.
253-2 Personality Module 56 The code indicates a The diagnostic code is
: Erratic, Intermittent, or customer or a system displayed but not logged.
Incorrect parameter has not been
programmed.

254-12 53 The ECM has detected The CID-FMI may be viewed

Error of the Electronic Control a internal fault with on display modules or a
Module the ECM memory, the electronic service tool.
microprocessor or the The fault is logged in the
power supply. ECM memory. The ECM
will reset. The ECM can
not communicate with an
electronic service tool.

Test Step 1. Inspect the Electrical Repair: Repair the wiring and connectors or
Connectors and the Wiring Harness replace the wiring or the connectors. Ensure that
all of the seals are properly connected. Verify that
A. Remove electrical power from the ECM. the repair eliminates the problem.

B. Thoroughly inspect connector P17/J17. Verify that the repair eliminates the problem.
Inspect the ECM connector J14/P14. Refer to
Troubleshooting, “Electrical Connectors - Inspect” STOP.
for details.
Test Step 2. Check The ECM Personality
C. Perform a 45 N (10 lb) pull test on each of the Module
wires that are associated with the circuit.
A. Turn the engine control switch to the OFF position.
D. Check the allen head screw on the ECM connector
for the proper torque. Refer to Troubleshooting, B. Remove the personality module access cover.
“Electrical Connectors - Inspect” for the correct
torque values. C. Remove the personality module. Refer to
Troubleshooting, “ECM Software - Install” for
Expected Result: details.

All connectors, pins, and sockets are completely D. Inspect the personality module for physical
coupled and/or inserted, and the harness and wiring damage or corrosion.
are free of corrosion, of abrasion and of pinch points.
E. Inspect the personality module socket inside the
Results: ECM for physical damage or corrosion.

• OK – All connectors, pins, and sockets are F. Reinstall the personality module.
completely coupled and/or inserted, and the
harness and wiring are free of corrosion, of Note: Do not use excessive force to insert the
abrasion and of pinch points. Proceed to Test Step personality module. The personality module is keyed
2. and the personality module will only install one way.
A click can be felt when the personality module is
• NOT OK – There is a problem with the connectors installed correctly. Make sure that the personality
and/or the wiring. module is completely seated into the socket. Take
care to not damage the O-ring during installation.
SENR6477-06 55
Troubleshooting Section

Expected Result: Repair: Check the power supply to the ECM.

Inspect the service tool connectors and wiring.
The personality module is free of damage and Refer to Troubleshooting, “Electronic Service Tool
corrosion. The personality module is firmly seated in Does Not Communicate” for more information.
the socket.
STOP.
Results:
Test Step 4. Review Parameters And Data
• OK – The personality module is free of damage
and corrosion. The personality module is firmly A. Turn the engine control switch to the ON position.
seated in the socket. Proceed to Test Step 3.
B. Use Cat ET to review the system configuration
• NOT OK – The personality module is not free of parameters and the engine lifetime totals.
damage and corrosion or the personality module
is not firmly seated in the socket. C. Check for active diagnostic event codes and for
logged diagnostic event codes.
Repair: If necessary, repair the personality module.
Refer to Troubleshooting, “Electrical Connectors - Expected Result:
Inspect” for more information.
The parameters and totals are correct.
STOP.
Results:
Test Step 3. Check the Part Number of
the Personality Module • OK – The parameters and totals are correct.
A. Connect an Caterpillar Electronic Technician to Repair: The ECM and the personality module are
the service tool connector. working correctly.

B. Turn the engine control switch to the ON position. STOP.

C. Use Cat ET to verify that the personality module • NOT OK – The parameters and totals are
part number agrees with the original engine incorrect.
arrangement.
Repair: Attempt to reprogram the parameters.
Note: If a failure has occurred, temporarily install a If the problem is not resolved, replace the ECM.
new part, and thoroughly retest the system. Refer to Troubleshooting, “ECM - Replace” for
more information.
Expected Result:
STOP.
Cat ET communicates with the ECM and the correct
personality module is displayed.
i03187771

Results: Electrical Power Supply - Test

• OK – Cat ET communicates with the ECM and the SMCS Code: 1401-038
correct personality module is displayed. Proceed
to Test Step 4. System Operation Description:
• NOT OK – The Cat ET does not display the correct The Electronic Control Module (ECM) receives
personality module. electrical power through the customer connector
(J14/P14). Typically, the ECM is powered whenever
Repair: Install the correct personality module. the engine control switch is turned to the ON position.
Aftermarket engine protection devices are often
STOP. wired in order to interrupt supply voltage to the ECM.
Check for proper installation and operation of the
• NOT OK – Cat ET does not communicate with the engine protection devices.
ECM.
56 SENR6477-06
Troubleshooting Section

Use this test if there are intermittent engine

shutdowns or if a difficulty in starting is not
accompanied by loss of electrical accessories.
Engine shutdowns that are accompanied by a loss of
other electrical accessories indicate a problem in the
keyswitch. This does not indicate a problem in the
wiring at the engine's ECM. Verify that there are no
problems with the starting system or the charging
system before you use this test.

g01626598
Illustration 24

g01635537
Illustration 25
(1) + Battery (21) - Battery

Use this procedure to troubleshoot the electrical

system if a problem is suspected with the power to
the engine's Electronic Control Module (ECM) or if
the diagnostic code in the Table is active or easily
repeated.

Table 21

Diagnostic Code

Code and Flash Default Conditions which Generate System Response

Description Code this Code

168-02 ECM Battery 51 Battery voltage at the ECM is The code is logged.
Power Intermittent less than 7 VDC.

Test Step 1. Inspect the Electrical B. Thoroughly inspect the ECM connector J14/P14.
Connectors and the Wiring Harness Also, inspect connector J17/P17. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
A. Remove electrical power from the ECM. for details.
SENR6477-06 57
Troubleshooting Section

C. Perform a 45 N (10 lb) pull test on each of the Repair: The batteries or the alternator are causing
wires that are associated with the circuit for the the problem. Recharge the batteries or replace
Power Supply. the batteries. Refer to Systems Operation/Testing
and Adjusting.
D. Check the allen head screw on the ECM connector
for the proper torque. Refer to Troubleshooting, STOP.
“Electrical Connectors - Inspect” for the correct
torque values. Test Step 3. Check the Voltage to the ECM
Expected Result: A. Disconnect the ECM connector J14/P14.

All connectors, pins, and sockets are completely B. Turn the circuit breaker for the battery to the ON
coupled and/or inserted, and the harness and wiring position.
are free of corrosion, of abrasion and of pinch points.
C. Turn the engine control switch to the ON position.
Results:
D. Measure the voltage between the following pins.
• OK – The connectors and wiring are OK. Proceed
to Test Step 2. • P14-1 and P14-21
• Not OK – There is a problem with the connectors • P17-19 and P17-13
and/or the wiring.
Expected Result:
Repair: Repair the wiring and connectors or
replace the wiring or the connectors. Ensure that The voltage measures 24 ± 3 VDC.
all of the seals are properly connected. Verify that
the repair eliminates the problem. Results:

Verify that the repair eliminates the problem. • OK – The ECM is receiving the correct battery
voltage.
STOP.
Repair: The problem may be intermittent. If the
Test Step 2. Check Battery Voltage at the problem is intermittent, refer to Troubleshooting,
Battery “Electrical Connectors - Inspect”.

A. Turn the engine control switch to the OFF position. STOP.

B. Turn the circuit breaker for the battery to the OFF • Not OK – The voltage is incorrect at the connection
position. to the ECM. The wiring or components between
the battery and the ECM are preventing the voltage
C. Measure no-load battery voltage at the battery from reaching the ECM. Proceed to Test Step 4.
terminals. Refer to Testing and Adjusting, “Test
Tools for the Electrical System” for the proper Test Step 4. Check Voltage at the Circuit
procedures to check the batteries. Breaker
D. Load test the battery. Use the 4C-4911 Battery A. Turn the circuit breaker for the battery to the ON
Load Tester. position.

Expected Result: B. Turn the engine control switch to the ON position.

The no-load voltage at the batteries is at least 23.5 C. Measure voltage from both terminals of the
VDC and the batteries pass the load test. breaker to engine ground.

Results: Expected Result:

• OK – The no-load voltage at the batteries is at The voltage measures 24 ± 3 VDC on both terminals.
least 23.5 VDC and the batteries pass the load
test. Proceed to Test Step 3. Results:

• Not OK – The no-load voltage at the batteries is • OK – The voltage measures 24 ± 3 VDC on both
less than 23.5 VDC, and/or the batteries fail the terminals. If the voltage is only present on one of
load test. the terminals, replace the fuse.
58 SENR6477-06
Troubleshooting Section

Repair: The problem may be intermittent. If the

problem is intermittent, refer to Troubleshooting,
“Electrical Connectors - Inspect”.

STOP.

• Not OK – The voltage does not measure 24 ± 3

VDC on both terminals.

Repair: The fuse or the breaker is in need of repair

or replacement.

STOP.

i03211061

Engine Speed - Test

SMCS Code: 1907-038; 1915-038

System Operation Description:

The engine speed sensor provides the engine speed

information to the ECM. The sensor magnetically
detects the teeth on the flywheel ring gear. The ECM
will not allow the engine to start until the ECM senses
a valid engine speed signal.

Engine speed is determined by the frequency of

the output signal. The signal frequency should be
between 0 and 5 kHz.

g01637404
Illustration 26
SENR6477-06 59
Troubleshooting Section

g01637405
Illustration 27
(10) +8 VDC (18) Engine speed (35) Analog return

Table 22

Diagnostic Code

Code and Flash Default Conditions which System Response

Description Code Generate this Code

190 -00 Engine Speed 35 The ECM detects a engine speed The diagnostic code is logged. Also, the
Sensor : High more than 2450 rpm. shutdown solenoid will de-energize until
the engine speed is below 2420 rpm.

190-02 Engine Speed 34 The ECM detects the loss of the The diagnostic code is active and logged.
Sensor : Erratic, primary engine speed signal.
Intermittent, or
Incorrect

190-08 Engine Speed 33 The engine speed is changing at a The diagnostic code is active and logged.
Sensor : Abnormal abnormal rate.
Frequency, Pulse
Width, or Period

190-10 Engine Speed 34 The engine speed is greater than 3000 The diagnostic code is active and logged.
Sensor : Abnormal rpm. This is due to noise or other Also, the shutdown solenoid will de-energize
Rate of Change conditions. until the engine speed is below 2420 rpm.

Test Step 1. Inspect Electrical Connectors D. Check the allen head screw on each ECM
and Wiring connector for the proper torque. Refer to service
Troubleshooting, “Electrical Connectors - Inspect”.
A. Turn the engine control switch to the OFF position.
E. Check the harness for abrasions and for pinch
B. Thoroughly inspect the J14/P14 connector, and points from the battery to the ECM.
the J10/P10 connector. Refer to Troubleshooting,
“Electrical Connectors - Inspect”. Expected Result:

C. Perform a 45 N (10 lb) pull test on each of the All connectors, pins, and sockets are completely
wires that are associated with the engine speed coupled and/or inserted. The harness and wiring are
sensor. free of corrosion, of abrasion, and of pinch points.
60 SENR6477-06
Troubleshooting Section

Results: Expected Result:

• OK – All connectors, pins, and sockets are The resistance is between 500 ohms and 1500 ohms.
completely coupled and/or inserted. The harness
and wiring are free of corrosion, of abrasion, and of Results:
pinch points. Proceed to Test Step 2.
• OK – The resistance is between 500 ohms and
• NOT OK – There is a problem in the connectors 1500 ohms. Proceed to Test Step 4.
and/or wiring.
• NOT OK – The resistance is not between 500
Repair: Repair the connectors or the harness ohms and 1500 ohms.
and/or replace the connectors or the harness.
Ensure that all of the seals are correctly in place Repair: The sensor is faulty. Replace the sensor.
and ensure that the connectors are completely
coupled. STOP.

Verify that the repair eliminates the problem. Test Step 4. Check for Shorts in the
Harness
STOP.
A. Turn the engine control switch to the OFF position.
Test Step 2. Check Engine Speed On
Caterpillar Electronic Technician (ET) B. Disconnect connector J10/P10 and connector
J14/P14.
A. Connect Cat ET to the service tool connector.
C. Measure the resistance between P14-18 and
B. Turn the engine control switch to the ON position. P14-35.

C. Attempt to start the engine. D. Measure the resistance between P14-18 and
engine ground.
D. Observe the engine speed on Cat ET.
E. Measure the resistance between P14-35 and
E. Turn the engine control switch to the OFF position. engine ground.

Note: Battery voltage may drop below the required Expected Result:
level during cranking. If the engine will not start, Cat
ET may need to be powered by an outside source. The resistance is greater than 20,000 ohms for each
measurement.
Expected Result:
Results:
Cat ET displayed a steady engine rpm.
• OK – The resistance is greater than 20,000 ohms
Results: for each measurement. Proceed to Test Step 5.

• OK – Cat ET displays a steady engine rpm. • NOT OK – The resistance is not greater than
20,000 ohms for each measurement.
Repair: The engine speed sensor is functioning
properly. For a intermittent problem, refer to Repair: There is a short in the harness. Repair the
Troubleshooting, “Electrical Connectors - Inspect”. harness or replace the harness.

STOP. STOP.

• NOT OK – Cat ET does not display a steady Test Step 5. Check the Resistance
engine rpm. Proceed to Test Step 3. through the Harness
Test Step 3. Check The Sensor for a Short A. Install Deutsch connectors on a 152 mm (6 inch)
or for an Open wire. This wire will be used to short the terminals
of the engine speed sensor.
A. Turn the engine control switch to the OFF position.
B. Connect the wire between P10-C and P10-B.
B. Disconnect connector J10/P10.

C. Measure the resistance between J10-B and

J10-C.
SENR6477-06 61
Troubleshooting Section

C. Measure the resistance between P14-18 C. Measure the frequency between P14-18 and
and P14-35. Wiggle the harness during the P14-35. Use a 9U-7330 Digital Multimeter to
measurement. This will reveal a intermittent measure the frequency. This measurement should
problem. be taken while the engine is cranking.

Expected Result: Expected Result:

The resistance is less than 10 ohms. The frequency is between 150 Hz and 1000 Hz while
the engine is cranking. Also, the frequency is steady.
Results:
Results:
• OK – The resistance is less than 10 ohms.
Proceed to Test Step 6. • OK – The frequency is between 150 Hz and
1000 Hz while the engine is cranking. Also, the
• NOT OK – The resistance is greater than 10 ohms. frequency is steady.

Repair: The harness has a open. Repair the Repair: Verify if the problem still exists. Check
harness or replace the harness. the rpm on a electronic service tool. If the
problem is not resolved, replace the ECM. Refer
STOP. to Troubleshooting, “ECM - Replace” for more
information.
Test Step 6. Check the Engine rpm Signal
at the Sensor STOP.

A. Reconnect all connectors. • NOT OK – The frequency is not between 150 Hz

and 1000 Hz while the engine is cranking. Also, the
B. Turn the engine control switch to the ON position. frequency is not steady.

C. Measure the frequency between J10-C and J10-B. Repair: The harness is faulty. Repair the harness
Use a 9U-7330 Digital Multimeter to measure or replace the harness.
the frequency. Take this measurement while the
engine is cranking. STOP.

Expected Result:
i03202426

The frequency is between 150 Hz and 1000 Hz while

the engine is cranking. Also, the frequency is steady.
Fuel Control - Test
SMCS Code: 1264-038
Results:
System Operation Description:
• OK – The frequency is between 150 Hz and
1000 Hz while the engine is cranking. Also, the Use this procedure to determine if the Electronic
frequency is steady. Proceed to Test Step 7. Control Module (ECM) is properly controlling the fuel
rack.
• NOT OK – The frequency is not between 150 Hz
and 1000 Hz while the engine is cranking. Also, the The engine is electronically controlled by the ECM.
frequency is not steady. The ECM senses the engine rpm by using the engine
speed sensor. The ECM controls the fuel rack by
Repair: The sensor is not producing the correct adjusting the voltage to the Rack Solenoid. Refer
frequency. Replace the sensor. to Troubleshooting, “System Overview” for more
information.
STOP.
The following variables are used in this test. These
Test Step 7. Check the Engine rpm Signal variables will be displayed on the electronic service
at the ECM tool.
A. Reconnect all connectors. • Desired engine rpm is an input to the electronic
governor within the ECM. Desired engine speed is
B. Turn the engine control switch to the ON position. based on throttle inputs, the engine speed sensor's
signal and customer specified parameters.
62 SENR6477-06
Troubleshooting Section

• The desired rack position indicates the position of

the rack in order to maintain the desired engine
rpm. The desired rack position will not exceed the
rack control for the fuel ratio. Also, the desired rack
position will not exceed the rated rack limits.

• The ECM receives a signal from the rack position

sensor. The ECM uses this signal to calculate
the actual rack position. The ECM uses the rack
position sensor signal as feedback to allow precise
control of the rack position. The actual rack position
follows the desired rack position if the rack controls
are functioning properly.

• The rack control for the fuel ratio limits the fuel
to the air ratio. The limit is used to reduce black
smoke during acceleration. When the ECM senses
a higher inlet manifold pressure, the rack control
for the fuel ratio is increased in order to allow more
fuel.

• The rated rack is a limit on the rack position that

provides the specified power and torque curves.
The rated rack is programmed into the personality
module.

g01634937
Illustration 28

g01635554
Illustration 29
(10) + 8 VDC (23) Rack solenoid (35) Analog return
(22) Solenoid ground (30) + 5 VDC (40) Rack position

Test Step 1. Inspect the Electrical

Connectors and the Wiring Harness
A. Remove electrical power from the ECM.
SENR6477-06 63
Troubleshooting Section

B. Thoroughly inspect the J6/P6 connector for the Expected Result:

rack solenoid (BTM) and the J11/P11 connector
for the rack position sensor. Inspect the ECM The desired engine rpm should equal the
connector J14/P14. Refer to Troubleshooting, programmed low idle setting and the rpm should
“Electrical Connectors - Inspect” for details. remain steady. The actual rack position should
follow the desired rack position within ± 0.5 mm
C. Perform a 45 N (10 lb) pull test on each of the (± 0.02 inch).
wires that are associated with the circuit.
Results:
D. Check the allen head screw on the ECM connector
for the proper torque. Refer to Troubleshooting, • OK – The desired engine rpm is equal to the
“Electrical Connectors - Inspect” for the correct programmed low idle setting and the rpm remains
torque values. steady. The actual rack position follows the desired
rack position within ± 0.5 mm (± 0.02 inch).
Expected Result: Proceed to Test Step 3.

All connectors, pins, and sockets are completely • NOT OK – The desired engine rpm is unstable or
coupled and/or inserted, and the harness and wiring too high.
are free of corrosion, of abrasion and of pinch points.
Repair: Refer to Troubleshooting, “Speed Control
Results: - Test”.

• OK – All connectors, pins, and sockets are STOP.

completely coupled and/or inserted, and the
harness and wiring are free of corrosion, of • NOT OK – The rack is not functioning properly.
abrasion and of pinch points. Proceed to Test Step
2. Repair: Refer to Troubleshooting, “Sensor Signal
(Analog, Active) - Test”.
• NOT OK – There is a problem with the connectors
and/or the wiring. STOP.

Repair: Repair the wiring and connectors or Test Step 3. Verify Normal Rack Operation
replace the wiring or the connectors. Ensure that Under Load
all of the seals are properly connected. Verify that
the repair eliminates the problem. A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
Verify that the repair eliminates the problem.
B. Start the engine.
STOP.
C. Apply a load to the engine.
Test Step 2. Verify Normal Rack Operation
at Idle D. Monitor the desired rack , the rated rack and the
rack control for the fuel ratio on Cat ET.
A. Connect a Caterpillar Electronic Technician (ET)
to the service tool connector. Expected Result:

B. Start the engine. The desired rack reaches the rated rack when the
engine is fully loaded.
C. Monitor the desired engine rpm , the desired rack
position and the actual rack position on Cat ET. Results:

Note: A lag in Cat ET may cause differences in the • OK – The desired rack reaches the rated rack
displayed values for the desired rack position and when the engine is fully loaded.
the actual rack position. For a typical engine at low
idle with normal accessory loads, the desired rack Repair: The rack operation is working properly.
position and the actual rack position is approximately Refer to Troubleshooting, “Electrical Connectors -
4.50 mm (0.18 inch) to 5.25 mm (0.20 inch). Inspect” for a intermittent problem.

STOP.

• NOT OK – The desired rack is limited to the rack

control for the fuel ratio which indicates low boost
pressure.
64 SENR6477-06
Troubleshooting Section

Repair: Refer to Troubleshooting, “Inlet Manifold

Pressure - Test” for further information.

STOP.

• NOT OK – The desired rack is limited to a value

below the rated rack.

Repair: The ECM may be limiting engine power or

rpm. Refer to Troubleshooting, “Engine Top Speed
Is Not Obtained” for further information.

STOP.

i03232726

Fuel Rack Solenoid - Test

SMCS Code: 1257-038

System Operation Description:

The rack solenoid is used to move the engine fuel

rack. The rack solenoid is actuated by a spring to the
fuel OFF position. The rack solenoid moves into the
ON position when voltage is applied.

g01643973
Illustration 30

g01643993
Illustration 31
(10) + 8 VDC (23) Rack solenoid (35) Analog return
(22) Solenoid ground (30) + 5 VDC (40) Rack position
SENR6477-06 65
Troubleshooting Section

Table 23
Diagnostic Codes Table

Code and Description Flash Code Conditions which System Response

Generate this Code
23-02 Engine Power 48 The actual rack position is The code is logged.
Excessive greater than the desired rack
position. Excessive power Factory passwords are
is being generated by the required to clear this code.
engine.
23-05 Rack BTM current low 43 The actual rack position The code is logged.
is not proportional to the
desired rack position. There The ECM uses the engine
are no sensor supply voltage speed to govern the engine.
faults. The arm of the rack The rack sensor signal is
solenoid is not in the desired ignored. The rack limit is
position. set to 13.5 mm (0.53 inch).

23-06 Rack BTM current high 43 The actual rack position The code is logged.
is not proportional to the
desired rack position. There The ECM uses the engine
are no sensor supply voltage speed to govern the engine.
faults. The arm of the rack The rack sensor signal is
solenoid is not in the desired ignored. The rack limit is
position. set to 13.5 mm (0.53 inch).

Test Step 1. Inspect the Electrical Repair: Repair the wiring and connectors or
Connectors and the Wiring Harness replace the wiring or the connectors. Ensure that
all of the seals are properly connected. Verify that
A. Remove electrical power from the ECM. the repair eliminates the problem.

B. Thoroughly inspect the J6/P6 connector for the Verify that the repair eliminates the problem.
rack solenoid (BTM) and the J11/P11 connector
for the rack position sensor. Inspect the ECM STOP.
connector J14/P14. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details. Test Step 2. Remove the Rack Solenoid
and Inspect the Rack Solenoid
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the circuit. A. Turn the engine control switch to the OFF position.

D. Check the allen head screw on the ECM connector B. Remove the rack solenoid.
for the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct C. Make sure that the rack and the rack servo have
torque values. free movement.

Expected Result: D. Inspect the arm of the rack solenoid for damage
and signs of binding in the sleeve of the servo.
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring Expected Result:
are free of corrosion, of abrasion and of pinch points.
The arm of the rack solenoid is not damaged or the
Results: arm of the rack solenoid does not show signs of
binding.
• OK – All connectors, pins, and sockets are
completely coupled and/or inserted, and the Results:
harness and wiring are free of corrosion, of
abrasion and of pinch points. Proceed to Test Step • OK – The arm of the rack solenoid is not damaged
2. or the arm of the rack solenoid does not show
signs of binding. Proceed to Test Step 3.
• NOT OK – There is a problem with the connectors
and/or the wiring. • NOT OK – The arm of the rack solenoid is
damaged or the arm of the rack solenoid shows
signs of binding.
66 SENR6477-06
Troubleshooting Section

Repair: Repair the arm of the rack solenoid or • NOT OK – The resistance is not between 0.5
replace the arm of the rack solenoid. Ohms and 1.5 Ohms.

STOP. Repair: Replace the rack solenoid.

Test Step 3. Sweep Test for the Rack STOP.

Solenoid
Test Step 5. Check the Harness for Shorts
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector. A. Disconnect the ECM connector J14/P14.

B. Turn the engine control switch to the ON position. B. Disconnect the rack solenoid connector J6/P6.

C. Activate the sweep test for the rack solenoid and C. Measure the resistance between pin (A) and pin
observe the arm of the rack solenoid. (B) of the J6 connector.

Note: Some applications may have an auxiliary D. Measure the resistance between pin (A) and
system that can interrupt power to the ECM. These engine ground.
systems may need to be temporarily bypassed in
order to perform the sweep test. E. Measure the resistance between pin (B) and
engine ground.
D. Deactivate the sweep test.
Expected Result:
Expected Result:
The resistance is greater than 20,000 Ohms.
The arm of the rack solenoid moves smoothly in
a clockwise direction. Once the arm moves slightly Results:
past the dot on the face plate, the arm moves back
to the OFF position. • OK – The resistance is greater than 20,000 Ohms.
Proceed to Test Step 6.
Results:
• NOT OK – The resistance is less than 20,000
• OK – The arm of the rack solenoid moves Ohms.
smoothly in a clockwise direction. Once the arm
moves slightly past the dot on the face plate, the Repair: Repair the harness or replace the harness.
arm moves back to the OFF position. The rack is
functioning properly. STOP. STOP.

• NOT OK – The arm of the rack solenoid does not Test Step 6. Check Resistance through
move smoothly in a clockwise direction. Once the the Harness
arm moves slightly past the dot on the face plate,
the arm does not move back to the OFF position. A. Connect Deutsch socket terminals at each end to
Proceed to Test Step 4. a 152 mm (6 inch) wire.

Test Step 4. Check the Resistance of the B. Connect the wire to pin (A) and pin (B) of
Rack Solenoid connector J6.

A. Turn the engine control switch to the OFF position. C. Measure the resistance between pin(23) and pin
(22) of connector P14.
B. Disconnect the rack solenoid connector J6/P6.
Expected Result:
C. Measure the resistance between pin (A) and pin
(B) of the rack solenoid connector. The resistance is less than 10 Ohms.

Expected Result: Results:

The resistance is between 0.5 Ohms and 1.5 Ohms. • OK – The resistance is less than 10 Ohms.
Proceed to Test Step 7.
Results:
• NOT OK – The resistance is greater than 10
• OK – The resistance is between 0.5 Ohms and 1.5 Ohms.
Ohms. Proceed To Test Step 5.
SENR6477-06 67
Troubleshooting Section

Repair: There is excessive resistance in the Results:

harness. Repair the harness or replace the
harness. • OK – The voltage starts at 0 VDC and increases to
3.6 ± 0.3 VDC. The voltage then decreases back
STOP. to 0 VDC.

Test Step 7. Check Voltage at the ECM Repair: Replace the solenoid.
During the Sweep Test
STOP.
A. Reconnect all connectors.
• NOT OK – The voltage does not start at 0 VDC
B. Turn the engine control switch to the ON position. and the voltage does not increase to 3.6 ± 0.3 VDC.
The voltage does not decrease back to 0 VDC.
C. Activate the sweep test for the rack.
Repair: The correct voltage is at the ECM but not
D. Measure the voltage between pin (23) and pin at the solenoid. Repair the harness or replace the
(22) of connector P14 during the sweep test for harness.
the rack.
STOP.
Note: If the voltage increases to 11 to 12 VDC,
recheck the harness for an open circuit.
i03190424

Expected Result: Fuel Shutoff - Test

The voltage starts at 0 VDC and increases to 3.6 ± SMCS Code: 1704-038
0.3 VDC. The voltage then decreases back to 0 VDC.
System Operation Description:
Results:
Use this procedure to troubleshoot the electrical
• OK – The voltage starts at 0 VDC and increases system if a problem is suspected with the circuit for
to 3.6 ± 0.3 VDC. The voltage then decreases back the fuel control solenoid or if one of the diagnostic
to 0 VDC. Proceed to Test Step 8. codes in Table 24 is active or easily repeated.
• NOT OK – The voltage does not start at 0 VDC
and the voltage does not increase to 3.6 ± 0.3 VDC.
The voltage does not decrease back to 0 VDC.

Repair: Check the supply voltage to the ECM.

Refer to Troubleshooting, “Electrical Power Supply
- Test”. If the voltage is correct, replace the ECM.
Refer to Troubleshooting, “ECM - Replace” for
further information.

STOP.

Test Step 8. Check the Voltage to the

Rack Solenoid During the Sweep Test
A. Activate the sweep test.

B. Measure the voltage between pin (A) and pin (B)

of connector P6 during the sweep test.

C. Observe the arm of the rack solenoid during the

sweep test.

D. Deactivate the sweep test.

Expected Result:

The voltage starts at 0 VDC and increases to 3.6 ±

0.3 VDC. The voltage then decreases back to 0 VDC.
68 SENR6477-06
Troubleshooting Section

Table 24
Diagnostic Codes Table

Code and Description Flash Code Conditions which System Response

Generate this Code
17-5 Fuel Shutoff Valve : 45 The solenoid voltage is less The code is logged.
Current Below Normal than 0.75 VDC. Also, the The shutoff solenoid is
engine speed is greater than de-energized. The shutoff
500 rpm for ten seconds. No solenoid is energized after
faults are present. the fault is cleared.
17-6 Fuel Shutoff Valve : 45 The solenoid voltage is The code is logged.
Current Above Normal above 2.5 VDC. Also, the The shutoff solenoid is
engine speed is greater than de-energized. The shutoff
500 rpm for ten seconds. solenoid is energized after
Also, there are no faults for the fault is cleared.
the supply voltage. Also,
the supply voltage does not
have a fault.

The Electronic Control Module (ECM) contains

the logic and the outputs for control of starting the
engine and stopping the engine. Some of the logic
for starting the engine and for stopping the engine
is customer programmable. The logic responds to
inputs from the following components: engine control
switch, emergency stop switch, and other inputs.

The ECM outputs a signal to the fuel control solenoid

in order to control the fuel shutoff valve. To enable
fuel flow to the engine, the fuel control solenoid
must be energized. The fuel control solenoid may
be controlled by the ECM or by the customer's
equipment. Use this procedure to troubleshoot either
configuration.

The most likely cause of a diagnostic code is a

poor electrical connection or a problem in a wiring
harness. The next likely cause may be a problem
with the fuel control solenoid. The least likely cause
is a problem with the ECM.

The following information describes the system's

operation when the fuel shutoff valve is controlled
by the ECM:

The ECM sends an output signal to the fuel control

solenoid that controls the operation of the fuel shutoff
valve. This output is energize-to-run. During the
crank cycle, when the engine speed exceeds 50 rpm,
the ECM provides a voltage of +Battery to the output
for the fuel control solenoid. The solenoid becomes
energized. This initiates fuel flow to the engine. The
ECM removes the voltage from this output in order to
stop the engine. The fuel control solenoid becomes
de-energized. This stops the fuel flow.
SENR6477-06 69
Troubleshooting Section

g01627351
Illustration 32

g01635794
Illustration 33
(22) Fuel shutoff solenoid (33) Solenoid ground

Test Step 1. Inspect the Electrical • Not OK – There is a problem with the connectors
Connectors and the Wiring Harness and/or the wiring.

A. Remove electrical power from the ECM. Repair: Repair the wiring and connectors or
replace the wiring or the connectors. Ensure that
B. Thoroughly inspect the P5/J5 connector for the all of the seals are properly connected.
fuel shutoff solenoid. Inspect the ECM J14/P14
connector. Refer to Troubleshooting, “Electrical Verify that the repair eliminates the problem.
Connectors - Inspect” for details.
STOP.
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the circuit for the Test Step 2. Check the Engine Start-up
fuel shutoff solenoid.
A. Turn the engine control switch to the ON position.
D. Check the allen head screw on the ECM connector The engine should remain in the OFF position.
for the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct Note: The solenoid should make an audible sound
torque values. when the solenoid is first energized.

Expected Result: B. Attempt to start the engine.

All connectors, pins, and sockets are completely Expected Result:

coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points. The engine will start and the engine will run.

Results: Results:

• OK – The connectors and wiring are OK. Proceed • OK – The engine will start and the engine will run.
to Test Step 2. Proceed to Test Step 3.
70 SENR6477-06
Troubleshooting Section

• NOT OK – The engine will not start and the engine B. Measure the resistance from connector J5-A to
will not run. Proceed to Test Step 4. connector J5-B.

Test Step 3. Check the Engine Shutdown C. Measure the resistance from connector J5-A and
engine ground.
A. Turn the engine control switch to the OFF position.
Expected Result:
Expected Result:
The resistance from connector J5-A to connector
The engine should shut down. J5-B is between 0.8 and 2.0 Ohms. The resistance
from connector J5-A and engine ground is greater
Results: than 20,000 Ohms.

• OK – The engine shuts down. Results:

Repair: The fuel shutoff solenoid is working • OK – The resistance from connector J5-A to
properly. Refer to Troubleshooting, “Electrical connector J5-B is between 0.8 and 2.0 Ohms. The
Connectors - Inspect” for a intermittent problem. resistance from connector J5-A and engine ground
is greater than 20,000 Ohms. Proceed to Test Step
STOP. 6.

• NOT OK – The engine does not shut down. • NOT OK – The resistance from connector J5-A to
connector J5-B is not between 0.8 and 2.0 Ohms
Repair: Check the linkage for binding. Also, check or the resistance from connector J5-A and engine
the plunger for the fuel shutoff solenoid for binding. ground is less than 20,000 Ohms.

STOP. Repair: The fuel shutoff solenoid is faulty. Replace

the fuel shutoff solenoid.
Test Step 4. Override the Shutoff
Solenoid with the Manual Shutoff Lever STOP.

A. Rotate the manual shutoff lever in a clockwise Test Step 6. Check for Shorts in the
direction. This will override the shutoff solenoid. Harness
B. Turn the engine control switch to the ON position. A. Turn the engine control switch to the OFF position.

C. Attempt to start the engine while the manual B. Disconnect connector J14/P14 and disconnect
shutoff lever is held in the clockwise position. connector J5/P5.

Expected Result: C. Measure the resistance between connector pins

P5-A and P5-B.
The engine should start and the engine should run
while the lever is held in the clockwise position. D. Measure the resistance between connector pin
P5-A and engine ground.
Results:
E. Measure the resistance between connector pin
• OK – The engine starts and the engine runs while P5-B and engine ground.
the manual shutoff lever is held in the clockwise
position. Proceed to Test Step 5. Expected Result:

• NOT OK – The engine will not start. The fuel The resistance reading is more than 20,000 Ohms
shutoff valve is not the problem. for each measurement.

Repair: The fuel shutoff valve is not the problem. Results:

Refer to Troubleshooting, “Engine Cranks but Does
Not Start” for more troubleshooting information. • OK – The resistance reading is more than 20,000
Ohms for each measurement. Proceed to Test
STOP. Step 7.

Test Step 5. Check the Solenoid Coil for • Not OK – The resistance reading is less than
Shorts or Opens. 20,000 Ohms for any measurement.

A. Disconnect J5/P5 connector.

SENR6477-06 71
Troubleshooting Section

Repair: There is an open circuit in the engine Repair: Check the ECM for proper supply voltage.
harness or the customer supplied wiring. Repair Refer to Troubleshooting, “Electrical Power Supply
the harness or replace the harness. as required. - Test”. If the voltage to the ECM is correct, replace
the ECM.
STOP.
STOP.
Test Step 7. Check Resistance through
the Harness Test Step 9. Check for Voltage at the
Shutoff Solenoid
A. Attach Deutsch terminals to a wire at each end.
A. Rotate the manual shutoff lever in the clockwise
B. Attach the wire to P5-A and P5-B. This will short direction.
the wires to the solenoid.
B. Measure the voltage between J5-A and J5-B while
C. Measure the resistance between P14-33 and the engine is cranking.
P14-22.
Expected Result:
Expected Result:
The voltage rises over 4 VDC while the engine is
The resistance is less than 10 Ohms. cranking. The voltage is between 2.5 and 1.5 VDC
within five seconds of the engine starting .
Results:
Results:
• OK – The resistance is less than 10 Ohms.
Proceed to Test Step 8. • OK – The voltage rises over 4 VDC while the
engine is cranking. The voltage is between 2.5 and
• NOT OK – The resistance is more than 10 Ohms. 1.5 VDC within five seconds of the engine starting .

Repair: There is an open circuit in the engine Repair: Check the linkage and the plunger for
harness or the customer supplied wiring. Repair binding.
the harness or replace the harness.
STOP.
STOP.
• NOT OK – The voltage does not rise over 4 VDC
Test Step 8. Check for Solenoid Voltage while the engine is cranking. The voltage is not
at the ECM between 2.5 and 1.5 VDC within five seconds of
the engine starting .
A. Reconnect all connectors.
Repair: The voltage is correct at the ECM but not
B. Measure the voltage between P14-33 and P14-22 at the solenoid. The problem is in the harness.
while the engine is cranking.
STOP.
Expected Result:
i03197683
The voltage rises over 4 VDC while the engine is
cranking. The voltage is between 2.5 and 1.5 VDC
within five seconds of the engine starting.
Indicator Lamp - Test
SMCS Code: 7431-038
Results:
System Operation Description:
• OK – The voltage rises over 4 VDC while the
engine is cranking. The voltage is between 2.5 and The indicator lamps are activated by the Electronic
1.5 VDC within 5 seconds of the engine starting. Control Module (ECM) in order to inform the operator
Proceed to Test Step 9. of various engine events. The ECM provides five
sinking outputs and the ECM provides one sourcing
• NOT OK – The voltage does not rise over 4 VDC output. The outputs drive lamps and/or alarms which
while the engine is cranking. The voltage is not indicate diagnostic conditions. Alarm outputs are
between 2.5 and 1.5 VDC within 5 seconds of the activated for five seconds when the ECM is powered
engine starting. up. This occurs for a self test of the alarm circuit.
72 SENR6477-06
Troubleshooting Section

The low oil pressure lamp indicates a low oil

pressure condition. A low oil pressure condition is
detected when the actual oil pressure is below a
predetermined level.

The lamp for the low boost pressure indicates that

the boost pressure is below a predetermined value.

The high coolant temperature lamp indicates a

high coolant temperature condition. The diagnostic
lamp indicates the presence of active diagnostic
conditions. The lamp provides a diagnostic message
in a series of flashes by the diagnostic lamp. The
first sequence of flashes represents the first digit of
a diagnostic flash code. The second sequence of
flashes represent the second digit of the diagnostic
flash code. This occurs after a two second pause.
Additional codes will follow a two second pause.
The additional codes will be displayed in the same
manner.

The lamp for the derate for atmospheric pressure

indicates a condition of low atmospheric pressure.

The low coolant level lamp illuminates when the

coolant level is low.

Note: The ECM applies battery positive voltage in

order to activate the low coolant level alarm.

The most likely cause of a problem with an indicator

lamp is the bulb. The next most likely cause is a
problem with a wire or with a connector. The least
likely cause is a problem with the ECM.

Use this procedure to troubleshoot the indicator

lamps or use this procedure if another procedure has
directed you here. Before you perform this procedure,
determine whether the bulb needs to be replaced.

g01629094
Illustration 34
SENR6477-06 73
Troubleshooting Section

g01635773
Illustration 35
(3) Low oil pressure (5) Atmospheric derate (14) Low coolant level
(4) Diagnostic (13) Low boost (15) High coolant temperature

Test Step 1. Inspect Electrical Connectors Verify that the repair eliminates the problem.
and Wiring
STOP.
A. Turn the engine control switch to the OFF position.
Test Step 2. Check for Normal Operation
B. Thoroughly inspect the J14/P14 connector, and of the Suspect Lamp
the lamp connections. Thoroughly inspect the
J17/P17 connector. Refer to Troubleshooting, A. Turn the engine control switch to the ON position
“Electrical Connectors - Inspect”. and monitor the indicator lamps.

C. Perform a 45 N (10 lb) pull test on each of the a. The diagnostic lamps will illuminate for a
wires that are associated with the indicator lamps. minimum of two seconds after the power is
returned to the ECM. The lamp will then turn
D. Check the allen head screw on each ECM off.
connector for the proper torque. Refer to service
Troubleshooting, “Electrical Connectors - Inspect”. B. Turn the engine control switch to the OFF position.

E. Check the harness for abrasions and for pinch Note: A lamp may remain on if a diagnostic condition
points from the battery to the ECM. is present.

Expected Result: Expected Result:

All connectors, pins, and sockets are completely The suspect lamp illuminates and the lamp turns off
coupled and/or inserted. The harness and wiring are per the above description.
free of corrosion, of abrasion, and of pinch points.
Results:
Results:
• OK – The suspect lamp illuminates and the lamp
• OK – All connectors, pins, and sockets are turns off per the above description.
completely coupled and/or inserted. The harness
and wiring are free of corrosion, of abrasion, and of Repair: The diagnostic lamps appear to operating
pinch points. Proceed to Test Step 2. correctly at this time. There may be an intermittent
electrical problem in the harness or in a connector.
• NOT OK – There is a problem in the connectors If an intermittent problem is suspected, refer to
and/or wiring. Troubleshooting, “Electrical Connectors - Inspect”.

Repair: Repair the connectors or the harness STOP.

and/or replace the connectors or the harness.
Ensure that all of the seals are correctly in place • NOT OK – The suspect lamp does not illuminate
and ensure that the connectors are completely or the suspect lamp does not turn off per the above
coupled. description. Proceed to Test Step 3.
74 SENR6477-06
Troubleshooting Section

Test Step 3. Measure the Voltage at the • NOT OK – The voltage measurement is not
Lamp Socket between 22 VDC and 27 VDC from the engine
ground to the supply wires of the alarm lamps. The
A. Turn the engine control switch to the ON position. resistance between the negative wire of the low
coolant level lamp and engine ground measures
B. Measure the voltage across each lamp socket. more than 10 Ohms.
The measurement must be recorded within five
seconds of turning the engine control switch to Repair: There is a problem in the wiring harness
the ON position. or the connectors. Refer to Troubleshooting,
“Electrical Connectors - Inspect”.
Expected Result:
STOP.
The voltage is between 22.0 VDC and 27.0 VDC.
Test Step 5. Check Battery Voltage to the
Results: ECM
• OK – The voltage is between 22.0 VDC and 27.0 A. Turn the engine control switch to the ON position.
VDC.
B. Measure the voltage between connectorP14-1
Repair: Replace the bulb. and connector P14-21.

Verify that the repair eliminates the problem. Expected Result:

STOP. The voltage is between 22 VDC and 27 VDC.

• NOT OK – The voltage is not between 12.0 VDC Results:

and 24.0 VDC. Proceed to Test Step 4.
• OK – The voltage is between 22 VDC and 27
Test Step 4. Check the Voltage Supply VDC. Proceed To Test Step 6.
and Engine Ground To The Lamps
• NOT OK – The voltage is not between 22 VDC
A. Turn the engine control switch to the ON position. and 27 VDC.

B. Measure the voltage between the supply wires to Repair: The ECM is not receiving the correct
the alarm lamps and engine ground. battery voltage. Refer to Troubleshooting,
“Electrical Power Supply - Test”.
C. Turn the engine control switch to the OFF position.
STOP.
D. Measure the resistance between the negative wire
for the low coolant level indicator and the engine Test Step 6. Bypass the ECM
ground.
A. Turn the engine control switch to the OFF position.
Expected Result:
B. Disconnect ECM connector P14.
The voltage measures between 22 VDC and 27 VDC
from the engine ground to the alarm lamps supply C. Install Deutsch connectors on a 203 mm (8 inch)
wires. The resistance between the negative wire of wire.
the low coolant level lamp and the engine ground
measures less than 10 Ohms. D. Turn the engine control switch to the ON position.

Results: E. Connect the wire between the following locations:

• OK – The voltage measures between 22 VDC and • P14-21 and P14-3 (low oil pressure lamp)
27 VDC from the engine ground to the alarm lamps
supply wires. The resistance between the negative • P14-21 and P14-4 (diagnostic lamp)
wire of the low coolant level lamp and the engine
ground measures less than 10 Ohms. Proceed to • P14-21 and P14-5 (derate for atmospheric
Test Step 5. pressure)

• P14-21 and P14-13 (low boost pressure)

• P14-21 and P14-15 (high coolant temperature
lamp)
SENR6477-06 75
Troubleshooting Section

• P14-1 and P14-14 (low coolant level lamp)

Expected Result:

Each lamp illuminates when the jumper wire is

installed.

Results:

• OK – Each lamp illuminates when the jumper wire

is installed.

Repair: The harness and the lamps are working

properly. Reconnect all of the connectors. Repeat
the self test of the alarm circuit. If the problem still
exists replace the ECM. Refer to Troubleshooting,
“ECM - Replace”.

STOP.

• NOT OK – A lamp does not illuminate when the

jumper is installed.

Repair: There is a problem in the wiring harness

or the connectors. Refer to Troubleshooting,
“Electrical Connectors - Inspect”.

STOP.

i03206134

Inlet Manifold Pressure - Test

SMCS Code: 1058-038-PXS; 1087-038-PX;
1439-038-PX

System Operation Description:

The Electronic Control Module (ECM) monitors the

inlet manifold pressure with a sensor. The sensor is
located at the front of the engine. A voltage of +5
VDC is supplied to the inlet manifold pressure sensor.
The sensor provides a output voltage of 0.4 VDC to
4.4 VDC. This voltage is proportional to the operating
pressure range of 0 kPa (0 psi) to 690 kPa (100 psi).

The ECM uses information from the boost

pressure sensor to reduce smoke emissions during
acceleration. When the ECM senses a higher inlet
manifold pressure, the rack limit is increased in order
to allow more fuel.

The boost pressure sensor must be calibrated

while the engine is off. Calibration is accomplished
electronically without the need for manual
adjustments. Use Caterpillar Electronic Technician
(ET) to recalibrate the sensor. Recalibrate the sensor
whenever the ECM or the sensor has been replaced.
76 SENR6477-06
Troubleshooting Section

g01635994
Illustration 36

g01636024
Illustration 37
(25) Boost pressure (30) + 5 VDC (35) Analog return
SENR6477-06 77
Troubleshooting Section

Table 25
Diagnostic Code

Code and Flash Default Conditions which System Response

Description Code Generate this Code

102 -00 Boost 25 The boost pressure signal voltage The diagnostic code is logged. Also, the
Pressure Sensor : is valid, but above normal. engine power is limited. boost pressure
High is set to 600 kPa (87 psi).

102-01 Boost 25 The boost pressure signal voltage is The diagnostic code is logged. Also, the
Pressure Sensor : valid, but below normal. engine power is limited. boost pressure
Low is set to 600 kPa (87 psi).

102-03 Boost 25 The boost pressure signal voltage is The diagnostic code is logged. Also, the
Pressure Sensor : greater than 5.0 VDC. engine power is limited. boost pressure
Voltage Above Normal is set to 600 kPa (87 psi).

102-04 Boost 25 The boost pressure signal voltage is The diagnostic code is logged. Also, the
Pressure Sensor : less than 0.75 VDC. engine power is limited. boost pressure
Voltage Below Normal is set to 600 kPa (87 psi).

102-13 Boost 42 The boost pressure sensor is not The fault is active and the ECM converts
Pressure Sensor : calibrated. to low power. Also, boost pressure is set to
Calibration Required 0 kPa (0 psi).

Test Step 1. Inspect Electrical Connectors Results:

and Wiring
• OK – All connectors, pins, and sockets are
A. Turn the engine control switch to the OFF position. completely coupled and/or inserted. The harness
and wiring are free of corrosion, of abrasion, and of
B. Thoroughly inspect the J14/P14 connector, and pinch points. Proceed to Test Step 2.
the J8/P8 connector. Refer to Troubleshooting,
“Electrical Connectors - Inspect”. • NOT OK – There is a problem in the connectors
and/or wiring.
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the inlet manifold Repair: Repair the connectors or the harness
pressure sensor. and/or replace the connectors or the harness.
Ensure that all of the seals are correctly in place
D. Check the allen head screw on each ECM and ensure that the connectors are completely
connector for the proper torque. Refer to coupled.
Troubleshooting, “Electrical Connectors - Inspect”.
Verify that the repair eliminates the problem.
E. Check the harness for abrasions and for pinch
points from the battery to the ECM. STOP.

Expected Result: Test Step 2. Check for Active Open or

Short Diagnostic Codes
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are A. Connect Caterpillar Electronic Technician (ET) to
free of corrosion, of abrasion, and of pinch points. the service tool connector.
78 SENR6477-06
Troubleshooting Section

B. Turn the engine control switch to the ON position. Expected Result:

C. Check for active diagnostic codes 102-03 or Cat ET displays 0 ± 20 kPa (0 ± 3 psi) when pressure
102-04. is not applied. Cat ET displays 100 ± 20 kPa
(14.5 ± 3 psi) when pressure is applied.
Expected Result:
Results:
No active diagnostic codes exist.
• OK – Cat ET displays 0 ± 20 kPa (0 ± 3 psi)
Results: when pressure is not applied. Cat ET displays
100 ± 20 kPa (14.5 ± 3 psi) when pressure is
• OK – No active diagnostic codes exist. Proceed applied.
to Test Step 3.
Repair: The boost sensor is working properly. For
• NOT OK – Diagnostic codes 102-03 or 102-04 are a intermittent problem, refer to Troubleshooting,
present. “Electrical Connectors - Inspect”.

Repair: Refer to Troubleshooting, “Sensor Signal STOP.

(Analog, Active) - Test.”.
• NOT OK – Cat ET does not display 0 ± 20 kPa
STOP. (0 ± 3 psi) when pressure is not applied. Cat ET
does not display 100 ± 20 kPa (14.5 ± 3 psi) when
Test Step 3. Calibrate the Boost Sensor pressure is applied. Proceed to Test Step 5.

A. Connect Cat ET to the Service Tool Connector. Test Step 5. Check Supply Voltage at the
Sensor
B. Turn the engine control switch to the ON position.
A. Turn the engine control switch to the ON position.
C. Select the boost sensor calibration screen.
B. Measure the voltage between P8-A and P8-B.
D. The calibration will take several seconds.
Expected Result:
Expected Result:
The voltage measures 5.0 ± 0.25 VDC.
The screen will display “Calibrated” when the
calibration is complete. Results:

Results: • OK – The voltage measures 5.0 ± 0.25 VDC.

Proceed to Test Step 7.
• OK – The screen displays “Calibrated” when the
calibration is complete. Proceed to Test Step 4. • NOT OK – The voltage does not measure 5.0 ±
0.25 VDC. Proceed to Test Step 6.
• NOT OK – The screen does not display
“Calibrated” when the calibration is complete. Test Step 6. Check Supply Voltage at the
Proceed to Test Step 5. ECM
Test Step 4. Boost Pressure Sensor Test A. Turn the engine control switch to the ON position.

A. Remove the sensor from the engine. B. Measure the voltage between P14-30 and P14-35.

B. Connect the FT-1906 Air Test Kit to the sensor. Expected Result:

C. Connect to the service tool connector. The voltage measures 5.0 ± 0.25 VDC.

D. Turn the engine control switch to the ON position. Results:

E. Close the valve on the test kit and apply 100 kPa • OK – The voltage measures 5.0 ± 0.25 VDC.
(14.5 psi) to the sensor.
Repair: The fault is in the wiring harness. Repair
F. Observe the display on Cat ET. the harness or replace the harness.

Note: The leakage rate should not exceed 20 kPa STOP.

(3 psi) in 30 seconds.
SENR6477-06 79
Troubleshooting Section

• NOT OK – The voltage does not measure 5.0 ± i03252063

0.25 VDC.
Sensor Signal (Analog, Active)
Repair: The fault is in the ECM. Replace the ECM. - Test
STOP. SMCS Code: 1439-038
Test Step 7. Check Signal Voltage at the System Operation Description:
Sensor
Use this procedure to troubleshoot the electrical
A. Turn the engine control switch to the ON position. system if a problem is suspected with the sensors
or if any one of the diagnostic codes in Table 26 is
B. Measure the voltage between P8-C and P8-B. active or easily repeated.
Expected Result:

The voltage measurement is between 0.4 VDC and

4.4 VDC.

Results:

• OK – The voltage measurement is between 0.4

VDC and 4.4 VDC. Proceed to Test Step 8.

• NOT OK – The voltage measurement is not

between 0.4 VDC and 4.4 VDC.

Repair: Replace the sensor.

STOP.

Test Step 8. Check Signal Voltage at the

ECM
A. Turn the engine control switch to the ON position.

B. Measure the voltage between P14-25 and P14-35.

Expected Result:

The voltage measurement is between 0.4 VDC and

4.4 VDC.

Results:

• OK – The voltage measurement is between 0.4

VDC and 4.4 VDC.

Repair: Replace the ECM.

STOP.

• NOT OK – The voltage measurement is not

between 0.4 VDC and 4.4 VDC.

Repair: The fault is in the wiring harness. Repair

the harness or replace the harness.

STOP.
80 SENR6477-06
Troubleshooting Section

Table 26
Diagnostic Codes Table
Code and Description Flash Code Conditions which Generate System Response
this Code
100-3 Oil Pressure voltage 24 The oil pressure signal is The diagnostic code is
high above 4.7 VDC for one active and logged.
second. Also, there are no
sensor supply diagnostic
codes.
100-4 Oil Pressure voltage 24 The oil pressure signal is less The diagnostic code is
low than 0.5 VDC for one second. active and logged.
Also, there are no sensor
supply diagnostic codes.
100-10 Oil Pressure signal 24 The ECM detects signal The diagnostic code is
rate of change voltage that is not changing active and logged.
at a normal rate for thirty
seconds.
102-03 Boost Pressure 25 The boost pressure sensor The diagnostic code is
voltage high signal is greater than 5.0 active and logged.
VDC for one second. Also, The ECM sets the boost
there are no sensor supply pressure to600 kPa (87 psi).
diagnostic codes. Engine power is limited.
102-04 Boost Pressure 25 The boost pressure sensor The diagnostic code is
voltage low signal is less than 0.75 active and logged.
VDC for one second. Also, The ECM sets the boost
there are no sensor supply pressure to 600 kPa (87 psi).
diagnostic codes. Engine power is limited.
106-03 Atmospheric Pressure 26 Voltage is above 4.8 VDC for The diagnostic code is
voltage high one second. Also, there are active and logged. The ECM
no sensor supply diagnostic will use a default value of
codes. 100 kPa (14.5 psi). This
value will also be displayed
on Caterpillar Electronic
Technician (ET).
106-04 Atmospheric Pressure 26 Voltage is below 0.2 VDC for The diagnostic code is
voltage low one second. Also, there are active and logged. The ECM
no sensor supply diagnostic will use a default value of
codes. 100 kPa (14.5 psi). This
value will also be displayed
on Caterpillar Electronic
Technician (ET).
110-03 Coolant Temperature 27 Voltage is above 4.7 VDC for The code is logged.
voltage high one second. Also, there are The value of the parameter
no sensor supply diagnostic is set to a gauge pressure of
codes. 0° F (32° C).
110-04 Coolant Temperature 27 Voltage is below 0.3 VDC for The code is logged.
voltage low one second. Also, there are The value of the parameter
no sensor supply diagnostic is set to a gauge pressure of
codes. 0° F (32° C).
241-00 5 Volt Open Circuit 21 The supply voltage is normal. The code is active and the
The rack signal is below code is logged.
0.3 VDC. The boost signal , All sensors are set to default
oil pressure signal and the values.
coolant temperature signal
are below 0.5 VDC. The
engine rpm is greater than 0.
(continued)
SENR6477-06 81
Troubleshooting Section

(Table 26, contd)

Diagnostic Codes Table
Code and Description Flash Code Conditions which Generate System Response
this Code
241-01 5 Volt Short Circuit 21 The supply voltage for the The code is active and the
sensors is less than 3 VDC or code is logged.
the supply voltage is greater All sensors are set to default
than 7.0 VDC. values.
241-02 8 Volt Open Circuit 21 The supply voltage for the The code is active and the
sensors is normal. The rack code is logged.
signal is equal to 5 VDC All sensors are set to default
and the coolant temperature values.
signal is less than 0.6 VDC.
241-03 8 Volt Short Circuit 21 The supply voltage for all of The code is active and the
the sensors is less than 6.4 code is logged.
VDC or the supply voltage is All sensors are set to default
greater than 9.6 VDC. values.

Use this procedure to troubleshoot any suspect

problems with the following sensors:

• Coolant temperature sensor

• Engine oil pressure sensor
• Atmospheric pressure sensor
• Intake manifold pressure sensor
82 SENR6477-06
Troubleshooting Section

g01652647
Illustration 38

g01657635
Illustration 39
(10) + 8 VDC (26) Coolant level (34) Atmospheric pressure
(20) Coolant temperature (27) Oil pressure (35) Analog return
(25) Boost pressure (30) + 5 VDC (40) Rack position

The supply voltage is routed to terminal (A) of each

sensor connector. The sensor return is routed to
terminal (B) of each sensor connector. The sensor
signal is routed to terminal (C) of each sensor
connector. The ECM provides short circuit protection
for the internal power supply. A short circuit to the
battery will not damage the internal power supply.
SENR6477-06 83
Troubleshooting Section

Repair: The problem may be intermittent. If the

problem is intermittent, refer to Troubleshooting,
“Electrical Connectors - Inspect”.

STOP.

• Not OK – A 04 diagnostic code is active. Proceed

to Test Step 2.

Test Step 2. Disconnect the Sensor and

Check for an Open Circuit Diagnostic
Code
A. Disconnect the suspect sensor.
g01159881
Illustration 40
B. View active diagnostic codes on CAT ET.
Sensor connector
(A) 5 V sensor supply Note: Wait at least 30 seconds in order for the
(B) Sensor return diagnostic codes to become active.
(C) Signal
Expected Result:
Test Step 1. Check for Active Diagnostic
Codes or Logged Diagnostic Codes An active diagnostic code (03) appears for the
disconnected sensor.
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector. Results:
B. Turn the engine control switch to the ON position. • OK – An active diagnostic code (03) appears for
the disconnected sensor.
C. Monitor the diagnostic codes on Cat ET. Check
and record any diagnostic codes. Repair: There is a short in the sensor or the
connector. Repair the connector. If the problem still
Note: Wait at least 30 seconds in order for the exists, replace the sensor.
diagnostic codes to become active.
STOP.
D. Determine if a diagnostic code has occurred
several times. • NOT OK – An active diagnostic code (03) does
not appear for the disconnected sensor. Proceed
Note: A diagnostic code that is logged several to Test Step 3.
times is an indication of an intermittent problem.
Most intermittent problems are the result of a bad Test Step 3. Create a Short at the Sensor
connection between a socket and a pin in a connector Connector
or a bad connection between a wire and a terminal.
The problem may be caused by moisture, corrosion, A. Turn the engine control switch to the OFF position.
or wear.
B. Disconnect the suspect sensor.
E. Determine if the problem is active and related to
one of the following diagnostic codes: C. Use a wire jumper in order to create a short
between terminal (C) and terminal (B) at the
• 03 sensor connector.
• 04 D. Turn the engine control switch to the ON position.
Expected Result: E. Monitor the diagnostic codes on Cat ET. Check
for an active 04 diagnostic code for the suspect
A diagnostic code is not active. sensor.
Results: Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
• OK – A diagnostic code is not active.
F. Turn the engine control switch to the OFF position.
84 SENR6477-06
Troubleshooting Section

Expected Result: G. Check the operation of the ECM by creating a

short circuit at the ECM.
A 04 diagnostic code is now active for the suspect
sensor(s). a. Short the jumper wire for the suspect sensor
to the analog return in order to create a short
Results: circuit condition.

• OK – A 03 diagnostic code was active before b. Monitor the active diagnostic code screen on
creating the short at the sensor connector. A 04 Cat ET. Check for a 04 diagnostic code for the
diagnostic code became active after creating the suspect sensor.
short at the sensor connector. The harness and
the ECM are OK. There may be a problem with Note: Wait at least 30 seconds in order for the
the sensor. diagnostic codes to become active.

Repair: Temporarily connect a new sensor to the H. Turn the engine control switch to the OFF position.
harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic I. Remove all jumper wires. Return the wiring to the
codes for the sensor. If there are no active original configuration.
diagnostic codes for the sensor, permanently
install the new sensor. Clear any logged diagnostic Expected Result:
codes.
A 03 diagnostic code is active when the sensor
STOP. signal wire is removed from the ECM connector. A
04 diagnostic code is active when the signal wire is
• Not OK – A 03 diagnostic code is still active for shorted to the analog return.
the suspect sensor(s). The problem may be in the
harness or with the ECM. Proceed to Test Step 4. Results:

Test Step 4. Test the Operation of the • OK – The ECM is operating properly. The problem
ECM is in the wiring between the ECM and the connector
for the sensor.
A. Fabricate jumper wires that can be used to replace
the signal wire in the ECM connector for the Repair: If the code is active for more than one
suspect sensor. Crimp a connector socket to one sensor, the problem is most likely in the return wire
end of the jumper wire. for the sensor. Repair the analog return wire for the
sensor or replace the harness.
B. Disconnect the ECM connector for the suspect
sensor. If the code is only active for one sensor, the
problem is most likely in the signal wire for the
C. Remove the signal wire for the suspect sensor sensor. Repair the signal wire for the sensor.
from the ECM connector.
STOP.
D. Install the jumper wire into the terminal location for
the suspect sensor at the ECM connector. • Not OK – One of the following conditions exists:
The 03 diagnostic code is not active when the
E. Connect the ECM connector. sensor signal wire is disconnected. The 04
diagnostic code is not active when the wire jumper
F. Check the operation of the ECM by creating an is shorted to the analog return.
open at the ECM.
Repair: Replace the ECM. Refer to
a. Hold the loose end of the jumper wire away Troubleshooting, “ECM - Replace”. Verify
from any components in order to create an that the problem is resolved.
open circuit condition.
STOP.
b. Turn the engine control switch to the ON
position.

c. Monitor the active diagnostic code screen on

Cat ET. Check for a 03 diagnostic code for the
suspect sensor.

Note: Wait at least 30 seconds in order for the

diagnostic codes to become active.
SENR6477-06 85
Troubleshooting Section

i03211740

Sensor Supply - Test

SMCS Code: 1439-038

System Operation Description:

Use this procedure to troubleshoot the electrical

system if a problem is suspected with a sensor
supply or if any one of the diagnostic codes in Table
27 is active or easily repeated.

Table 27
Diagnostic Codes Table
Code and Description Flash Code Conditions which Generate System Response
this Code
241-00 5 Volt Open Circuit 21 The supply voltage is normal. The code is active and the
The rack signal is below code is logged.
0.3 VDC. The boost signal , All sensors are set to default
oil pressure signal and the values.
coolant temperature signal
are below 0.5 VDC. The
engine rpm is greater than 0.
241-01 5 Volt Short Circuit 21 The supply voltage for the The code is active and the
sensors is less than 3 VDC or code is logged.
the supply voltage is greater All sensors are set to default
than 7.0 VDC. values.
241-02 8 Volt Open Circuit 21 The supply voltage for the The code is active and the
sensors is normal. The rack code is logged.
signal is equal to 5 VDC All sensors are set to default
and the coolant temperature values.
signal is less than 0.6 VDC.
241-03 8 Volt Short Circuit 21 The supply voltage for all of The code is active and the
the sensors is less than 6.4 code is logged.
VDC or the supply voltage is All sensors are set to default
greater than 9.6 VDC. values.

The Electronic Control Module (ECM) supplies a Note: The sensors are not protected from
regulated voltage of 5.0 ± 0.2 VDC to the following overvoltage. A short from the supply line to the
sensors: +Battery may damage the sensors. Repair the sensor
supply and check for any active sensor diagnostic
• Engine oil pressure sensor codes in order to determine if a sensor has failed.

• Atmospheric pressure sensor

• Intake manifold pressure sensor
The ECM supplies a regulated voltage of 8.0 ± 0.4
VDC and 5.0 ± 0.2 VDC to the rack position sensor.

The supply voltage for the sensors is routed from the

ECM to terminal (A) of each sensor connector. The
sensor return for the sensors is routed from the ECM
to terminal (B) of each sensor connector. The ECM
provides short circuit protection for the internal power
supply. A short circuit to the battery will not damage
the internal power supply.
86 SENR6477-06
Troubleshooting Section

g01638014
Illustration 41

g01638357
Illustration 42
(10) + 8 VDC (30) + 5 VDC (35) Analog return

Test Step 1. Inspect the Electrical C. Perform a 45 N (10 lb) pull test on each of the
Connectors and the Wiring wires that are associated with the circuit for the
coolant level sensor.
A. Remove electrical power from the ECM.
D. Check the allen head screw on the ECM connector
B. Thoroughly inspect the customer connector for the proper torque. Refer to Troubleshooting,
J17/P17. Inspect the ECM connector J14/P14. “Electrical Connectors - Inspect” for the correct
Refer to Troubleshooting, “Electrical Connectors - torque values.
Inspect” for details.
SENR6477-06 87
Troubleshooting Section

Expected Result: Repair: Check the supply voltage to the ECM.

Refer to Troubleshooting, “Electrical Power Supply
All connectors, pins, and sockets are completely - Test”.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points. If the voltage is correct, proceed to Test Step 4.

Results: Test Step 3. Check Sensor Supply Voltage

at the 5 Volt Sensors
• OK – The connectors and wiring are OK. Proceed
to Test Step 2. A. Turn the engine control switch to the ON position.

• Not OK – There is a problem with the connectors B. Measure the sensor supply voltage between pin
and/or the wiring. (A) and pin (B) of the following sensor connectors:
inlet manifold pressure sensor, engine oil pressure
Repair: Repair the wiring and connectors or sensor, and atmospheric pressure sensor.
replace the wiring or the connectors. Ensure that
all of the seals are properly connected. Verify that C. Measure the sensor supply voltage between pin
the repair eliminates the problem. (C) and pin (B) of the rack sensor connector.

Verify that the repair eliminates the problem. Expected Result:

STOP. The voltage is 5.0 ± 0.25 VDC for each measurement.

Test Step 2. Check Sensor Supply Results:

Voltages at the ECM
• OK – The voltage is 5.0 ± 0.25 VDC for each
A. Reconnect all connectors. measurement. Proceed to Test Step 4.

B. Turn the engine control switch to the ON position. • NOT OK – The voltage is not 5.0 ± 0.25 VDC for
each measurement. Supply voltage is present at
C. Measure the voltage between P14-30 and P14-35. the ECM but not at the sensor.

D. Measure the voltage between P14-10 and P14-35. Repair: There is a problem in the harness. There
may be a problem in a connector. Repair the wire
Expected Result: and/or the connector, when possible. Replace
parts, if necessary. Verify that the problem is
The voltage measures 5.0 ± 0.25 VDC between resolved.
P14-30 and P14-35. The voltage measures 8.0 ± 0.4
VDC between P14-10 and P14-35. STOP.

Results: Test Step 4. Check Sensor Supply Voltage

at the 8 Volt Sensors.
• Ok – The voltage measures 5.0 ± 0.25 VDC
between P14-30 and P14-35. The voltage A. Turn the engine control switch to the ON position.
measures 8.0 ± 0.4 VDC between P14-10 and
P14-35. Proceed to Test Step 3. B. Measure the sensor supply voltage between pin
(A) and pin (B) of the coolant temperature sensor
• NOT OK – The voltage did not measure 5.0 ± 0.25 connector.
VDC between P14-30 and P14-35.
C. Measure the sensor supply voltage between
Repair: Check the supply voltage to the ECM. pin (A) and pin (B) of the coolant level sensor
Refer to Troubleshooting, “Electrical Power Supply connector.
- Test”.
D. Disconnect the rack sensor connector J11/P11.
If the voltage is correct, proceed to Test Step 5.
E. Measure the sensor supply voltage between pin
• NOT OK – The voltage did not measure 8.0 ± 0.4 (A) and pin (B) of the rack sensor connector.
VDC between P14-10 and P14-35.
Expected Result:

The voltage is 8.0 ± 0.40 VDC for each measurement.

88 SENR6477-06
Troubleshooting Section

Results: Repair: The ECM is not producing the

correct voltage. Replace the ECM. Refer to
• OK – The voltage is 8.0 ± 0.40 VDC for each Troubleshooting, “ECM - Replace” for further
measurement. information.

Repair: The supply voltage is reaching the sensor. STOP.

Refer to Troubleshooting, “Electrical Connectors -
Inspect” if the problem is intermittent.
i03199981

STOP. Shutdown - Test

• NOT OK – The voltage is not 8.0 ± 0.40 VDC for SMCS Code: 1900-038; 7332-038
each measurement.
System Operation Description:
Repair: The supply voltage is present at the ECM
but not at the sensor. There is an open circuit in the Use this procedure to troubleshoot the electrical
harness or in the connector. Repair the harness system if a problem is suspected with the shutdown
or replace the harness. switch.
STOP. The engine shutdown switch provides a primary
means for shutting down the engine. The input is
Test Step 5. Check the ECM occasionally connected to an engine protection
system such as a Electronic Modular Control Panel
A. Reconnect P14 and leave all the sensors (EMCP II). Refer to the Electrical System Schematic
disconnected. for details.
B. Turn the engine control switch to the ON position. The engine shutdown is activated by connecting the
engine shutdown input to ground. A open circuit at the
C. Measure the voltage between P14-30 and P14-35. engine shutdown input deactivates the system. The
Electronic Control Module (ECM) closes the linkage
D. Measure the voltage between P14-10 and P14-35. to the rack and the ECM cuts power to the fuel shutoff
solenoid when an engine shutdown is detected.
Expected Result:

The voltage measures 5.0 ± 0.25 VDC between

P14-30 and P14-35. The voltage measures 8.0 ± 0.4
VDC between P14-10 and P14-35.

Results:

• OK – The voltage measures 5.0 ± 0.25 VDC

between P14-30 and P14-35. The voltage
measures 8.0 ± 0.4 VDC between P14-10 and
P14-35.

Repair: There is a problem with the harness.

Repair the harness or replace the harness.

STOP.

• NOT OK – The voltage did not measure 5.0 ± 0.25

VDC between P14-30 and P14-35.

Repair: The ECM is not producing the

correct voltage. Replace the ECM. Refer to
Troubleshooting, “ECM - Replace” for further
information.

STOP.

• NOT OK – The voltage did not measure 8.0 ± 0.4

VDC between P14-10 and P14-35.
SENR6477-06 89
Troubleshooting Section

g01631694
Illustration 43

g01635597
Illustration 44
(21) - Battery (31) Engine shutdown

Test Step 1. Inspect Electrical Connectors Results:

and Wiring
• OK – All connectors, pins, and sockets are
A. Turn the engine control switch to the OFF position. completely coupled and/or inserted. The harness
and wiring are free of corrosion, of abrasion, and of
B. Thoroughly inspect the J14/P14 pinch points. Proceed to Test Step 2.
connector.Thoroughly inspect the J17/P17
connector. The connectors should be free of • NOT OK – There is a problem in the connectors
abrasions, corrosion and pinch points. Refer to and/or wiring.
Troubleshooting, “Electrical Connectors - Inspect”.
Repair: Repair the connectors or the harness
C. Perform a 45 N (10 lb) pull test on each of and/or replace the connectors or the harness.
the wires that are associated with the engine Ensure that all of the seals are correctly in place
shutdown switch. and ensure that the connectors are completely
coupled.
D. Check the allen head screw on each ECM
connector for the proper torque. Refer to Verify that the repair eliminates the problem.
Troubleshooting, “Electrical Connectors - Inspect”.
STOP.
E. Check the harness for abrasions and for pinch
points from the battery to the ECM. Test Step 2. Check the Switch Status with
Caterpillar Electronic Technician (ET)
Expected Result:
A. Turn the engine control switch to the OFF position.
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are B. Connect to the service tool connector.
free of corrosion, of abrasion, and of pinch points.
C. Turn the engine control switch to the ON position.
90 SENR6477-06
Troubleshooting Section

D. Toggle the engine shutdown switch. Observe the Repair: The ECM and the harness are functioning
status on Cat ET. properly. The customer wiring and the junction box
are the source of the problem.
Expected Result:
STOP.
The status reads “RUN” when the switch is in the
RUN position. The status reads “STOP” when the • NOT OK – The status does not read “RUN” when
switch is in the STOP position. the wire is disconnected. The status does not read
“STOP” when the wire is connected. Proceed to
Results: Test Step 4.

• OK – The status reads “RUN” when the switch Test Step 4. Short The Switch Inputs At
is in the RUN position. The status reads “STOP” The ECM
when the switch is in the STOP position.
A. Turn the engine control switch to the OFF position.
Repair: The shutdown input is functioning properly.
Refer to Troubleshooting, “Electrical Connectors - B. Remove wire B450-BU from P14-17 and leave the
Inspect” for further information. wire disconnected.

STOP. C. Turn the engine control switch to the ON position.

• NOT OK – The status does not read “RUN” when D. Observe status of the engine shutdown switch on
the switch is in the RUN position. The status does Cat ET.
not read “STOP” when the switch is in the STOP
position. Proceed to Test Step 3. E. Install Deutsch connectors on a 203 mm
(8 inch wire).
Test Step 3. Short the Inputs at the
Connector F. Connect the wire between P14-17 and the battery
negative.
A. Turn the engine control switch to the OFF position.
G. Observe the status of the engine shutdown switch
B. Remove wire B450-BU from P17-14 and leave the on Cat ET.
wire disconnected.
Expected Result:
C. Turn the engine control switch to the ON position.
The status of the engine shutdown switch reads
D. Observe the status of the engine shutdown switch “RUN” when the wire is not installed. The status of
on Cat ET. the engine shutdown switch reads “STOP” when the
wire is installed.
E. Turn the engine control switch to the OFF position.
Results:
F. Short wire B450-BU to the battery negative. Use
an ohmmeter to verify the connection. • OK – The status of the engine shutdown switch
reads “RUN” when the wire is not installed. The
G. Observe the status of the engine shutdown switch status of the engine shutdown switch reads “STOP”
on Cat ET. when the wire is installed.

H. Turn the engine control switch to the OFF position. Repair: The ECM reads the inputs properly. There
is a problem in the harness or the junction box.
Expected Result:
STOP.
The status reads “RUN” when the wire is
disconnected. The status reads “STOP” when the • NOT OK – The status of the engine shutdown
wire is connected. switch does not read “RUN” when the wire is not
installed. The status of the engine shutdown switch
Results: does not read “STOP” when the wire is installed.

• OK – The status reads “RUN” when the wire is Repair: The ECM is not reading the inputs correctly.
disconnected. The status reads “STOP” when the Replace the ECM. Refer to Troubleshooting, “ECM
wire is connected. - Replace” for further information.

STOP.
SENR6477-06 91
Troubleshooting Section

i03193301

Speed Control (Auxiliary) - Test

SMCS Code: 1276-038; 1913-038; 1915-038;
7332-038-VF

System Operation Description:

The idle/rated switch allows the operator to maintain

the engine at low idle. This is allowed after sufficient
oil pressure has been obtained. Idle mode is activated
by an open circuit at the idle/rated Input to the ECM.
Rated mode is selected by connecting the idle/rated
input to ground. The idle/rated input should measure
approximately 24 VDC at P14-17. The switch input
is open at this time. When the switch is closed, the
voltage will be less than .5 VDC.

Use this procedure to troubleshoot the electrical

system if a problem is suspected with the circuit for
the idle/rated switch.

g01627553
Illustration 45

g01635735
Illustration 46
(17) Idle/Rated switch

Test Step 1. Inspect the Electrical B. Thoroughly inspect the P17/J17 connector for
Connectors and the Wiring the idle/rated switch. Inspect the ECM connector
J14/P14. Refer to Troubleshooting, “Electrical
A. Remove electrical power from the ECM. Connectors - Inspect” for details.

C. Perform a 45 N (10 lb) pull test on each of the

wires that are associated with the circuit for the
coolant level sensor.
92 SENR6477-06
Troubleshooting Section

D. Check the allen head screw on the ECM connector Test Step 3. Short the Switch Inputs at
for the proper torque. Refer to Troubleshooting, the Switch
“Electrical Connectors - Inspect” for the correct
torque values. A. Turn the engine control switch to the OFF position.

Expected Result: B. Disconnect the wires from the idle/rated switch.

All connectors, pins, and sockets are completely C. Turn the engine control switch to the ON position.
coupled and/or inserted, and the harness and wiring The engine should remain in the OFF position.
are free of corrosion, of abrasion and of pinch points.
D. Connect and disconnect the wires for the idle/rated
Results: switch. Observe the status on Cat ET.

• OK – The connectors and wiring are OK. Proceed Expected Result:

to Test Step 2.
The status of the idle/rated switch reads “Idle”
• Not OK – There is a problem with the connectors when the wires are disconnected. The status of the
and/or the wiring. idle/rated switch reads “Rated” when the wires are
shorted.
Repair: Repair the wiring and connectors or
replace the wiring or the connectors. Ensure that Results:
all of the seals are properly connected. Verify that
the repair eliminates the problem. • OK – The status of the Idle/Rated Switch reads
“Idle” when the wires are disconnected. The status
Verify that the repair eliminates the problem. of the idle/rated switch reads “Rated” when the
wires are shorted.
STOP.
Repair: Check the switch terminals for corrosion
Test Step 2. Check the Switch Status with or damage. If there is no corrosion or damage,
an Electronic Service Tool replace the idle/rated switch.

A. Turn the engine control switch to the OFF position. STOP.

B. Connect Caterpillar Electronic Technician (ET) to • NOT OK – The status of the idle/rated switch does
the service tool connector. not read “Idle” when the wires are disconnected.
The status of the idle/rated switch does not read
C. Turn the engine control switch to the ON position. “Rated” when the wires are shorted. Proceed to
The engine should remain in the OFF position. Test Step 4.

D. Observe the status of the idle/rated switch on Cat Test Step 4. Check for Engine Ground at
ET. Operate the idle/rated switch and observe the the Switch
status.
A. Disconnect the -Battery wire at the idle/rated
Expected Result: switch.

The status of the idle/rated switch should read “Idle” B. Measure the resistance between the- battery wire
when the switch is open. The status of the idle/rated and engine ground.
switch should read “Rated” when the switch is closed.
Expected Result:
Results:
The resistance measures less than 10 Ohms.
• OK
Results:
Repair: The idle/rated switch is functioning
properly. Refer to Troubleshooting, “Electrical • OK – The resistance measures less than 10
Connectors - Inspect”. Ohms. Proceed to Test Step 5.

STOP. • NOT OK – The resistance measures more than

10 Ohms.
• NOT OK – The status of the idle/rated switch does
not read “Idle” when the switch is open. The status
of the idle/rated switch does not read “Rated” when
the switch is closed. Proceed to Test Step 3.
SENR6477-06 93
Troubleshooting Section

Repair: There is an open in the harness. Repair Test Step 7. Short the Switch Input at the
the harness or replace the harness. ECM
STOP. A. Turn the engine control switch to the OFFposition.

Test Step 5. Check the Resistance B. Remove wire C418-WH from connector P14-17.
through the Harness
C. Turn the engine control switch to the ON position.
A. Disconnect the wires from the idle/rated switch. Observe the status on Cat ET.
Connect the two wires together without the switch.
D. Turn the engine control switch to the OFF position.
B. Disconnect J14/P14. Observe the status on the Cat ET.

C. Measure the resistance between P14-17 and E. Insert a wire with a “Deutsch” socket terminal into
P14-21. P14-17. Connect the other end to engine ground.

Expected Result: F. Turn the engine control switch to the ON position.

Observe the status on Cat ET.
The resistance measures less than 10 Ohms.
G. Turn the engine control switch to the OFF position.
Results: Observe the status on Cat ET.

• OK – The resistance measures less than 10 Expected Result:

Ohms. Proceed to Test Step 6.
The status of the idle/rated switch reads “Idle” when
• NOT OK – The resistance measures more than the wire is disconnected. The status of the idle/rated
10 Ohms. switch reads “Rated” when the wire is connected.

Repair: There is a open in the harness. Repair the Results:

harness or replace the harness.
• OK – The status of the idle/rated switch reads
STOP. “Idle” when the wire is disconnected. The status of
the idle/rated switch reads “Rated” when the wire
Test Step 6. Check For Shorts In The is connected.
Harness.
Repair: The harness is faulty. Repair the harness
A. Disconnect the wires for the idle/rated switch. or replace the harness.

Note: The wires should be isolated from each other. STOP.

The wires should not be allowed to come in contact
with the engine ground. • NOT OK – The ECM is not reading the signal.
Replace the ECM. STOP.
B. Disconnect J14/P14.
i03245491
C. Measure the resistance between P14-17 and
P14-21. Speed Control (PWM) - Test
Expected Result: SMCS Code: 1276-038; 1913-038; 1915-038
The resistance measures more than 20,000 Ohms. System Operation Description:
Results: The throttle and the inputs of the droop to the ECM
are provided by a throttle or by a load share module.
• OK – The resistance measures more than 20,000 The inputs are provided through the wiring of the
Ohms. Proceed to Test Step 7. equipment. These inputs are constant frequency
signals with a variable pulse width. The signals are
• NOT OK – The resistance measures less than expressed as a percentage between 0 and 100
20,000 Ohms. percent duty cycle.
Repair: There is a short in the harness. Repair the
harness or replace the harness.

STOP.
94 SENR6477-06
Troubleshooting Section

The throttle signal and the input signal of the droop

have a duty cycle of 5 percent to 10 percent for low
throttle and 90 percent to 95 percent at full throttle.
The throttle signal is translated by the ECM into the
throttle position between 0 and 100 percent. The
signal for the droop is translated into a setting for the
droop of 0 to 10 percent.

Use this procedure to troubleshoot the electrical

system if a problem is suspected with the throttle
input or if the diagnostic code in Table 1 is active.

Table 1
Diagnostic Codes Table
Code and Description Flash Code Conditions which Generate System Response
this Code
91-8 Throttle Position Sensor 32 The Engine's Electronic The diagnostic code is active
: Abnormal Frequency, Pulse Control Module (ECM) and the code is logged. The
Width, or Period detects a sensor frequency throttle signal defaults to a
that is less than 150 Hz or zero percent duty cycle.
a sensor frequency that is
greater than 1000 Hz for two
seconds.
91-10 Throttle Position 32 The Engine's Electronic The diagnostic code is active
Sensor : Abnormal Rate of Control Module (ECM) and the code is logged.
Change detects a sensor frequency
that is changing at a abnormal
rate.

g01646874
Illustration 47

g01646895
Illustration 48
(08) Primary throttle (37) Droop
SENR6477-06 95
Troubleshooting Section

Test Step 1. Inspect the Electrical D. Record the throttle position reading and the
Connectors and the Wiring Harness reading of the droop on Cat ET during the
movement of the throttle setting and the droop
A. Remove electrical power from the ECM. setting from minimum to maximum.

B. Thoroughly inspect the J14/P14 ECM connector. E. Turn the engine control switch to the OFF position.
Inspect the J17/P17 customer connector. Refer to
Troubleshooting, “Electrical Connectors - Inspect” Expected Result:
for details.
The status of the throttle changes from 0 percent to
C. Perform a 45 N (10 lb) pull test on each of the 100 percent as the throttle input is changed from low
wires that are associated with the circuit. idle to high idle.

D. Check the allen head screw on the ECM connector The status of the droop changes from 0 percent to 10
for the proper torque. Refer to Troubleshooting, percent as the input of the droop is changed from
“Electrical Connectors - Inspect” for the correct low droop to high droop.
torque values.
Results:
Expected Result:
• OK – The status of the throttle changes from 0
All connectors, pins, and sockets are completely percent to 100 percent as the throttle input is
coupled and/or inserted, and the harness and wiring changed from low idle to high idle. The status of
are free of corrosion, of abrasion and of pinch points. the droop should change from 0 percent to 10
percent as the input of the droop is changed from
Results: low droop to high droop.

• OK – All connectors, pins, and sockets are Repair: The throttle Input is working properly.
completely coupled and/or inserted, and the Reset the throttle and the droop to the original
harness and wiring are free of corrosion, of settings. Reconnect all wires.
abrasion and of pinch points. Proceed to Test Step
2. STOP.

• NOT OK – There is a problem with the connectors • NOT OK – The status of the throttle does not
and/or the wiring. change from 0 percent to 100 percent as the
throttle input is changed from low idle to high idle.
Repair: Repair the wiring and connectors or The status of the droop does not change from 0
replace the wiring or the connectors. Ensure that percent to 10 percent as the input of the droop is
all of the seals are properly connected. Verify that changed from low droop to high droop. Proceed
the repair eliminates the problem. to Test Step 3.

STOP. Test Step 3. Check the Supply Voltage for

the Throttle's Module
Test Step 2. Check Throttle and Droop
Readings on Caterpillar Electronic A. Turn the engine control switch to the ON position.
Technician (ET)
B. Measure the voltage between terminal (+B) and
A. Connect to the service tool connector. terminal (-B) of the throttle's module.

Note: Disconnect the wires from the output terminals C. Turn the engine control switch to the OFF position.
when you troubleshoot a generator with a load share
module. Connect a 9X-9591 Electrical Converter Gp Expected Result:
with a 122-9458 Potentiometer to the wires. Do not
attempt to parallel the generator when the load share The voltage measures between 24 VDC and 27 VDC
module is disconnected.
Results:
B. Turn the engine control switch to the ON position.
• OK – The voltage is between 24 VDC and 27
C. Record the throttle position and the readings of VDC. Proceed to Test Step 4.
the droop on Cat ET.
• NOT OK – The voltage is not between 24 VDC
and 27 VDC.
96 SENR6477-06
Troubleshooting Section

Repair: The throttle's module is not receiving the Test Step 5. Check the Isolated Droop
correct voltage. Repair the wiring or replace the Signal of the Duty Cycle at the Throttle's
wiring. Module
STOP. A. Turn the engine control switch to the OFF position.

Test Step 4. Check the Isolated Throttle B. Remove the wire from terminal (D) of the throttle's
Signal at the Throttle's Module module.

A. Turn the engine control switch to the OFF position. C. Turn the engine control switch to the ON position.

B. Remove the wire from terminal (S) of the throttle's D. Measure the duty cycle between terminal (D) and
module. terminal (-B). Record the measurement of the duty
cycle during the movement of the input for the
C. Turn the engine control switch to the ON position. droop from the low position to the high position.

D. Measure the duty cycle between terminal (S) and E. Measure the frequency between terminal (D) and
terminal (-B). Record the duty cycle during the terminal (-B). Record the frequency during the
movement of the throttle input from low idle to movement of the input for the droop from the low
high idle. position to the high position.

E. Measure the frequency between terminal (S) and F. Turn the engine control switch to the OFF position.
terminal (-B). Record the frequency during the
movement of the throttle input from low idle to G. Reconnect the wire to terminal (D).
high idle.
Expected Result:
F. Reconnect the wire to terminal (S).
The duty cycle is between 5 percent and 10 percent
G. Turn the engine control switch to the OFF position. while the throttle input is set to the LOW IDLE
position. The duty cycle is between 90 percent and
Expected Result: 95 percent while the throttle input is set to the HIGH
IDLE position. The frequency is between 400 Hz and
The measurement of the duty cycle is between 5 600 Hz.
percent and 10 percent while the throttle input is set
to the low idle position. The measurement of the duty Results:
cycle is between 90 percent and 95 percent while
the throttle input is set to the high idle position. The • OK – The duty cycle is between 5 percent and
frequency is between 400 Hz and 600 Hz. 10 percent while the throttle input is set to the
LOW IDLE position. The duty cycle is between
Results: 90 percent and 95 percent while the throttle input
is set to the HIGH IDLE position. The frequency
• OK – The measurement of the duty cycle is is between 400 Hz and 600 Hz. Proceed to Test
between 5 percent and 10 percent while the Step 6.
throttle input is set to the low idle position. The
measurement of the duty cycle is between 90 • NOT OK – The duty cycle is not between 5 percent
percent and 95 percent while the throttle input is set and 10 percent while the throttle input is set to the
to the high idle position. The frequency is between LOW IDLE position. The duty cycle is not between
400 Hz and 600 Hz. Proceed to Test Step 5. 90 percent and 95 percent while the throttle input
is set to the HIGH IDLE position. The frequency is
• NOT OK – The measurement of the duty cycle is not between 400 Hz and 600 Hz.
not between 5 percent and 10 percent while the
throttle input is set to the low idle position. The Repair: Replace the throttle's module.
measurement of the duty cycle is not between 90
percent and 95 percent while the throttle input is STOP.
set to the high idle position. The frequency is not
between 400 Hz and 600 Hz. Test Step 6. Check the Throttle and the
Droop Signal at the ECM
Repair: Replace the throttle's module.
A. Turn the engine control switch to the ON position.
STOP.
SENR6477-06 97
Troubleshooting Section

B. Measure the duty cycle of the throttle signal Results:

between pin 8 of connector P14 and engine
ground. Record the duty cycle during the • OK – The duty cycle is between 5 percent and
movement of the throttle input from low idle to 10 percent while the throttle input is set to the
high idle. LOW IDLE position. The duty cycle is between 90
percent and 95 percent while the throttle input is
C. Measure the duty cycle of the droop signal set to theHIGH IDLE position.
between pin 37 of ECM connector P14 and
engine ground. Record the duty cycle during the Repair: The throttle's module is operating properly.
movement of the throttle input from low droop to
high droop. STOP.

D. Turn the engine control switch to the OFF position. • NOT OK – The duty cycle is not between 5 percent
and 10 percent while the throttle input is set to the
Expected Result: LOW IDLE position. The duty cycle is not between
90 percent and 95 percent while the throttle input
The duty cycle is between 5 percent and 10 percent is set to the HIGH IDLE position.
while the throttle input is set to the low idle position.
The duty cycle is between 90 percent and 95 percent Repair: Disconnect connector P14 and check for
while the throttle input is set to the high idle position. damage or corrosion on pin 37 and pin 8. If the
problem is not resolved, replace the ECM. Refer to
Results: Troubleshooting, “ECM - Replace”.

• OK – The duty cycle is between 5 percent and STOP.

10 percent while the throttle input is set to the
LOW IDLE position. The duty cycle is between 90
i03238691
percent and 95 percent while the throttle input is set
to the HIGH IDLE position. Proceed to Test Step 7. Speed Control - Test
• NOT OK – The duty cycle is not between 5 percent SMCS Code: 7332-038-VF
and 10 percent while the throttle input is set to the
LOW IDLE position. The duty cycle is not between System Operation Description:
90 percent and 95 percent while the throttle input
is set to the HIGH IDLE position. The engine speed switch monitors the engine rpm for
overspeed conditions and for crank termination.
Repair: The throttle's module is producing the
correct signal. The signal is not reaching the ECM. Crank termination signals when cranking must be
Repair the wiring harness or replace the wiring terminated. When the crank termination speed is
harness. reached, terminal 10 is energized in order to start the
engine hour meter.
STOP.

Test Step 7. Check The ECM

A. Connect Cat ET to the service tool connector.

B. Turn the engine control switch to the ON position.

C. Record the duty cycle of the throttle position

sensor from Cat ET during the movement of the
throttle input from low idle to high idle.

D. Record the droop from Cat ET during the

movement of the setting for the droop from
minimum to maximum.
g01644993
Illustration 49
Expected Result:
Engine speed switch

The duty cycle is between 5 percent and 10 percent

while the throttle input is set to the low idle position.
The duty cycle is between 90 percent and 95 percent
while the throttle input is set to the HIGH IDLE
position.
98 SENR6477-06
Troubleshooting Section

Test Step 1. Check the Engine Speed Repair: Check the diode between ESS terminal
Switch for Supply Voltage 8 and ESS terminal 10. If the voltage is still high,
remove all wires from terminal 10. This should
A. Make sure that the wiring is connected according show the voltage source. If the problem is not
to the wiring schematic. resolved, replace the ESS.

B. Turn the engine control switch to the ON position. STOP.

C. Measure the voltage between terminal 6 and Test Step 3. Check Voltage at Terminal 10
terminal 5 of the engine speed switch (ESS). at Crank Terminate rpm Input
D. Measure the voltage between ESS terminal 11 A. Disconnect the harness of the engine speed input
and terminal 5. at ESS Terminal 3 and terminal 4.

E. Turn the engine control switch to the OFF position. B. Connect a signal generator to ESS terminal 3 and
terminal 4.
Expected Result:
C. Set the signal generator frequency to 0 Hz.
The voltage is between 22 VDC and 27 VDC.
D. Turn the engine control switch to the ON position.
Results:
E. Slowly increase the frequency. Monitor the voltage
• OK – The voltage is between 22 VDC and 27 between ESS terminal 5 and terminal 10. Record
VDC. Proceed to Test Step 2. the frequency that causes the voltage to increase
to battery positive voltage.
• NOT OK – The voltage is not between 22 VDC
and 27 VDC. F. Turn the engine control switch to the OFF position.

Repair: The ESS is not receiving the correct Expected Result:

voltage. Repair the harness or replace the harness.
The voltage between ESS terminal 10 and ESS
STOP. terminal 5 increases to battery positive voltage when
the frequency reaches 875 Hz to 920 Hz.
Test Step 2. Check the Voltage at Terminal
10 at 0 rpm Input Results:

A. Turn the engine control switch to the ON position. • OK – The voltage between ESS terminal 10
and ESS terminal 5 increases to battery positive
B. Measure the voltage between ESS terminal 10 voltage when the frequency reaches 875 Hz to 920
and terminal 5. Hz. Proceed to Test Step 4.

Note: The hour meter must be connected during the • NOT OK – The voltage between ESS terminal 10
test of the crank terminate in order to provide a load. and ESS terminal 5 does not increase to battery
The positive terminal of the engine hour meter should positive voltage when the frequency reaches 875
be connected to ESS terminal 10. Hz to 920 Hz.

C. Turn the engine control switch to the OFF position. Repair: Refer to Troubleshooting, “Crank
Terminate - Calibrate”.
Expected Result:
STOP.
The voltage should be less than 1 VDC.
Test Step 4. Check the Voltage at the
Results: Engine Hour Meter
• OK – The voltage is less than 1 VDC. Proceed to A. Turn the engine control switch to the ON position.
Test Step 3.
B. Measure the voltage between the terminals of the
• Not OK – The voltage is greater than 1 VDC. engine hour meter.

C. Turn the engine control switch to the OFF position.

SENR6477-06 99
Troubleshooting Section

Expected Result: C. Use a test lamp and monitor the voltage across
the engine hour meter. Monitor the test lamp
The voltage between the terminals of the engine hour during the starting of the engine.
meter is +battery.
Expected Result:
Results:
The test lamp illuminates as the engine accelerates
• OK – The voltage between the terminals of the from cranking rpm to idle rpm.
engine hour meter is +battery. Replace the hour
meter if the hour meter is not recording engine Results:
hours of operation. Proceed to Test Step 5.
• OK – The test lamp illuminates as the engine
• NOT OK – The correct voltage is present at the accelerates from cranking rpm to idle rpm.
ESS but not at the hour meter. Repair the harness
or replace the harness. STOP. Repair: The ESS is functioning properly.

Test Step 5. Reduce the Frequency and STOP.

Check the Voltage at Terminal 10
• NOT OK – The test lamp does not illuminate as the
A. Disconnect the harness of the engine speed input engine accelerates from cranking rpm to idle rpm.
at ESS terminal 3 and terminal 4.
Repair: The crank terminate functions properly
B. Connect a signal generator to ESS terminal 3 and with a signal generator, but not with the harness of
terminal 4. the engine speed input. Repair the engine speed
input circuit.
C. Turn the engine control switch to the ON position.
STOP.
D. Set the signal generator frequency to 900 Hz.

E. Slowly decrease the frequency. Monitor the

voltage between ESS terminal 5 and terminal 10.
Record the frequency that causes the voltage to
drop below 1.0 VDC.

F. Turn the engine control switch to the OFF position.

Expected Result:

The voltage between terminal 5 and terminal 10

should drop below 1.0 VDC when the frequency is
less than 20 Hz. The frequency is equivalent to 9 rpm.

Results:

• OK – The voltage between terminal 5 and terminal

10 drops below 1.0 VDC when the frequency is
less than 20 Hz. Proceed to Test Step 6.

• NOT OK – The voltage between terminal 5 and

terminal 10 does not drop below 1.0 VDC when the
frequency is less than 20 Hz.

Repair: Replace the ESS.

STOP.

Test Step 6. Check the Operation of the

Crank Terminate
A. Turn the engine control switch to the OFF position.

B. Reconnect the harness of the engine speed input.

100 SENR6477-06
Troubleshooting Section

Service i02385531

Factory Passwords
i03502923
SMCS Code: 0785; 1900
Customer Passwords
SMCS Code: 0785; 1900
Passwords
Passwords are part of a security system that helps to
Customer passwords may be used to protect
prevent unauthorized changing of certain parameters.
customer parameters from being changed. Caterpillar
Passwords prevent unauthorized erasing of logged
Electronic Technician (ET) can be used to change
events. Passwords allow the factory to control access
certain parameters. There are some parameters that
to engine calibration parameters. Passwords allow
cannot be changed and there are some applications
the customer to control access to certain engine
that do not allow any changes to the programmable
parameters.
monitoring system. The passwords are programmed
into the Electronic Control Module (ECM) with
the Cat ET. One password may be programmed Factory Passwords
or both passwords may be programmed. If
customer passwords are not programmed, customer Factory passwords are required to clear any event
parameters may be changed by anyone. code. Factory passwords are required to change
certain parameters such as “Full Load Setting”.
To obtain customer passwords, contact the owner of Factory passwords restrict changes to authorized
the engine. If the owner has forgotten the customer personnel. When the correct factory passwords have
passwords, customer passwords may be read by been entered, the changes can then be made.
using Cat ET. Factory passwords are required in
order to read customer passwords. Note: Factory passwords are calculated on a
computer system that is only available to Caterpillar
Use the following procedure in order to read customer dealers.
passwords with Cat ET:
In order to obtain the proper factory passwords,
1. Select the “Information” menu. Then select certain information must be given to an authorized
“Passwords”. Caterpillar dealer. Since the factory passwords
contain alphabetic characters, the Caterpillar
2. When the “Factory Password” screen appears, Electronic Technician (ET) can be used to perform
record the information that is listed on the “Factory this function. In order to obtain the factory passwords,
Passwords Worksheet”. Refer to programming proceed as if you already have the factory passwords.
parameters Troubleshooting, “Factory Passwords At some point, if the factory passwords are actually
Worksheet” for additional information. needed, Cat ET will request the factory passwords
and Cat ET will display the information that is required
3. Obtain the factory passwords. The information to obtain the factory passwords.
that is recorded on the “Factory Passwords
Worksheet” must be provided. When you obtain Note: The old interlock code and the new interlock
the factory passwords, a permanent record of your code are required to change the interlock code on a
access is generated at Caterpillar. used Electronic Control Module (ECM).

4. From the “Factory Password” screen, enter the The Cat ET screen for factory passwords will display
factory passwords. the following parameters:

5. When the “Read Customer Passwords” screen • Serial number of the ECM
appears, record the customer passwords. The
customer passwords may then be used to change • Engine serial number
parameters that are customer programmable.
• Serial number for Cat ET
• Reason code
• Interlock code
• Total tattletale
SENR6477-06 101
Troubleshooting Section

Note: Factory passwords are only valid for the current 3. Use Cat ET to verify that the following information
Cat ET screen. A different set of factory passwords has been entered correctly:
will be required if you exit the current Cat ET screen.
A different set of passwords will be required to • Engine serial number
change information on another Cat ET screen.
• Serial number for the electronic control module
Customer Passwords
• Serial number for Cat ET
Customer passwords allow the customer to restrict
access to parameters that can be changed by the • Total tattletale
customer. The customer passwords cannot be longer
than eight characters. The customer passwords may • Reason code
consist of alphanumeric characters. The customer
has the option of entering one or two customer For additional information, refer to Troubleshooting,
“Factory Passwords”.
passwords.

If customer passwords have been entered, then i03175286

the customer passwords are required to change
any parameter that is customer programmable. Electronic Service Tool Does
Refer to the diagnostic procedure Troubleshooting,
“System Configuration Parameters” for more detail
Not Communicate
on parameters that are customer programmable.
SMCS Code: 0785; 1900
Note: If the customer passwords are lost, the
System Operation Description:
parameters that are protected by customer
passwords cannot be changed. You must use factory
Use this procedure to solve communication problems
passwords in order to read the customer passwords.
between Caterpillar Electronic Technician (ET) and
You may then use those customer passwords to
the Electronic Control Module (ECM). Cat ET must
change parameters that have been protected by
communicate with the ECM in order to fully service
customer passwords.
the engine.

i02826488 There is a power indicator on the communication

adapter that indicates that the communication
ECM Will Not Accept Factory adapter is receiving power. An indicator on the
Passwords communication adapter indicates that communication
is occurring on the data link. Cat ET displays a
SMCS Code: 0785; 1901 message if Cat ET can not communicate with the
data link.

Probable Causes The following items can cause a communication

problem:
One of the following items may not be recorded
correctly on the Caterpillar Electronic Technician • Cat ET
(ET):
• Communication adapter and/or cables
• Passwords
• Connector or wiring problem
• Serial numbers
• Electrical power supply to the service tool
• Total tattletale connector

• Reason code • ECM or personality module

Recommended Actions This procedure determines the root cause of failure

to communicate on the data link.
1. Verify that the correct passwords were entered.
Check every character in each password. Remove Test Step 1. Verify that the Newest
the electrical power from the engine for 30 Version of Cat ET is Being Used
seconds and then retry.
Check the version of Cat ET. Cat ET must be the
2. Verify that Cat ET is displaying the “Enter Factory newest version.
Passwords” dialog box.
102 SENR6477-06
Troubleshooting Section

Expected Result: D. Verify that “Caterpillar Communications Adapter II

(Serial IP)” is selected.
Cat ET is the most current version.
If “Caterpillar Communications Adapter II (Serial
Results: IP)” is not an option for selection, the firmware for
the communications adapter must be updated.
• OK – Cat ET is the most current version. Attempt Perform the following procedure:
to establish communication. Continue with this
procedure if the communication adapter does not Update the communication adapter's firmware by
communicate. using the “Comm Adapter II Toolkit”. Then, select
the “Caterpillar Communications Adapter II (Serial
• Not OK – Cat ET is an old version. IP)” option.

Repair: Download the newest version of Cat ET. Continue with this procedure.

Attempt to establish communication. Continue with E. Check for any hardware that is utilizing the
this procedure if the communication adapter does same port as the communications adapter. If any
not communicate. devices are configured to use the same port, exit
or close the software programs for that device.
Test Step 2. Verify that the Correct
Communication Adapter and Cables are Note: The most commonly used port is “COM 1”.
Being Used
F. Click “OK”.
Refer to Troubleshooting, “Electronic Service Tools”
in order to determine the correct communication Note: Cat ET must reconnect in order for any
adapter and cables. changes to be used. Electronically disconnect Cat
ET if changes were made to any of the settings
Expected Result: for communications. Electronically connect Cat ET.
Attempt to establish communication. Observe the
The correct communication adapter and cables are indicator on the communications adapter.
used.
Expected Result:
Results:
Cat ET communicates.
• OK – The correct communication adapter and
cables are being used. Attempt to establish Results:
communication. Continue with this procedure if the
communication adapter does not communicate on • OK – Cat ET communicates. STOP.
the data link.
• Not OK – Cat ET does not communicate. The
• Not OK – An incorrect communication adapter or power indicator is not illuminated. Proceed to Test
cable was being used. Step 4.

Repair: Connect the correct communication • Not OK – Cat ET does not communicate. The
adapter or cable. Refer to Troubleshooting, power indicator is illuminated. Proceed to Test
“Electronic Service Tools”, if necessary. Step 6.

Attempt to establish communication. Continue with

this procedure if the communication adapter does
not communicate on the data link.

Test Step 3. Verify that Cat ET is

Configured Correctly
Cat ET must be configured correctly in order to
communicate. Perform the following procedure:

A. Click on the “Utilities” menu.

B. Click on the “Preferences” menu.

C. Select the “Communications” tab.

SENR6477-06 103
Troubleshooting Section

Test Step 4. Check the Electrical Power Test Step 5. Check the Service Tool
to the Communications Adapter Connector
A. Perform a visual inspection of the wiring to the
service tool connector. Look for these problems:

• Harness damage that is caused by chafing

• Harness damage that is caused by excessive
heat

B. Inspect the service tool connector. Pull on each

wire that is associated with the data link. This
verifies that each wire is properly attached to the
terminal and that the terminal is properly inserted
into the connector.
g01350067
Illustration 50 Repair any wiring problems. Attempt to establish
Power terminals on the service tool connectors. communication after the wiring has been repaired.
(A) +Battery
(B) −Battery Expected Result:

A. Refer to Illustration 50. Check for battery voltage The harness for the service tool is OK.
at the service tool connector.
Results:
Expected Result:
• OK – The harness for the data link is OK.
Battery voltage is not present at the service tool
connector. Repair: Test the circuit for the Cat Data Link.

Results: STOP.

• OK – Battery voltage is not present at the service Test Step 6. Check the ECM and the
tool connector. Personality Module
Repair: Inspect the wiring and fuses. Determine The electronic service tool will not communicate with
the cause of the missing voltage. Make the the ECM if the personality module is not correctly
necessary repairs. installed.

Attempt to establish communication after the Expected Result:

electrical power is at the service tool connector.
Proceed to Test Step 6 if the service tool does not The personality module is installed correctly.
communicate.
Results:
• Not OK – Battery voltage is present at the service
tool connector. • OK – The personality module is installed correctly.
STOP.
Repair: Verify that the cable between the service
tool connector and the communication adapter is • Not OK – The personality module is not installed
OK. Replace the cable, if necessary. correctly.

Replace the communication adapter if the following Repair: Refer to Troubleshooting,

conditions are true: “ECM/Personality Module - Test” for testing
procedures.
• There is power at the cable's data link connector.
STOP.
• The communication adapter's power indicator
is not illuminated.

STOP.
104 SENR6477-06
Troubleshooting Section

i03167560 Note: Customer parameters and system parameters

must be programmed on the initial installation of
ECM Software - Install a new ECM. Program the parameters into the
ECM when the ECM is initially energized. Refer to
SMCS Code: 1901-591; 7620-012 Troubleshooting, “ECM/Personality Module - Test” for
troubleshooting procedures.
Replacing the Personality Module
i03165849
The personality module is the software which controls
the behavior of the Electronic Control Module (ECM). ECM - Replace
The personality module contains all of the software
for the ECM. When troubleshooting has indicated SMCS Code: 1901-510
that the personality module has failed, temporarily
mount a new personality module on the side of the The Electronic Control Module (ECM) contains no
engine. Test the engine with the new personality moving parts. Replacement of the ECM can be
module. If the problem no longer exists, proceed with costly. Replacement can also be a time consuming
the following steps. task. Most electronic failures occur in the wiring and
connectors.
Note: Updating the personality module to a different
version may cause some engine functions to behave When troubleshooting has indicated that the ECM
in a different manner. has failed, temporarily mount a new ECM on the side
of the engine. Test the engine with the new ECM.
If the problem no longer exists, proceed with the
following steps.

Replacement of the ECM

1. Record customer specified parameters from the
failed ECM. Refer to Troubleshooting, “Electronic
Service Tool Does Not Communicate” if the
electronic service tool will not communicate.

a. Obtain the customer passwords and record the

customer passwords. Refer to Troubleshooting,
“Customer Passwords” if the customer has lost
g01622820 the passwords.
Illustration 51

1. Remove the personality module access cover. b. Use Caterpillar Electronic Technician (ET) to
access read customer specified parameters
2. Firmly grasp the clips on the old personality from the ECM.
module and detach the module from the ECM.
c. Record customer parameters on the “Customer
3. Install the new personality module into the ECM. Specified Parameters Worksheet”.
Make sure that the personality module seats
properly into the socket of the ECM. 2. Replace the faulty ECM.

Note: The personality module will only match the 3. Obtain the factory passwords.
keyed socket in one position. A click can be felt when
the module is pushed in correctly. a. Record the engine hours from the engine hour
meter.
4. Install the personality module cover. The O-Ring
must be seated properly. b. Use Cat ET to access the system configuration
parameters. When the factory password screen
Note: Improper installation of the O-Ring could result appears, record the following information on
in damage to the module from improper sealing. This the “factory passwords worksheet”. ECM Serial
will allow moisture to enter the socket. Number, Engine Serial Number, Number Of the
Service Tool, and Total Tattletales
5. Start the engine and check for proper operation.
c. Leave Cat ET on the factory password
screen and obtain passwords by providing
the information on the “factory passwords
worksheet”.
SENR6477-06 105
Troubleshooting Section

4. Program the new ECM. Check Connectors for Moisture

a. Enter the factory passwords at the factory
and Corrosion
password screen.
Inspect all the harnesses. Ensure that the routing
of the wiring harness allows the wires to enter the
b. Record the following settings from the
face of each connector at a perpendicular angle.
worksheet.Full Load Setting, Full Torque
Otherwise, the wire will deform the seal bore. This
Setting, and Engine Serial Number Program
will create a path for the entrance of moisture. Verify
the “Personality Module Diagnostic Code” to
that the seals for the wires are sealing correctly.
zero. All system configuration parameters
must be programmed before exiting the factory
Ensure that the sealing plugs are in place. If any of
password screen. The necessary system
the plugs are missing, replace the plug. Ensure that
configuration parameters must be programmed
the plugs are inserted correctly into the connector.
before exiting this screen. If the parameters are
not entered, new passwords are required.

Note: If the customer specified parameters are

entered before the system configuration parameters,
the total tattletales will change. A new set of factory
passwords will be necessary to access the system
configuration parameters.

c. Enter the original values in the “Read/Change

Customer Specified Parameters”. Obtain these
values from the worksheet.

d. Use Cat ET to access “Calibrate/Monitor

Sensors” screen. Also, use Cat ET to access
and calibrate the boost pressure sensor and the Illustration 52
g01131019
rack position sensor. Refer to Troubleshooting,
Seal for a three-pin connector (typical example)
“Fuel Rack Position Sensor - Calibrate
*new*” and Troubleshooting, “Inlet Manifold
Pressure-Test” for calibration. Disconnect the suspect connector and inspect the
connector seal. Ensure that the seal is in good
condition. If necessary, replace the connector.
i03168220
Thoroughly inspect the connectors for evidence of
Electrical Connectors - Inspect moisture entry.
SMCS Code: 7553-040-WW Note: It is normal to see some minor seal abrasion
on connector seals. Minor seal abrasion will not allow
Most electrical faults are caused by poor connections. the entry of moisture.
The following procedure will assist in detecting
faults with connectors and with wiring. If a fault is If moisture or corrosion is evident in the connector,
found correct the condition and verify that the fault the source of the moisture entry must be found and
is resolved. the source of the moisture entry must be repaired. If
the source of the moisture entry is not repaired, the
Intermittent electrical faults are sometimes resolved fault will recur. Simply drying the connector will not fix
by disconnecting and reconnecting connectors. the fault. Check the following items for the possible
It is very important to check for diagnostic codes moisture entry path:
immediately before you disconnect a connector.
Also check for diagnostic codes after you reconnect • Missing seals
the connector. If the status of a diagnostic code is
changed due to disconnecting and reconnecting a • Incorrectly installed seals
connector, there are several possible reasons. The
likely reasons are loose terminals, improperly crimped • Nicks in exposed insulation
terminals, moisture, corrosion, and inadequate
mating of a connection. • Improperly mated connectors
106 SENR6477-06
Troubleshooting Section

Moisture can also travel to a connector through the Ensure that the locking wedge for the connector
inside of a wire. If moisture is found in a connector, is installed correctly. Terminals cannot be retained
thoroughly check the connector harness for damage. inside the connector if the locking wedge is not
Also check other connectors that share the harness installed correctly.
for moisture.
Perform the 45 N (10 lb) pull test on each wire. Each
terminal and each connector should easily withstand
Check the Wires for Damage to the 45 N (10 lb) of tension and each wire should remain
Insulation in the connector body. This test checks whether
the wire was correctly crimped in the terminal and
Carefully inspect each wire for signs of abrasion, whether the terminal was correctly inserted into the
nicks and cuts. connector.

Inspect the wires for the following conditions:

• Exposed insulation
• Rubbing of a wire against the engine
• Rubbing of a wire against a sharp point
Check all of the fasteners for the harness and the
ECM in order to verify that the harness is correctly
secured. Also check all of the fasteners in order
to verify that the harness is not compressed. Pull
back the harness sleeves in order to check for a
flattened portion of wire. A fastener that has been
overtightened flattens the harness. This damages the
wires that are inside the harness.

Inspect the Connector Terminals

Visually inspect each terminal in the connector. Verify
that the terminals are not damaged. Verify that the
terminals are correctly aligned in the connector and
verify that the terminals are correctly located in the
connector.

Perform a Pull Test on Each Wire

Terminal Connection

g01237430
Illustration 53
A typical example of the lock wedge.
(1) Locking wedge
SENR6477-06 107
Troubleshooting Section

Check Individual Pin Retention into

the Socket

g01687376
Illustration 54
Diagram for testing pin retention

Verify that the sockets provide good retention for i03201024

the pins. Insert a new pin into each socket one at a
time in order to check for a good grip on the pin by Crank Terminate - Calibrate
the socket.
SMCS Code: 1900-524
Check the Locking Mechanism of
System Operation
the Connectors
Use this procedure to calibrate the crank terminate
Ensure that the connectors lock correctly. After you of the engine speed switch (ESS). This procedure
lock the connectors, ensure that the two halves should be performed when the ESS is replaced or
cannot be pulled apart. when calibration is necessary. Calibration of the
crank termination requires a signal generator and a
Verify that the latch tab of the connector is correctly 4C-6534 Adapter Group to simulate a 400 rpm input.
latched. Also verify that the latch tab of the connector
returns to the locked position. Crank termination is a adjustable setting that signals
that the engine is firing. Crank termination also
Perform the Wiggle Test on the signals when cranking must be terminated. When the
crank termination speed is reached, terminal 10 is
Caterpillar Electronic Technician energized in order to start the engine hour meter.
(ET)
Select the “Wiggle Test” from the diagnostic tests
on Cat ET.

Choose the appropriate group of parameters to

monitor.

Press the “Start” button. Wiggle the wiring harness in

order to reproduce intermittent faults.

If an intermittent fault exists, the status will be

highlighted and an audible beep will be heard.

g01633296
Illustration 55
Engine speed switch
108 SENR6477-06
Troubleshooting Section

Set The Crank Termination 1. Turn the engine control switch to the OFF position.

1. Remove the lockwire and the seal from the access 2. Connect Caterpillar Electronic Technician (ET) to
hole for the adjustment screw for the crank the service tool connector.
terminate.
3. Remove the rack solenoid and the cover of the
2. Use a screwdriver to lightly turn the adjustment governor housing.
screw for the crank terminate by twenty turns in
the clockwise direction. 4. Remove the shutoff lever.

3. Disconnect the engine speed input at ESS 5. Remove the plugs from the governor housing.
terminal 3 and terminal 4.
6. Install the 4C-9581 Rack Zero Pins in the top
4. Connect a signal generator to ESS terminal 3 and of the fuel injection pump housing. Move the bar
terminal 4. Use 4C-6534 Adapter Harness for the of the rack control in order to engage both pins
connection. behind the rack.

5. Turn the engine control switch to the ON position. 7. Turn the engine control switch to the ON position.

6. Adjust the signal generator frequency to 0 Hz. 8. Select the “Calibrate/Monitor” screen on Cat ET.
Next, adjust the signal generator frequency to 900 Next, select the “Rack Position Sensor Calibration”
Hz. screen.

7. Connect a voltmeter between terminal 10 and 9. Move the control bar of the rack 25 mm (1.0 inch)
terminal 5. toward the front of the engine. Block this position.

8. Slowly rotate the adjustment screw for the crank 10. With the rack against the zero pins, read the
terminate in the counterclockwise direction. status of the rack position on Cat ET.
Monitor the voltage between terminal 10 and
terminal 5. Stop rotating the screw when the Note: If the reading of the rack position is
voltage changes to battery positive voltage. 9.5 ± 0.05 mm (0.37 ± 0.002 inch), the rack position
sensor is calibrated correctly.
Note: The voltage between ESS terminal 10 and
terminal 5 should increase to battery positive voltage Note: If the reading of the rack position is not
when the approximate setting for the crank terminate 9.5 ± 0.05 mm (0.37 ± 0.002 inch), the rack position
is reached. sensor is not calibrated correctly. Continue to follow
the procedure.
Adjust the Setting for the Crank 11. Use a 136-3124 Slotted Socket to loosen the
Terminate locknut on the rack position sensor.

1. Set the frequency generator to 0 Hz. 12. Make sure that the wiring of the rack position
sensor is connected to the engine harness.
2. Slowly increase the frequency. Monitor the voltage
between ESS terminal 5 and terminal 10. Record 13. Select the screen “Rack Position Sensor
the frequency that causes the voltage to increase Calibration” on Cat ET.
to battery positive voltage.
14. Make sure that the engine control switch is in the
Note: The voltage between ESS terminal 10 and ESS ON position.
terminal 5 should increase to battery positive voltage
when the frequency reaches 875 Hz to 920 Hz. 15. Turn the collar of the rack position sensor
clockwise or counterclockwise. The direction
is indicated by Cat ET. Turn the collar until
i03242872
“Calibrated” is displayed.
Fuel Rack Position Sensor - 16. Tighten the locknut to 55 ± 7 N·m (41 ± 5.0 lb ft).
Calibrate
17. Check that the rack position sensor is calibrated
SMCS Code: 1911-524 after the locknut is tightened.

System Calibration 18. Turn the engine control switch to the OFF position.

Note: Perform the following procedure in order. 19. Install the rack solenoid.
SENR6477-06 109
Troubleshooting Section

20. Install the shutoff lever. Install the cover of the

governor housing.

21. Remove the 4C-9581 Rack Zero Pins.

22. Install the plugs in the top of the fuel injection

pump housing.

i03201520

Overspeed - Calibrate
SMCS Code: 1900-524

System Operation
Use this procedure to calibrate the overspeed of the
engine speed switch (ESS). Perform this procedure
when the ESS is replaced or when calibration is
necessary.

The engine overspeed is a adjustable setting.

Typically, the setting is 118 percent of rated speed.
Engine overspeed prevents the engine from running
at a speed that could cause damage to the engine.
A overspeed condition causes the ESS to energize
the normally closed contacts of relay “SR1”. This
opens the normally closed contacts of relay “SR1”.
The fuel shutoff solenoid is de-energized and the
engine shuts down. A overspeed lamp is provided on
the ESS. A overspeed event has occurred when the
overspeed lamp is on. The “RESET” button on the
ESS will de-energize the overspeed lamp. Pressing
the “RESET” button also returns power to the fuel
shutoff solenoid.

g01633296
Illustration 56
110 SENR6477-06
Troubleshooting Section

Table 2
Engine Information Overspeed Setting 75% Overspeed Setting Setting for the Crank
“(Minimum - Maximum)” “(Minimum - Maximum)” Termination
“(Minimum - Maximum)”
Engine Number Typical Engine Magnetic Engine Magnetic Engine Magnetic
Model Of Teeth Rated Speed Pickup Speed Pickup Speed Pickup
On Engine Set at Frequency (RPM) Frequency (RPM) Frequency
Flywheel Speed 118% (Hz) (Hz) (Hz)
(RPM) of rated
speed
3412 136 1200 1416 3210 1062 2407 400 907
(1409- (3194-3226) (1051-1094) (2383- (386-406) (875-920)
1423) 2479)
1500 1770 4012 1327 3009
(1761- (3992-4032) (1314-1367) (2979-
1779) 3099)
1800 2124 4814 1593 3610
(2113- (4790-4838) (1577-1641) (3575-
2135) 3719)

Set the Approximate 75 Percent 6. Increase the engine speed by 10 rpm.

Overspeed with the Engine RPM 7. Press the “75% VERIFY” button.
1. Remove the lockwire and the seal from the access
8. Continue increasing the engine speed in 10 rpm
hole for the overspeed of the engine speed switch.
increments until the overspeed lamp illuminates.
2. Use a screwdriver to lightly turn the screw for the
overspeed of the engine speed switch. Turn the Use a Signal Generator to Verify
screw twenty times in the clockwise direction. the Overspeed Setting
3. Start and operate the engine at 75 percent of the
1. Turn the engine control switch to the OFF position.
desired overspeed setting.
2. Disconnect the engine speed input at ESS
4. Press the button and hold the “75% Verify” button
terminal 3 and terminal 4.
on the ESS.
3. Connect a signal generator to ESS terminal 3 and
5. Slowly rotate the overspeed adjustment screw in
terminal 4. Use 4C-6534 Adapter Harness for the
the counterclockwise direction. connection.
6. Rotate the overspeed adjustment screw until the
4. Turn the engine control switch to the ON position.
overspeed lamp illuminates.
5. Slowly increase the frequency. Monitor the
Note: This is the approximate overspeed setting.
overspeed lamp. Record the frequency that
causes the overspeed lamp to illuminate.
Adjust The 75 Percent Overspeed
Setting Note: The engine overspeed lamp should illuminate
when the frequency input is within the range in table
2.
1. Momentarily press the “RESET” button on the
ESS.

2. Restart the engine.

3. Operate the engine at 75 percent of the desired

overspeed setting minus 100 RPM.

4. Press the “75% VERIFY” button.

5. Release the “75% VERIFY” button.

SENR6477-06 111
Index Section

Index
A Electrical Connectors............................................. 17
ECM Connector ................................................. 18
Acceleration Is Poor or Throttle Response Is Harness Connectors .......................................... 19
Poor ..................................................................... 26 Service Tool Connector for Cat ET .................... 18
Probable Causes ............................................... 26 Electrical Connectors - Inspect............................ 105
Recommended Actions...................................... 26 Check Connectors for Moisture and
Atmospheric Pressure - Test ................................. 43 Corrosion........................................................ 105
Check Individual Pin Retention into the
Socket ............................................................ 107
B Check the Locking Mechanism of the
Connectors..................................................... 107
Boost Pressure Is High.......................................... 28 Check the Wires for Damage to the Insulation.. 106
Probable Causes ............................................... 28 Inspect the Connector Terminals ..................... 106
Recommended Actions...................................... 28 Perform a Pull Test on Each Wire Terminal
Boost Pressure Is Low........................................... 28 Connection ..................................................... 106
Probable Causes ............................................... 28 Perform the Wiggle Test on the Caterpillar
Electronic Technician (ET) ............................. 107
Electrical Power Supply - Test ............................... 55
C Electronic Service Tool Does Not Communicate.. 101
Electronic Service Tools .......................................... 6
Circuit Tests ........................................................... 43 Caterpillar Electronic Technician (ET).................. 7
Component Location ............................................. 15 Optional Service Tools ......................................... 7
Coolant Level - Test............................................... 46 PL1000E Communication ECM (If Equipped).... 10
Coolant Temperature - Test ................................... 50 Service Tools........................................................ 6
Coolant Temperature Is High................................. 29 Electronic System Overview................................... 11
Probable Causes ............................................... 30 Engine Cranks but Does Not Start ........................ 31
Recommended Actions...................................... 30 Probable Causes ............................................... 31
Coolant Temperature Is Low.................................. 31 Recommended Actions...................................... 31
Probable Causes ............................................... 31 Engine Does Not Crank......................................... 32
Recommended Actions...................................... 31 Probable Causes ............................................... 32
Crank Terminate - Calibrate................................. 107 Recommended Actions...................................... 33
Adjust the Setting for the Crank Terminate ...... 108 Engine Misfires, Runs Rough or Is Unstable......... 33
Set The Crank Termination ............................. 108 Probable Causes ............................................... 33
System Operation ............................................ 107 Engine Overspeeds ............................................... 35
Customer Passwords .......................................... 100 Probable Causes ............................................... 36
Recommended Actions...................................... 36
Engine Shutdown Is Intermittent............................ 36
D Probable Causes ............................................... 36
Engine Speed - Test .............................................. 58
Diagnostic Capabilities .......................................... 17 Engine Stalls Immediately After Starting ............... 37
Diagnostic Codes............................................... 17 Probable Causes ............................................... 37
Diagnostic Trouble Codes ..................................... 21 Engine Top Speed Is Not Obtained ....................... 38
Active Diagnostic Codes .................................... 23 Probable Causes ............................................... 38
Cross-Reference Information for Diagnostic Recommended Actions...................................... 39
Codes............................................................... 21
Diagnostic Codes............................................... 23
Flash Codes....................................................... 24 F
Logged Diagnostic Codes.................................. 24
Factory Passwords .............................................. 100
Customer Passwords....................................... 101
E Factory Passwords .......................................... 100
Passwords ....................................................... 100
ECM - Replace .................................................... 104 Fuel Control - Test ................................................. 61
Replacement of the ECM................................. 104 Fuel Rack Position Sensor - Calibrate................. 108
ECM Software - Install......................................... 104 System Calibration........................................... 108
Replacing the Personality Module ................... 104 Fuel Rack Solenoid - Test...................................... 64
ECM Will Not Accept Factory Passwords............ 101 Fuel Shutoff - Test ................................................. 67
Probable Causes ............................................. 101
Recommended Actions.................................... 101
ECM/Personality Module - Test ............................. 53
G System Overview................................................... 12
Electrical Connectors and Functions ................. 13
General Information (System Operation)................. 4 Pin Descriptions ................................................. 13
Crank Termination................................................ 5 System Component Diagram............................. 12
Electronic Controls............................................... 4
Engine Overspeed ............................................... 5
Engine Speed Switch........................................... 5 T
Load Share Module.............................................. 5
Passwords ........................................................... 5 Table of Contents..................................................... 3
Programmable Parameters.................................. 4 Troubleshooting Section.......................................... 4
Rack Controls ...................................................... 4
Self-Diagnostics ................................................... 5
Warning Lamps.................................................... 5 W

Welding Precaution ................................................. 5

I

Important Safety Information ................................... 2

Indicator Lamp - Test ............................................. 71
Inlet Manifold Pressure - Test ................................ 75
Introduction.............................................................. 4

Oil Pressure Is Low ............................................... 40

Probable Causes ............................................... 41
Recommended Actions...................................... 41
Overspeed - Calibrate ......................................... 109
Adjust The 75 Percent Overspeed Setting........ 110
Set the Approximate 75 Percent Overspeed with
the Engine RPM .............................................. 110
System Operation ............................................ 109
Use a Signal Generator to Verify the Overspeed
Setting ............................................................. 110

Power Is Intermittently Low or Power Cutout Is

Intermittent........................................................... 41
Probable Causes ............................................... 41
Programmable Parameters ................................... 17

Sensor Signal (Analog, Active) - Test .................... 79

Sensor Supply - Test ............................................. 85
Service................................................................. 100
Service Meter Problem .......................................... 42
Probable Causes ............................................... 42
Recommended Actions...................................... 42
Shutdown - Test..................................................... 88
Speed Control - Test.............................................. 97
Speed Control (Auxiliary) - Test............................. 91
Speed Control (PWM) - Test.................................. 93
Symptom Troubleshooting..................................... 26

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