RENR9348-01 January 2007 Troubleshooting C27 and C32 Generator Set Engines DWB1-Up (Generator Set) SXC1-Up (Generator Set) MED1-Up (Power Module) MEG1-Up (Power Module) WDR1-Up (Generator Set)
i01658146 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
RENR9348-01 3 Table of Contents Table of Contents Troubleshooting Section Electronic Troubleshooting System Overview .................................................... 5 Electronic Service Tools .......................................... 6 Replacing the ECM ................................................. 9 Self-Diagnostics .................................................... 10 Sensors and Electrical Connectors ....................... 12 Engine Wiring Information ....................................
Table of Contents CID 0175 FMI 04 Engine Oil Temperature short to ground ................................................................. 66 CID 0190 FMI 08 Engine Speed signal abnormal .. 66 CID 0247 FMI 09 J1939 Data Link communications .................................................. 66 CID 0253 FMI 02 Personality Module mismatch .. 67 CID 0261 FMI 11 Engine Timing Offset fault ........ 67 CID 0261 FMI 13 Engine Timing Calibration required ...........................................................
RENR9348-01 5 Troubleshooting Section Troubleshooting Section Cold Mode Electronic Troubleshooting The ECM limits engine power during cold mode operation. Injection timing is also modified during cold mode operation.
Troubleshooting Section RENR9348-01 Once the ECM calculates the amount of fuel that is required for the engine, the timing of the fuel injection cycle must be calculated. The ECM receives information about the top center position of each cylinder from the engine speed/timing sensor’s signal. The ECM calculates the initiation of the fuel injection cycle relative to the top center position of the piston. The injection signal is then provided to the injector at the desired time.
RENR9348-01 7 Troubleshooting Section Caterpillar Electronic Technician (ET) Table 4 Standard Hardware for the Use of Cat ET Part Number Cat ET can display the following information: Description N/A Personal Computer (PC) • Event codes 171-4400(1) Communication Adapter Gp (CAT ET TO ECM INTERFACE) • Diagnostic codes 237-7547(2) Adapter Cable As 225-5985(3) Parallel Port Cable (COMMUNICATION ADAPTER) • Parameters • Engine configuration Cat ET can be used by the technician to perform the fol
Troubleshooting Section RENR9348-01 a. Connect cable (4) between the “COMPUTER” end of communications adapter (5) and the parallel port of PC (1). Be sure to configure Cat ET for the parallel port. This configuration provides the fastest connection. b. Connect cable (3) between the “COMPUTER” end of communication adapter (5) and the RS232 serial port of PC (1). c. Connect cables (2) and (3) between the “COMPUTER” end of communication adapter (5) and the USB port of PC (1). 3.
RENR9348-01 9 Troubleshooting Section i02518796 Replacing the ECM SMCS Code: 1901-510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Troubleshooting Section a. If the old mounting hardware is in good repair, you can use the old mounting hardware to install the replacement ECM. b. Reconnect the fuel lines (if equipped). c. Ensure that the ECM mounting hardware is installed correctly. The fuel lines must not put tension on the ECM. The rubber grommets are used to protect the ECM from excessive vibration. The ECM must be able to drift in the rubber grommets.
RENR9348-01 Every generated code is stored in the permanent memory of the ECM. The codes are logged. Logged codes may not indicate that a repair is needed. The problem may have been temporary. The problem may have been resolved since the logging of the code. If the system is powered, it is possible to generate an active diagnostic code whenever a component is disconnected. When the component is reconnected, the code is no longer active. Logged codes may be useful to help troubleshoot intermittent problems.
Troubleshooting Section RENR9348-01 i02409268 Sensors and Electrical Connectors SMCS Code: 1439; 7553-WW Illustration 3 g01203891
RENR9348-01 13 Troubleshooting Section Block diagram C27 and C32 Engines g01204004 Illustration 4 Component locations (typical left side engine view) (1) Atmospheric pressure sensor (2) Engine coolant temperature sensor (3) Intake manifold pressure sensor (4) Intake manifold air temperature sensor (5) Injector valve cover entry connectors (6) Termination resistor (7) Service tool connector (8) Interface connector (9) Primary engine speed/timing sensor (10) Air shutoff solenoids (11) Engine oil temper
Troubleshooting Section RENR9348-01 g01203895 Illustration 5 Component locations (typical right side engine view) (15) Electronic Control Module (ECM) (16) J2/P2 ECM connector (17) J1/P1 ECM connector (18) Secondary engine speed/timing sensor (19) Engine oil pressure sensor (20) Fuel filter differential pressure switch (21) Fuel pressure sensor (22) Fuel temperature sensor
RENR9348-01 15 Troubleshooting Section i02433503 Table 7 Engine Wiring Information SMCS Code: 1408 The wiring schematics are revised periodically. The wiring schematics will change as updates are made to the engine’s harness. For the most current information, always check the revision number of the schematic. Use the schematic with the latest revision number. Harness Wire Identification Caterpillar identifies all wires with eleven solid colors.
Troubleshooting Section Illustration 6 RENR9348-01 g01143634 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 spatter. 5. Weld the materials by using standard welding methods.
RENR9348-01 17 Troubleshooting Section Programming Parameters i02253984 Programming Parameters SMCS Code: 1901 The Caterpillar Electronic Technician (ET) can be used to view certain parameters that can affect the operation of the engine. Cat ET can also be used to change certain parameters. The parameters are stored in the Electronic Control Module (ECM). Some of the parameters are protected from unauthorized changes by passwords. Parameters that can be changed have a tattletale number.
Troubleshooting Section RENR9348-01 If the new ECM does not fix the problem, the original ECM is not the problem. Remove the new ECM before the 24 hour timer expires. Reconnect the original ECM. i02433393 Factory Passwords SMCS Code: 0785 NOTICE Operating the engine with a flash file not designed for that engine will damage the engine. Be sure the flash file is correct for your engine. Note: Factory passwords are provided only to Caterpillar dealers.
RENR9348-01 19 Troubleshooting Section Programming a Flash File • The ECM is replaced. 1. Establish communication between Cat ET and the engine’s ECM. • “Injector Trim” is displayed below a 268-02 2. Select “WinFlash” from the “Utilities” menu on Cat ET. • Injectors are exchanged between cylinders. Note: If “WinFlash” will not communicate with the ECM, refer to troubleshooting without a diagnostic code Troubleshooting, “Electronic Service Tool Will Not Communicate with ECM”. 3.
Troubleshooting Section The injector trim file is loaded into the ECM. 13. Repeat the procedure for each cylinder, as required.
RENR9348-01 21 Troubleshooting Section System Configuration Parameters Test Spec i02421358 System Configuration Parameters This is the engine’s “Test Specifiction Number”. Use this number to retrieve data that is related to the engine’s specifications from the Technical Marketing Information System (TMI).
Troubleshooting Section RENR9348-01 Total Tattletale Number of Crank Cycles The total tattletale counts the number of changes to system parameters. This parameter defines the number of crank cycles for the engine. Engine Accel. Rate Engine Oil Temperature Sensor Installation Status This parameter defines the maximum rate of engine acceleration. Low Idle Speed This parameter defines the low idle rpm of the engine.
RENR9348-01 Remote Emergency Stop Switch Input Type Configuration This parameter sets the installation status and the configuration of the emergency stop switch. Air Intake Shutoff Detection Installation Status This parameter sets the installation status of an air shutoff system. Coolant Level Sensor Installation Status This parameter sets the installation status of the coolant level switch.
Troubleshooting Section RENR9348-01 Parameter Table Table 9 System Configuration Parameters Parameter Available Range or Options Default Required Password Selected Engine Ratings Rating Number Software Dependent None Rated Frequency Software Dependent Read Only(1) Rated Engine Speed Software Dependent Read Only(1) Rated Real Genset Power Kilowatts (if applicable) Rated power Read Only(1) Rated Apparent Genset Power Kilowatts (if applicable) Rated power Read Only(1) Rating Configur
RENR9348-01 25 Troubleshooting Section (Table 9, contd) System Configuration Parameters Available Range or Options Default Required Password Fuel Filter Differential Pressure Switch Configuration Uninstalled Normally Open Normally Closed Uninstalled Customer Emergency Shutdown Override Switch Installation Status Installed or Uninstalled Uninstalled Customer Emergency Shutdown Override Switch Configuration Switch to Ground CAN Input Switch to Ground Customer Remote Emergency Stop Switch Inp
Troubleshooting Section RENR9348-01 (Table 10, contd) Parameter Worksheet Droop mode selection Ether Control Prelube Duration Cranking Duration Maximum Number of Crank Cycles Desired Speed Input Configuration Engine State Control Configuration Cooldown Duration Secondary Desired Speed Input Configuration Fuel Filter Differential Pressure Switch Configuration Emergency Shutdown Override Switch Installation Status Emergency Shutdown Override Switch Configuration Remote Emergency Stop Switch Input Type C
RENR9348-01 27 Troubleshooting Section Troubleshooting without a Diagnostic Code i02121176 Alternator (Charging Problem) SMCS Code: 1405-035 i02422398 Can Not Reach Top Engine RPM SMCS Code: 1915-035 Note: If the problem occurs during high engine loads then refer to Troubleshooting, “Low Power/Poor or No Response to Throttle”. Probable Causes The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death.
Troubleshooting Section 2. Monitor the status of the intake manifold pressure sensor on Cat ET for normal operation. Ensure that the status for the “Boost Pressure” parameter is reasonable. Ensure that the intake manifold pressure fluctuates with the demand of the engine. RENR9348-01 Accessory Equipment Check all accessory equipment for problems that may create excessive load on the engine. Repair any damaged components or replace any damaged components. Fuel Supply 1.
RENR9348-01 29 Troubleshooting Section Cylinder Liner i02480112 Check for cracked cylinder liners. Replace any cracked cylinder liners. Refer to the Disassembly and Assembly manual. Cylinder Block ECM Will Not Communicate with Other Systems or Display Modules SMCS Code: 1901-035 Inspect the cylinder block for cracks. If a crack is found, repair the cylinder block or replace the cylinder block.
Troubleshooting Section • Caterpillar Electronic Technician (ET) and related hardware • Electrical power supply to the Electronic Control Module (ECM) • Flash file • Cat Data Link Recommended Actions Start the engine. If the engine starts, but the ECM will not communicate with Cat ET, continue with this procedure. If the engine will not start, refer to the troubleshooting without a diagnostic code procedure Troubleshooting, “Engine Cranks but Will Not Start”.
RENR9348-01 31 Troubleshooting Section i02475556 Engine Cranks but Will Not Start SMCS Code: 1000-035 Probable Causes • Diagnostic codes and event codes Starting Motor, Solenoid, or Starting Circuit Remove the starter and visually inspect the pinion of the starter and the flywheel ring gear for damage. Test the operation of the starting motor solenoid. Check the condition of the engine wiring for the starting motor solenoid. Test the operation of the starting motor.
Troubleshooting Section RENR9348-01 3. Check the fuel tank for foreign objects which may block the fuel supply. 4. Prime the fuel system if any of the following procedures have been performed: Recommended Actions Incorrect Engine Oil • Replacement of the fuel filters Use engine oil that is recommended and change the engine oil at the interval that is recommended by the engine’s Operation and Maintenance Manual.
RENR9348-01 33 Troubleshooting Section i02513923 Engine Misfires, Runs Rough or Is Unstable SMCS Code: 1000-035 Note: If the symptom is intermittent and the symptom cannot be repeated, refer to troubleshooting without a diagnostic code Troubleshooting, “Intermittent Low Power or Power Cutout”. If the symptom is consistent and the symptom can be repeated, continue with this procedure. Probable Causes • Diagnostic codes • Electrical connectors Throttle Signal Monitor throttle signal on Cat ET.
Troubleshooting Section RENR9348-01 2. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation/Testing and Adjusting, “Air Inlet and Exhaust System”. i02173692 Engine Oil in Cooling System • Air supply • Engine idle • Accessory equipment Recommended Actions Unit Injectors SMCS Code: 1348-035; 1350-035 1. Check for correct installation of the J1/P1 and J2/P2 connectors for the Electronic Control Module (ECM).
RENR9348-01 35 Troubleshooting Section 5. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual. 6. Check the fuel pressure after the fuel filter while the engine is being cranked. For the correct pressure values, refer to the Systems Operation/Testing and Adjusting manual. If the fuel pressure is low, replace the fuel filters.
Troubleshooting Section Batteries and/or Battery Cables 1. Inspect the battery posts, and battery cables for loose connections and for corrosion. If the battery cables are corroded, remove the battery cables and clean the battery cables. Tighten any loose connections. 2. Inspect the batteries. RENR9348-01 2. Inspect the pinion for the starting motor and the flywheel ring gear for damage. Engine Accessories 1. Ensure free movement of the driveline. 2.
RENR9348-01 • Valve adjustment Recommended Actions Air Inlet or Exhaust System 1. Check the air inlet system for restrictions and/or for leaks. a. Check for an air filter restriction. b. Perform a visual inspection of the system for restrictions and/or for leaks in the air inlet piping . 2. Ensure that the turbocharger is in good repair. 3. Check the exhaust system for restrictions. 4. Repair any leaks that were found. Remove any restrictions that were found.
Troubleshooting Section RENR9348-01 Turbocharger Fuel Leaks Check for turbocharger shaft seal leakage. Remove the air inlet piping and the exhaust outlet piping from the turbocharger. Check the compressor wheel and the turbine for evidence of an oil leak. If necessary, repair the turbocharger or replace the turbocharger. Refer to Systems Operation/Testing and Adjusting. Check the fuel pressure during engine cranking. Check the fuel pressure after the fuel filter.
RENR9348-01 39 Troubleshooting Section i02285926 i02399564 Excessive Valve Lash Excessive White Smoke SMCS Code: 1105-035 SMCS Code: 1088-035 Probable Causes Note: Some white smoke may be present during cold start-up conditions when the engine is operating normally. If the white smoke persists, there may be a problem.
Troubleshooting Section 2. Verify that the timing of the crankshaft and camshaft drive gears are set with the proper orientation. Refer to Disassembly and Assembly for information that is related to the correct gear installation. Unit Injectors 1. Perform the “Cylinder Cutout Test” on Cat ET in order to try to isolate any cylinders that may be misfiring. A misfiring cylinder could be related to an injector that is worn or in poor repair. Refer to Troubleshooting, “Injector Solenoid Circuit - Test”. 2.
RENR9348-01 41 Troubleshooting Section Excessive Leakage from the Unit Injector Tip or a Broken Unit Injector Tip Look for signs of damage to the unit injectors. If necessary, replace the unit injectors that have damaged tips. Cracked Cylinder Head or Leaking Cylinder Head Gasket Check for symptoms of a damaged cylinder head or cylinder head gasket. Inspect the cooling system for contamination of fuel. Inspect the crankcase for dilution of the engine oil.
Troubleshooting Section RENR9348-01 5. Check fuel quality. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual. 6. Check the filtered fuel pressure while the engine is being cranked. Refer to Systems Operation/Testing and Adjusting. 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.
RENR9348-01 43 Troubleshooting Section i02430113 Low Engine Oil Pressure SMCS Code: 1348-035-LP NOTICE Do not operate engine with low oil pressure. Engine damage will result. If measured engine oil pressure is low, discontinue engine operation until the problem is corrected. Probable Causes • Engine oil level • Engine oil filters and oil filter bypass valve Fuel Dilution Check for presence of fuel in lubricating oil.
Troubleshooting Section Certain diagnostic codes and/or event codes may cause poor performance. Use Cat ET to check for active codes and for logged codes. Troubleshoot any codes that are present before continuing with this procedure. 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.
RENR9348-01 45 Troubleshooting Section NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again. 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 • Replacement of unit injectors Note: Check the fuel system for air.
Troubleshooting Section RENR9348-01 Unit Injectors Recommended Actions 1. Check the connectors at the Electronic Control Module (ECM). Check for correct installation of the J1/P1 and J2/P2 ECM connectors. Also, thoroughly inspect the unit injector wiring harness from the ECM to the J300/P300 valve cover entry connector. Refer to the diagnostic functional test Troubleshooting, “Electrical Connectors - Inspect”.
RENR9348-01 47 Troubleshooting Section Unit Injectors 1. Perform the “Injector Solenoid Test” on Cat ET in order to determine if all of the injector solenoids are being energized by the ECM. 2. Perform the “Cylinder Cutout Test” on Cat ET in order to determine the performance of each cylinder. Refer to Troubleshooting, “Injector Solenoid Circuit - Test” for the proper procedure. Intake Manifold Pressure 1.
Troubleshooting Section Recommended Actions Valve components 1. A valve rotator that is cracked or a valve rotator that is broken is an indication of an engine overspeed. Determine the cause of the engine overspeed. Repair the condition. 2. Inspect the following components for damage: • Valve rotators • Spring locks • Valve springs • Valves Note: Ensure that the valve has not contacted the piston. If the valve has contacted the piston, check the exhaust system for debris. 3.
RENR9348-01 49 Troubleshooting Section Troubleshooting with a Diagnostic Code i02432846 Diagnostic Codes SMCS Code: 1900 Diagnostic Codes Diagnostic codes alert the operator that a problem in the electronic system has been detected. Diagnostic codes also indicate the nature of the problem to the service technician. The Caterpillar Electronic Technician (ET) is a software program that is designed to run on a personal computer.
Troubleshooting Section RENR9348-01 Logged Diagnostic Codes For information on event codes, refer to Troubleshooting, “Event Codes”. When the ECM generates a diagnostic code, the ECM logs the code in permanent memory. The ECM has an internal diagnostic clock.
RENR9348-01 51 Troubleshooting Section Cross-Reference for SPN-FMI Code to CID-FMI Table 13 Cross-Reference for SPN-FMI Code to CID-FMI Description of Code SPN/FMI CID-FMI 91-08 91-08 Throttle Position signal abnormal 94-03 94-03 Fuel Pressure open/short to +batt 94-04 94-04 Fuel Pressure short to ground 100-03 100-03 Engine Oil Pressure open/short to +batt 100-04 100-04 Engine Oil Pressure short to ground 100-10 100-10 Engine Oil Pressure Sensor abnormal rate of change 108-03 274-0
Troubleshooting Section RENR9348-01 (Table 13, contd) Cross-Reference for SPN-FMI Code to CID-FMI SPN/FMI CID-FMI Description of Code 654-06 4-06 Cylinder #4 Injector short 655-05 5-05 Cylinder #5 Injector open circuit 655-06 5-06 Cylinder #5 Injector short 656-05 6-05 Cylinder #6 Injector open circuit 656-06 6-06 Cylinder #6 Injector short 657-05 7-05 Cylinder #7 Injector open circuit 657-06 7-06 Cylinder #7 Injector short 658-05 8-05 Cylinder #8 Injector open circuit 658-0
RENR9348-01 53 Troubleshooting Section Cross-Reference for SPN-FMI Code to EID Table 14 Cross-Reference for SPN-FMI Code to EID SPN/FMI EID Description of Code 16-17 E390-1 Fuel Filter Restriction Warning 16-19 E390-2 Fuel Filter Restriction Derate 16-01 E390-3 Fuel Filter Restriction Shutdown 94-15 E096-1 High Fuel Pressure Warning 94-16 E096-2 High Fuel Pressure Derate 94-00 E096-3 High Fuel Pressure Shutdown 94-17 E198-1 Low Fuel Pressure Warning 94-18 E198-2 Low Fuel Pressur
Troubleshooting Section RENR9348-01 i02430358 Troubleshooting: CID 0001 FMI 05 Cylinder #1 Injector open circuit Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test” SMCS Code: 1290-038 Results: Conditions Which Generate This Code: • OK – STOP. The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects an open circuit in the circuit for the injector.
RENR9348-01 55 Troubleshooting Section System Response: i02430366 The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has been logged. CID 0003 FMI 06 Cylinder #3 Injector short SMCS Code: 1290-038 Possible Performance Effect: Conditions Which Generate This Code: • The engine may misfire. The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects a short circuit in the circuit for the injector.
Troubleshooting Section RENR9348-01 Troubleshooting: System Response: Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has been logged. Results: Possible Performance Effect: • OK – STOP. • The engine may misfire. i02430370 CID 0004 FMI 06 Cylinder #4 Injector short • The engine may experience low power.
RENR9348-01 57 Troubleshooting Section i02430375 Troubleshooting: CID 0006 FMI 05 Cylinder #6 Injector open circuit Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test” SMCS Code: 1290-038 Results: Conditions Which Generate This Code: • OK – STOP. The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects an open circuit in the circuit for the injector.
Troubleshooting Section RENR9348-01 Possible Performance Effect: i02420872 CID 0008 FMI 06 Cylinder #8 Injector short • Engine misfires • Low power SMCS Code: 1290-038 Troubleshooting: Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test” Conditions Which Generate This Code: Results: The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects a short circuit in the circuit for the injector. • OK – STOP.
RENR9348-01 59 Troubleshooting Section Troubleshooting: Possible Performance Effect: Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test” • Engine misfires Results: • Low power Troubleshooting: • OK – STOP. i02420876 CID 0009 FMI 06 Cylinder #9 Injector short Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test” Results: • OK – STOP.
Troubleshooting Section RENR9348-01 System Response: i02420764 The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has been logged. CID 0012 FMI 05 Cylinder #12 Injector open circuit SMCS Code: 1290-038 Possible Performance Effect: Conditions Which Generate This Code: • Engine misfires The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects an open circuit in the circuit for the injector.
RENR9348-01 61 Troubleshooting Section Troubleshooting: System Response: Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test” The code is logged. The ECM flags fuel pressure as invalid data and a default value is used. Results: Possible Performance Effect: • OK – STOP. • There are no performance effects.
Troubleshooting Section RENR9348-01 System Response: i02581776 Possible Performance Effect: CID 0100 FMI 10 Engine Oil Pressure Sensor abnormal rate of change • There are no performance effects. SMCS Code: 1439-038-OC; 1924-038 Troubleshooting: Conditions Which Generate This Code: Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test” This code indicates that the 5 volt supply is missing from the sensor connector.
RENR9348-01 63 Troubleshooting Section i02427669 • The engine may experience reduced speed (rpm) and/or low power. CID 0110 FMI 03 Engine Coolant Temperature open/short to +batt Troubleshooting: Perform the following diagnostic procedure: “Engine Temperature Sensor Open or Short Circuit - Test” SMCS Code: 1439-038-CLT; 1906-038 Results: Conditions Which Generate This Code: • OK – STOP. The signal voltage from the engine coolant temperature sensor is above normal.
Troubleshooting Section RENR9348-01 i02480880 CID 0168 FMI 01 System Voltage Low Possible Performance Effect: • An engine misfire may occur. • An engine shutdown condition may occur. SMCS Code: 1401-038 Troubleshooting: Conditions Which Generate This Code: The Electronic Control Module (ECM) has been powered for at least three seconds.
RENR9348-01 65 Troubleshooting Section i02424787 CID 0172 FMI 04 Intake Manifold Air Temp short to ground SMCS Code: 1439-038-AI; 1921-038 Troubleshooting: Perform the following diagnostic procedure: “Engine Temperature Sensor Open or Short Circuit - Test” Results: • OK – STOP. Conditions Which Generate This Code: i02424798 The Electronic Control Module (ECM) detects a signal voltage that is below normal. System Response: The code is logged.
Troubleshooting Section RENR9348-01 Possible Performance Effect: System Response: • There are no performance effects. The code is logged. Troubleshooting: Possible Performance Effect: Perform the following diagnostic procedure: “Engine Temperature Sensor Open/Short Circuit - Test” • The engine may not start. Results: • The engine will run rough. Troubleshooting: • OK – STOP.
RENR9348-01 67 Troubleshooting Section i02428636 i02437198 CID 0253 FMI 02 Personality Module mismatch CID 0261 FMI 11 Engine Timing Offset fault SMCS Code: 1902-038 SMCS Code: 1439-038; 1912-038 Conditions Which Generate This Code: Conditions Which Generate This Code: The flash file that is used for replacement is for a different engine family or for a different engine application.
Troubleshooting Section C. Ensure that the harness is properly secured, and ensure that each tie-wrap is placed in the correct location. Expected Result: The sensors, the connectors, and the wiring are correctly installed. Results: • OK – The sensors and the harness are OK. The problem is not with the sensor or the harness. There may be a mechanical problem with the engine’s front gear train. Proceed to Test Step 2.
RENR9348-01 69 Troubleshooting Section Results: Troubleshooting: • OK – STOP. Perform the following diagnostic procedure: “5 Volt Engine Pressure Sensor Supply Circuit - Test” i02416460 CID 0262 FMI 03 5 Volt Sensor DC Power Supply short to +batt Conditions Which Generate This Code: The Electronic Control Module (ECM) detects an above normal voltage on the 5 volt supply. System Response: The code is logged. The check engine lamp will illuminate while this diagnostic code is active.
Troubleshooting Section RENR9348-01 i02417898 i02407807 CID 0274 FMI 03 Atmospheric Pressure open/short to +batt CID 0342 FMI 08 Secondary Engine Speed signal abnormal SMCS Code: 1439-038-AI; 1923-038 SMCS Code: 1439-038-VF; 1907-038 Conditions Which Generate This Code: Conditions Which Generate This Code: The Electronic Control Module (ECM) detects a signal voltage that is above normal. The signal from the secondary engine speed/timing sensor is intermittent or the signal has been lost.
RENR9348-01 71 Troubleshooting Section Results: i02418765 CID 0446 FMI 06 Air Shutoff Relay short • OK – STOP. i02418715 CID 0444 FMI 06 Start Relay short to ground SMCS Code: 4493-038 Conditions Which Generate This Code: SMCS Code: 1426-038 The Electronic Control Module (ECM) detects an excessive current in the circuit. Conditions Which Generate This Code: System Response: The Electronic Control Module (ECM) detects a short to ground in the circuit. The ECM logs the code.
Troubleshooting Section RENR9348-01 i02407894 CID 1785 FMI 04 Intake Manifold Pressure Sensor voltage low Possible Performance Effect: • Low power Troubleshooting: Repair the Sensor Supply Circuit SMCS Code: 1439-038-IL Conditions Which Generate This Code: A. Repair the circuit for the supply wire between the ECM and the sensor. The Electronic Control Module (ECM) detects a signal voltage below the normal. Expected Result: The problem is resolved. System Response: The code is logged.
RENR9348-01 73 Troubleshooting Section Troubleshooting with an Event Code i02422406 Event Codes SMCS Code: 1901 Event codes alert the operator that an abnormal engine operating condition such as low oil pressure or high coolant temperature has been detected. When the event code is generated, this indicates that an event has taken place. Active of Event Codes An event code represents a problem with engine operation. Correct the problem as soon as possible.
Troubleshooting Section RENR9348-01 • E360-1 Low Oil Pressure Warning Troubleshooting • E360-2 Low Oil Pressure Derate For basic troubleshooting of the engine, perform the following steps in order to diagnose a malfunction: • E360-3 Low Oil Pressure Shutdown The definition for a warning, a derate, and a shutdown are defined below: Warning – This condition represents a serious problem with engine operation. However, this condition does not require a derate or a shutdown. 1.
RENR9348-01 Table 15 contains the conditions that are monitored and the default trip points for each condition. Each condition has an associated parameter. The settings for each parameter can be viewed with the Caterpillar Electronic Technician (ET). The trip points for some of the parameters may be adjustable with Cat ET.
Troubleshooting Section RENR9348-01 Table 15 Trip Points for the Monitoring System Parameter Action Default Value Time Delay in Seconds Set Points Range Default Range Default E057 Low Engine Coolant Level Derate Off N/A N/A N/A N/A E059 Low Engine Coolant Level Warning Off 4 to 65 30 N/A N/A Warning On E096 High Fuel Pressure Derate 758 kPa (110 psi) 8 N/A 10 760 kPa (110 psi) N/A Off Shutdown Warning E197 High Engine Oil Temperature Derate 100 to 110 °C (212 to 230 °
RENR9348-01 77 Troubleshooting Section (Table 15, contd) Trip Points for the Monitoring System Parameter E539 High Intake Manifold Air Temperature (1) (2) Action Default Value Warning On Derate Off Time Delay in Seconds Range Default N/A 8 Set Points Range 75 °C (167 °F) 79 °C (174 °F) Default N/A Refer to Table 16 for trigger points. Refer to Table 17 for trigger points.
Troubleshooting Section RENR9348-01 Repair: There may be a problem with the coolant level sensor. Refer to the diagnostic functional test Troubleshooting, “Coolant Level Sensor Circuit Test”. Ensure that any repairs eliminate the problem. STOP. Note: If the coolant has been changed recently, ensure that the air has been purged from the cooling system. Refer to Systems Operation/Testing and Adjusting, “Cooling System” for additional information. Expected Result: The coolant level is low.
RENR9348-01 79 Troubleshooting Section • The engine power is derated. • Intake manifold air temperature E096(3) • Barometric pressure • The engine is shut down. • Engine speed Troubleshooting: High intake manifold air temperature, high altitude operation, and high engine loads can cause the exhaust temperature to increase to a level that may damage the components of the exhaust system. When this occurs, the ECM derates the engine in order to reduce the exhaust temperature.
Troubleshooting Section Repair: Clean the fins of the ATAAC. Clear the event. Return the engine to service. STOP. • Not OK – The fins of the ATAAC are clear of obstructions. Proceed to Test Step 3. Test Step 3. Check the 5 Volt Supply to the Atmospheric Pressure Sensor If the atmospheric pressure sensor is not being powered by the 5 volt supply, the output of the sensor will float to a value that indicates a high barometric pressure. This is interpreted by the ECM as a high altitude condition.
RENR9348-01 Possible Performance Effect: E197-1 • Engine performance is not affected. E197-2 • An engine derate will be initiated. E197-3 • The engine will shut down. Troubleshooting: A high engine oil temperature may be caused by the following problems: • Improper engine oil level • Faulty engine oil cooler bypass valve • Damaged engine oil cooler core • Problems with other engine systems Test Step 1. Check the Level of the Engine Oil Use the engine oil dipstick to check for the correct oil level.
Troubleshooting Section RENR9348-01 J. Check for a restriction in the exhaust system. A restriction of the air that is coming out of the engine can cause high cylinder temperatures. • There are no performance effects. K. Consider high ambient temperatures. When ambient temperatures are too high for the rating of the cooling system, there is not enough of a temperature difference between the ambient air and coolant temperatures. • The engine power is derated. L. Consider high altitude operation.
RENR9348-01 83 Troubleshooting Section i02342292 E264 Emergency Stop Activated SMCS Code: 7418-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects an open circuit on the emergency stop input to the ECM. System Response: The ECM disables the injection signals to the injector solenoids. Possible Performance Effect: The engine will shut down.
Troubleshooting Section RENR9348-01 C. The inlet screen of the oil suction tube for the engine oil pump can have a restriction. This restriction will cause cavitation and a loss of engine oil pressure. Check the inlet screen on the oil pickup tube and remove any material that may be restricting engine oil flow. Low engine oil pressure may also be the result of the oil pickup tube that is drawing in air. Check the joints of the oil pickup tube for cracks or a damaged O-ring seal. D.
RENR9348-01 Clamps that are damaged and hoses that are leaking can usually be discovered during a visual inspection. Hoses that have no visual leaks can soften during operation. The soft areas of the hose can kink or the soft areas of the hose may collapse during operation. This can restrict the coolant flow. This can cause the engine to overheat. Check the hoses for soft spots. Internal cracks can also develop in cooling system hoses.
Troubleshooting Section RENR9348-01 System Response: Troubleshooting: The event code will be logged. Check the Fuel System Possible Performance Effect: Check the fuel system. E362(1) Expected Result: • There are no performance effects. A thorough inspection of the fuel system revealed a problem. E362(3) Results: • The engine will be shut down. • OK – There is a problem with the fuel system. Troubleshooting: The operator may be operating the engine incorrectly.
RENR9348-01 87 Troubleshooting Section B. Restart the engine and check for an active event code. Expected Result: The event code is no longer active. Results: • OK – The event code is no longer active. STOP. • Not OK – The event code is active. Repair: There may be an electrical problem with the circuit for the fuel filter differential pressure switch. Refer to Troubleshooting, “Fuel Filter Differential Pressure Switch Circuit - Test” for diagnostic information. STOP.
Troubleshooting Section RENR9348-01 Repair: Cycle the power to the ECM. Reset the air shutoff mechanism. Restart the engine. Repair: Repair the problem. STOP. • Not OK – A thorough inspection did not reveal a problem. Repair: Connect Caterpillar Electronic Technician (ET) to the service tool connector. Check Cat ET for active/logged diagnostic codes related for the inlet air system. If an active/logged code is found, refer to the appropriate troubleshooting procedure. STOP. STOP.
RENR9348-01 Check the Programmable Parameters Determine the setting of the parameter. The Air Intake Shutoff Detection Circuit Detected but Not Installed parameter may need to be set to “Installed”. Results: • OK – STOP.
Troubleshooting Section RENR9348-01 Diagnostic Functional Tests i02410077 5 Volt Engine Pressure Sensor Supply Circuit - Test SMCS Code: 1439-038 System Operation Description: Use this procedure to troubleshoot any suspect problems with the +5 V sensor supply.
RENR9348-01 Illustration 9 Schematic for the pressure sensor supply Test Step 1. Inspect the Electrical Connectors and the Wiring A. Remove electrical power from the ECM.
Troubleshooting Section RENR9348-01 Illustration 11 P2 ECM connector Illustration 10 g01204463 Sensor locations (1) (2) (3) (4) (5) Intake manifold pressure sensor Atmospheric pressure sensor J2/P2 ECM connectors Engine oil pressure sensor Fuel pressure sensor B. Thoroughly inspect connectors (3). Also, thoroughly inspect the connectors for sensors (1), (2), (4), and (5). Refer to Troubleshooting, “Electrical Connectors Inspect” for details.
RENR9348-01 93 Troubleshooting Section B. Restore electrical power to the ECM. C. Monitor the active diagnostic code screen on Cat ET. Check for an active 262-03 code and an active 262-04 code. Note: Wait at least 30 seconds in order for the diagnostic codes to become active. D. Remove electrical power from the ECM. Expected Result: No diagnostic codes are active. Illustration 12 g01159881 Results: Sensor connector (A) Sensor supply (B) Sensor return (C) Sensor signal C.
Troubleshooting Section RENR9348-01 The diagnostic code deactivates when a particular sensor is disconnected. Repair: There is a problem in the engine harness. The problem may be with a connector. Repair the harness and/or the connector. Replace parts, if necessary. Verify that the problem is resolved. Results: STOP. Expected Result: • OK – The 262-03 or 262-04 diagnostic code deactivates when a particular sensor is disconnected. Repair: Connect the suspect sensor.
RENR9348-01 95 Troubleshooting Section Emergency Stop Sequence – The third condition occurs when the emergency stop switch is activated. When the emergency stop switch is placed in the STOP position, voltage is supplied to the relay control for the ECM relay. The ECM relay removes electrical power from the ECM. Voltage is also supplied to the air shutoff timer. The air shutoff timer supplies voltage to the air shutoff relay for 2.5 seconds. This latches the air shutoff valves in the closed position.
Troubleshooting Section Illustration 14 RENR9348-01 g01206567 Location of the ECM connectors (typical engine view) (1) J2/P2 ECM connectors (2) J1/P1 ECM connectors Illustration 16 g01209725 P1 terminals for the air shutoff system (P1-10) Air shutoff Illustration 15 g01210157 Air shutoff mechanism (3) Terminals for the air shutoff solenoid C. Thoroughly inspect connectors (1) and (2). Also, thoroughly inspect connections (3) at the air shutoff solenoid.
RENR9348-01 E. Check the allen head screw on each ECM connector for the proper torque. Refer to the diagnostic functional test Troubleshooting, “Electrical Connectors - Inspect” for the correct torque values. F. Check the harness and the wiring for abrasion and for pinch points from the air shutoff solenoid to the ECM. Expected Result: All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion and of pinch points.
Troubleshooting Section Test Step 3. Test for Control Input Voltage at the Timer A. Remove the wire connection from terminal 3 (control) at the air shutoff timer. B. Turn the battery disconnect switch to the ON position. C. Place the emergency stop switch in the STOP position. D. Measure the voltage between the wire that has been removed from terminal 3 (control) at the air shutoff timer and the engine ground stud. The correct voltage is 24 ± 3 VDC. E.
RENR9348-01 2. Turn the battery disconnect switch to the ON position. 3. Measure the voltage between the wires for these terminals. 4. Turn the battery disconnect switch to the OFF position. If voltage is 24 ± 3 VDC, the problem is in the air shutoff timer. Replace the air shutoff timer. Verify that the repair resolved the original problem. If voltage is not 24 ± 3 VDC, the problem is in the supply circuit or the ground circuit for the air shutoff timer.
Troubleshooting Section RENR9348-01 Results: Expected Result: • OK – The voltage is 24 ± 3 VDC when the engine As the engine speed increases above 75 percent of the rated engine speed, the voltage is 24 ± 3 VDC. speed increases above 75 percent of the rated engine speed. The ECM and the wiring to the air shutoff relay are OK. The problem is with the air shutoff relay’s secondary circuit or the relay. Proceed to Test Step 8.
RENR9348-01 Turn the battery disconnect switch to the OFF position. Restore the wiring to the original configuration. Expected Result: As the engine speed increases above 75 percent of the rated engine speed, the voltage is 24 ± 3 VDC at the supply wire for each solenoid. 101 Troubleshooting Section • Not OK – The voltage is not 24 ± 3 VDC when the engine speed increases above 75 percent of the rated engine speed. The air shutoff solenoids are not receiving the correct voltage. Proceed to Test Step 9.
Troubleshooting Section • Not OK – The voltage is not 24 ± 3 VDC when the engine speed increases above 75 percent of the rated engine speed. The secondary output of the air shutoff relay is not supplying the correct voltage. There may be a problem with the relay. Proceed to Test Step 10. Test Step 10. Check the Supply Voltage to the Air Shutoff Relay A. Remove the wire from the supply to the secondary circuit of the air shutoff relay. B. Turn the battery disconnect switch to the ON position. C.
RENR9348-01 103 Troubleshooting Section g01209787 Illustration 18 Schematic for the CAN data link Test Step 1. Inspect the Electrical Connectors and the Wiring A. Turn the keyswitch to the OFF position. Illustration 20 g01207179 Location of the engine interface connector and the service tool connector (typical engine view) Illustration 19 Location of the ECM (typical engine view) (1) J1/P1 ECM conntctors g01167488 (2) Engine interface connector (3) Service tool connector B.
Troubleshooting Section RENR9348-01 Illustration 23 g01209794 Terminals at the service tool connector that are associated with the CAN data link (C) CAN shield (G) CAN data link + (F) CAN data link − C. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the CAN data link. D. Check the allen head screw on each ECM connector for the proper torque. Also, check the allen head screw on the engine interface connector for the proper torque.
RENR9348-01 Test Step 2. Check for Active Diagnostic Codes A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. B. Turn the keyswitch to the ON position. C. Observe the active diagnostic code screen on Cat ET. Wait at least 15 seconds so that any diagnostic codes may become active. Check for a 247-09 diagnostic code. Expected Result: No diagnostic codes are active. Results: • OK – No codes are active.
Troubleshooting Section Test Step 5. Check for an Open Circuit A. Verify that all of the connections are disconnected. B. Fabricate a jumper wire. Use the jumper wire in order to create a short circuit between terminals G and F on the service tool connector. C. Measure the resistance between terminals P1-50 (CAN data link +) and P1-34 (CAN data link -). D. Remove the jumper wire from the service tool connector. Expected Result: The resistance is less than ten Ohms.
RENR9348-01 Illustration 25 107 Troubleshooting Section g01167488 Location of the J1/P1 ECM connectors (typical engine view) (1) J1/P1 ECM connectors Illustration 27 g01207225 P1 terminals that are associated with the Cat Data Link (P1-8) Cat Data Link + (P1-9) Cat Data Link − Illustration 26 g01207179 Location of the engine interface connector and the service tool connector (typical engine view) (2) Engine interface connector (3) Service tool connector B.
Troubleshooting Section RENR9348-01 C. Measure the resistance between the points that are listed in Table 19. Be sure to wiggle the wires in the harnesses as you make each resistance measurement.
RENR9348-01 109 Troubleshooting Section Results: • OK – The resistance check indicates that continuity exists. Repair: Perform the following procedure: 1. Connect the J1/P1 connectors. Connect Cat ET to the service tool connector. 2. Check the Cat Data Link for proper operation. If the Data Link does not operate correctly, there may be a problem with the ECM. Replace the ECM. Refer to Troubleshooting, “Replacing the ECM” for information that is related to ECM replacement.
Troubleshooting Section RENR9348-01 g01204880 Illustration 31 Schematic for coolant level sensor Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Test Step 1. Inspect the Electrical Connectors and the Wiring A. Remove electrical power from the ECM.
RENR9348-01 111 Troubleshooting Section Illustration 35 g01205323 Terminal locations for the P1 ECM connector (P2-4) Digital supply (+8 V) (P2-5) Digital sensor return Illustration 34 g01205002 Terminal locations for the P2 ECM connector (P2-39) Coolant level sensor Illustration 36 g01159881 Harness connector for the coolant level sensor (A) Sensor supply (B) Sensor return (C) Sensor signal C.
Troubleshooting Section RENR9348-01 D. Check the allen head screw on each ECM connector for the proper torque. Refer to Troubleshooting, “Electrical Connectors - Inspect” for the correct torque values. Test Step 3. Check the Coolant Level Expected Result: Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
RENR9348-01 113 Troubleshooting Section Expected Result: The status changes from “OK” to “LOW” when the sensor is disconnected. Results: • OK – The status is “LOW” when the sensor is disconnected. There may be a problem with the coolant level sensor. Proceed to Test Step 5. • Not OK – The status is “OK” when the sensor is disconnected. The problem is between the ECM and the harness connector. There may be a problem with the ECM. Proceed to Test Step 6. Test Step 5.
Troubleshooting Section RENR9348-01 The correct resistance measurement is a short circuit. Remove the jumper wire. Leave the sensor connector disconnected. The measurement indicates that a short circuit exists for the signal wire. Results: • OK – The measurement indicated a short circuit. There is not an open circuit in the harness wire for the sensor signal. Proceed to Test Step 7. • Not OK – The measurement did not indicate a short circuit.
RENR9348-01 115 Troubleshooting Section Repair: The ECM is properly reading the switch input. There may be an intermittent problem in the harness or in a connector. If an intermittent electrical problem is suspected, refer to Troubleshooting, “Electrical Connectors - Inspect” for troubleshooting information. STOP. • Not OK – The status is “LOW” when the jumper wire is connected. Repair: The ECM is not reading the switch input. Replace the ECM. Refer to Troubleshooting, “Replacing the ECM”.
Troubleshooting Section Illustration 38 RENR9348-01 g01131276 Diagram for the installation of a connector plug (typical example) (1) Electronic Control Module (ECM) connector (2) Correctly inserted plug (3) Incorrectly inserted plug B. Ensure that the sealing plugs are in place. If any of the plugs are missing, replace the plug. Ensure that the plugs are inserted correctly into the connector. Refer to Illustration 38. Illustration 40 g01131165 Seal for ECM connector (typical example) C.
RENR9348-01 117 Troubleshooting Section Expected Result: Results: The harness wiring, connectors, and seals are in good condition. There is no evidence of moisture in the connectors. • OK – The harness is OK. Proceed to Test Step 3. Results: • OK – The harness wiring, connectors, and seals are in good condition. Proceed to Test Step 2. • Not OK – A problem has been found with the harness or the connectors. Repair: Repair the connectors or the wiring, as required.
Troubleshooting Section RENR9348-01 A. Ensure that the locking wedge for the connector is installed properly. Terminals cannot be retained inside the connector if the locking wedge is not installed properly. B. Perform the 45 N (10 lb) pull test on each wire. Each terminal and each connector should easily withstand 45 N (10 lb) of tension and each wire should remain in the connector body.
RENR9348-01 Illustration 43 119 Troubleshooting Section g01132827 Allen head screw for the 120 pin ECM connector (typical example) a. Torque the allen head bolt for the 120 pin ECM connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). Illustration 46 g01133047 Allen head screw for the 40 pin customer connector and the 70 pin customer connector (typical example) B. Connect the customer connector. Torque the allen head screw for the 40 pin customer connector and the 70 pin customer connector to 2.25 ± 0.
Troubleshooting Section RENR9348-01 Expected Result: No intermittent problems were indicated during the “Wiggle Test”. Results: • OK – No intermittent problems were found. The harness and connectors appear to be OK. If you were sent from another procedure, return to the procedure and continue testing. If this test has resolved the problem, return the engine to service. STOP. • Not OK – At least one intermittent problem was indicated. Repair: Repair the harness or the connector.
RENR9348-01 Illustration 47 Schematic for the electrical power supply (typical example) Test Step 1. Inspect the Electrical Connectors and the Wiring A. Turn the battery disconnect switch to the OFF position.
Troubleshooting Section RENR9348-01 Illustration 50 g01206446 Location of the battery isolator switch, the ECM relay, and the starting motor magnetic switch (typical left side engine view) (4) Battery disconnect switch (5) ECM relay (6) Starting motor magnetic switch Illustration 48 g01206567 Location of the J1/P1 and the J2/P2 ECM connectors (typical engine view) (1) J2/P2 ECM connector (2) J1/P1 ECM connector Illustration 49 g01207955 Location of the engine interface connector (typical engine
RENR9348-01 123 Troubleshooting Section Illustration 52 P1 ECM connector Illustration 51 P2 ECM connector (P2-59) SMMS (P2-60) Digital return g01206553 (P1-48) (P1-52) (P1-53) (P1-55) (P1-57) (P1-61) (P1-63) (P1-65) (P1-67) (P1-69) (P1-70) +Battery +Battery +Battery +Battery +Battery −Battery −Battery −Battery −Battery −Battery Keyswitch g01206554
Troubleshooting Section RENR9348-01 Results: • OK – The connectors and wiring appear to be OK. Proceed to Test Step 2. • Not OK – The connectors and/or wiring are not OK. Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. Verify that the original problem has been resolved. STOP. Illustration 53 g01207957 Terminal locations for the engine interface connector Test Step 2. Check the Battery Voltage at the ECM A. Disconnect the J1/P1 ECM connector.
RENR9348-01 • Not OK – The voltage is not correct at the ECM. There is a problem with the electrical power supply circuit. Leave the J1/P1 ECM connectors disconnected. Proceed to Test Step 3. 125 Troubleshooting Section F. Turn the battery disconnect switch to the ON position. Ensure that the emergency stop switch is in the RUN position. Test Step 3. Check the Batteries G. Measure the voltage between the loose end of the jumper wire and engine ground. A.
Troubleshooting Section Repair: There is an open circuit in the harness or in a connector between the batteries and the ECM relay. Ensure that the circuit breaker for the ECM relay has not tripped. Repair the wiring and/or the connectors. Replace parts, if necessary. Verify that the original problem has been resolved. STOP. Test Step 6. Check the Voltage for the Relay Control at the ECM Relay A. Check that the battery disconnect switch is in the ON position.
RENR9348-01 127 Troubleshooting Section i02414122 Emergency Stop Switch Circuit - Test SMCS Code: 7332-038 System Operation Description: This application is equipped with an emergency stop switch. The switch is located on the control panel. The Electronic Control Module (ECM) is configured to record an event when the switch is activated. The emergency stop switch provides a switch in the circuit from the +Battery to the control input for the ECM relay.
Troubleshooting Section Illustration 56 RENR9348-01 g01207034 Location of the ECM relay (typical left side engine view) Illustration 59 g01206963 Terminal locations at the connector for the emergency stop switch (5) +Battery (11) Emergency stop Illustration 57 g01210817 Location of the engine interface connector (typical engine view) Illustration 60 B. Thoroughly inspect the connector for relay (1) and connector (2).
RENR9348-01 • Not OK – The connectors and/or wiring are not OK. Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. STOP. Test Step 2. Check for Voltage at the Connector for the Emergency Stop Switch A. Disconnect the connectors for the emergency stop switch. B. Turn the battery disconnect switch to the ON position. C. Measure the voltage between terminal 5 on the harness side of the connector for the emergency stop switch and the engine ground stud. D.
Troubleshooting Section Results: • OK – The measurements agree with the results that are stated above. The emergency stop switch is operating correctly. There may be a problem in the harness between the emergency stop switch and the engine interface connector. Connect the connectors for the emergency stop switch. Proceed to Test Step 5. • Not OK – The measurements did not agree with the results that are stated above. Repair: There is a problem with the emergency stop switch. Replace the switch.
RENR9348-01 131 Troubleshooting Section Repair: The correct supply voltage is reaching the ECM relay. The circuit for the emergency stop switch is operating correctly at this time. There may be an intermittent condition in the harness or in a connector. • 1785-03 Intake Manifold Pressure Sensor voltage If an intermittent electrical problem is suspected, refer to Troubleshooting, “Electrical Connectors Inspect”. The 5 volt sensor supply provides power to all 5 volt sensors.
Troubleshooting Section Illustration 61 Schematic for the engine pressure sensors Test Step 1. Inspect the Electrical Connectors and the Wiring A. Remove electrical power from the ECM.
RENR9348-01 133 Troubleshooting Section Illustration 63 P2 ECM connector Illustration 62 g01204463 Sensor locations (1) (2) (3) (4) (5) Intake manifold pressure sensor Atmospheric pressure sensor J2/P2 ECM connectors Engine oil pressure sensor Fuel pressure sensor B. Thoroughly inspect connectors (3). Also, thoroughly inspect the connectors for sensors (1), (2), (4), and (5). Refer to Troubleshooting, “Electrical Connectors Inspect” for details.
Troubleshooting Section RENR9348-01 Test Step 2. Check the Supply Voltage at the Sensor Connector A. Remove electrical power from the ECM. B. Disconnect the harness connectors for the following sensors: • Atmospheric pressure sensor • Intake manifold pressure sensor • Engine oil pressure sensor Illustration 64 g01159881 Sensor connector (A) Sensor supply (B) Sensor return (C) Sensor signal C.
RENR9348-01 135 Troubleshooting Section B. Restore electrical power to the ECM. Results: C. Monitor the active diagnostic code screen on Cat ET. Look for an active diagnostic code for an engine pressure sensor. • OK – A 04 diagnostic code was active before the Note: Wait at least 30 seconds so that any codes may become active. D. Determine if the problem is related to an open circuit diagnostic code (03) or a short circuit diagnostic code (04). Expected Result: No diagnostic codes are active.
Troubleshooting Section Repair: There is a problem with the sensor. Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine. Verify that there are no active diagnostic codes for the sensor. If there are no active diagnostic codes for the sensor, permanently install the new sensor. Clear any logged diagnostic codes. STOP. • Not OK – The 03 diagnostic code remains active with the jumper in place.
RENR9348-01 137 Troubleshooting Section i02450722 Engine Speed/Timing Sensor Circuit - Test SMCS Code: 1439-038-VF; 1912-038 System Operation Description: Use this procedure to troubleshoot any suspect problems with the following sensors: • Primary engine speed/timing sensor • Secondary engine speed/timing sensor This procedure covers the following diagnostic codes: • 190-08 Engine Speed abnormal • 342-08 Secondary Engine Speed signal abnormal The engine uses two engine speed/timing sensors.
Troubleshooting Section RENR9348-01 g01223579 Illustration 65 Schematic for the engine speed/timing sensors Test Step 1. Check for Diagnostic Codes A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. B. Restore electrical power to the ECM. C. Start the engine and run the engine until the engine is at the normal operating temperature. Repair: Refer to the appropriate symptoms in Troubleshooting, “Troubleshooting Without a Diagnostic Code”. STOP.
RENR9348-01 139 Troubleshooting Section 3. Tighten the bracket bolt. 4. Connect the sensor’s electrical connectors. Verify that the connector is latched. 5. Ensure that the harness is properly secured, and that the tie-wraps are placed in the correct location. Verify that the problem is resolved. STOP. Illustration 67 g01167704 Test Step 3. Inspect the Electrical Connectors and the Wiring Typical engine speed/timing sensor (3) O-ring D. Ensure that one O-ring (3) is installed on the sensor.
Troubleshooting Section Illustration 69 RENR9348-01 g01167873 (6) J2/P2 ECM connector A. Thoroughly inspect connectors (4), (5), and (6). Refer to Troubleshooting, “Electrical Connectors - Inspect”. Illustration 70 g01212538 P2 terminals that are associated with the engine speed/timing sensors (P2-25) (P2-35) (P2-46) (P2-47) (P2-92) Primary engine speed/timing − Primary engine speed/timing + Secondary engine speed/timing + Secondary engine speed/timing − Speed/timing shield B.
RENR9348-01 D. Check the harness and the wiring for abrasion and for pinch points from each sensor back to the ECM. Expected Result: 141 Troubleshooting Section Resistance at 25 °C (77 °F) ................................ 600 to 1800 Ohms Expected Result: The resistance measurement is within the specifications. All of the connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion, and of pinch points.
Troubleshooting Section RENR9348-01 • Not OK – The reading is not within the specification. There is an electrical problem with the engine speed/timing sensor. Repair: Perform the following procedure in order to check and install the new sensor assembly: 1. Before you install the new sensor assembly, measure the resistance of the new sensors.
RENR9348-01 Illustration 71 Schematic for the engine temperature sensors Test Step 1. Inspect the Electrical Connectors and the Wiring A. Remove electrical power from the ECM.
Troubleshooting Section RENR9348-01 Illustration 73 g01223584 P2 ECM connector (P2-13) (P2-30) (P2-56) (P2-65) Illustration 72 Engine coolant temperature Sensor return Intake manifold air temperature Fuel temperature g01204650 Left side engine view (typical example) (1) (2) (3) (4) (5) Intake manifold air temperature sensor Engine coolant temperature sensor Engine oil temperature sensor J2/P2 ECM connectors Fuel temperature sensor B.
RENR9348-01 C. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the temperature sensors. D. Check the allen head screw for each of the ECM connectors for the proper torque. Refer to Troubleshooting, “Electrical Connectors - Inspect” for correct torque values. E. Check the harness and wiring for abrasions and for pinch points from each sensor to the ECM. Expected Result: All connectors, pins, and sockets are completely coupled and/or inserted.
Troubleshooting Section Test Step 4. Short at the Suspect Sensor at the Harness Connector A. Remove electrical power from the ECM. B. Disconnect the suspect sensor at the harness connector. C. Fabricate a jumper wire that is long enough to short circuit the two terminals at the connector for the suspect sensor. Crimp connector pins to each end of the jumper wire. D.
RENR9348-01 147 Troubleshooting Section Repair: The ECM is working properly. The problem is in the wiring harness between the ECM and the sensor connector. Repair the harness and/or the connectors. Replace parts, if necessary. STOP. • Not OK – One of the following conditions exists: The 03 diagnostic code is not active when the sensor signal wire is open. The 04 diagnostic code is not active when the wire jumper is shorted to ground. Repair: There is a problem with the ECM. Replace the ECM.
Troubleshooting Section RENR9348-01 g01206657 Illustration 75 Schematic for the ether injection system Test Step 1. Inspect the Electrical Connectors and the Wiring A. Remove electrical power from the ECM. Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures. Use ether only in well ventilated areas. Do not smoke while changing ether cylinders. Use ether with care to avoid fires.
RENR9348-01 149 Troubleshooting Section B. Thoroughly inspect connectors (1) and (2). Also, thoroughly inspect all of the other connectors that are in the circuit. Refer to the diagnostic functional test Troubleshooting, “Electrical Connectors Inspect” for details.
Troubleshooting Section Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled. STOP. Test Step 2. Check the Ether Canisters for Fluid A. Ensure that the electrical power is removed from the ECM. B. Remove the ether canister from the ether valve. C. Determine if the canister is empty. Expected Result: The ether canister is not empty.
RENR9348-01 151 Troubleshooting Section Test Step 5. Check the Operation of the ECM Test Step 6. Check the Voltage at the Starting Aid Solenoid A. Fabricate two jumper wires that are long enough to create a short circuit between terminal locations at the ECM connector. Crimp a connector socket to one end of each of the jumper wires. A. Disconnect the connector for the starting aid solenoid. B. Disconnect the J1/P1 ECM connectors. C.
Troubleshooting Section RENR9348-01 D. Connect the J1/P1 ECM connector. • E390-1 Fuel Filter Restriction Warning E. Connect a voltmeter between the loose ends of the wire jumpers at the P1 ECM connector. • E390-2 Fuel Filter Restriction Derate F. Restore the electrical power to the ECM. G. Select the “Override Parameters” option from the “Diagnostic Tests” on Cat ET. H. Activate the override for “Ether Injection”. I. Measure the voltage at the connector for the starting aid solenoid valve.
RENR9348-01 153 Troubleshooting Section g01223587 Illustration 81 Schematic for fuel filter differential pressure switch Test Step 1. Inspect the Electrical Connectors and the Wiring A. Remove electrical power from the ECM. Illustration 83 g01161069 Fuel filter base (typical example) (2) Fuel filter differential pressure switch Illustration 82 Left side engine view (typical example) (1) J2/P2 ECM connectors g01214446 B. Thoroughly inspect connectors (1).
Troubleshooting Section RENR9348-01 C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the active diagnostic code. D. Check the allen head screw of each ECM connector for the proper torque. Refer to the diagnostic functional test Troubleshooting, “Electrical Connectors - Inspect” for the correct torque value. E. Check the harness and wiring for abrasions and for pinch points from the switch back to the ECM.
RENR9348-01 Results: • OK – The event code is not active. Repair: The wiring between the connector and the ECM is OK. Replace the fuel filter element. Restart the engine and check for an event code. If the event code is still active, temporarily replace the fuel filter differential pressure switch. Verify that the problem is resolved before permanently replacing the fuel filter differential pressure switch. STOP. • Not OK – The event code is still active.
Troubleshooting Section • 6-06 Cylinder #6 Injector short RENR9348-01 • 7-05 Cylinder #7 Injector open circuit The Caterpillar Electronic Technician (ET) includes the following tests that aid in troubleshooting the injector solenoids: • 7-06 Cylinder #7 Injector short “Cylinder Cutout Test” • 8-05 Cylinder #8 Injector open circuit The “Cylinder Cutout Test” is used on an engine in order to determine the individual cylinder performance while the engine is running.
RENR9348-01 Illustration 86 Schematic for the injector solenoids 157 Troubleshooting Section g01223595
Troubleshooting Section RENR9348-01 Test Step 1. Inspect the Electrical Connectors and the Wiring Electrical shock hazard. The electronic unit injector system uses 90-120 volts. A. Remove the electrical power from the ECM. Illustration 87 g01166729 Left side engine view (typical example) (1) J2/P2 ECM connectors (2) R1/P3 Injector valve cover entry connectors (right bank) (3) R1/P4 Injector valve cover entry connectors (left bank) B. Thoroughly inspect connectors (1), (2), and (3).
RENR9348-01 159 Troubleshooting Section Expected Result: All connectors, pins, and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion, or of pinch points. Results: • OK – The harnesses and the wiring appear to be OK. Proceed to Test Step 2. • Not OK – There is a problem in the connectors and/or wiring.
Troubleshooting Section RENR9348-01 • “Diagnostics” • “Diagnostics” • “Diagnostic Tests” • “Diagnostic Tests” • “Cylinder Cutout Test” • “Injector Solenoid Test” D. Shut off all parasitic loads such as air compressors which could affect the results of the test. E. Follow the instructions that are given on the screen. F. To start the test, select the start button at the bottom of the screen. G.
RENR9348-01 161 Troubleshooting Section D. Fabricate a jumper wire that will be long enough to short circuit two terminal locations at the P300 connector. Crimp connector pins to both ends of the jumper wire. F. Perform the “Injector Solenoid Test” at least two times. G. Repeat this test for each suspect circuit. Stop the “Injector Solenoid Test” before handling the jumper wire. Restore the wiring to the original configuration. Expected Result: Cat ET displays “Short” for each circuits that was jumpered.
Troubleshooting Section RENR9348-01 Test Step 7. Check the Injector Harness Under the Valve Cover for an Open Circuit or a Short Circuit K. Perform the “Injector Solenoid Test” at least two times. L. Remove the electrical power from the ECM. Expected Result: Electrical shock hazard. The electronic unit injector system uses 90-120 volts. A. Remove the electrical power from the ECM. B. Remove the valve cover in order to gain access to the suspect injector. C.
RENR9348-01 C. Disconnect the P2 connector. D. Remove the supply wire from the terminal location for the suspect injector at the ECM connector. Install the jumper wire into this socket. E. Connect the J2/P2 ECM connectors. F. Verify that the ECM will detect an open circuit for the suspect injector: 163 Troubleshooting Section • Not OK – The ECM does not detect the correct status of the circuit. Repair: There is a problem with the ECM. Replace the ECM. Refer to Troubleshooting, “Replacing the ECM”.
Troubleshooting Section RENR9348-01 g01207558 Illustration 94 Schematic for the speed control circuit (typical example) Test Step 1. Inspect the Electrical Connectors and the Wiring A. Remove electrical power from the ECM. Illustration 96 g01207581 Location of the engine interface connector (typical engine view) (2) Engine interface connector B. Thoroughly inspect connectors (1) and (2). Also, thoroughly inspect all of the other connectors that are in the circuit.
RENR9348-01 165 Troubleshooting Section D. Check the allen head screw on each ECM connector and the engine interface connector for the proper torque. refer to the diagnostic functional test Troubleshooting, “Electrical Connectors Inspect” for the correct torque values. E. Check the harness and the wiring for abrasion and for pinch points.
Troubleshooting Section RENR9348-01 1. Check the voltage between engine ground and the following test points. If voltage is not present at a test point, the problem is in the device, in the wire or in the connector that precedes the point in the circuit. Refer to Illustration 94 as a reference. Table 22 D. Adjust the speed adjust potentiometer from the lowest setting to the highest setting. Monitor the status for the throttle position on Cat ET while you perform the test. E.
RENR9348-01 • Not OK – The throttle signal is not present at the speed control. Repair: There is a problem with the speed control. Replace the speed control. Verify that the problem is no longer present. STOP. Test Step 5. Check the PWM Signal at the Engine Interface Connector A. Disconnect the engine interface connectors. B. Remove the wires from terminal locations 15 (digital return) and 21 (rated speed) on the side of the engine interface connector that is from the speed control. C.
Troubleshooting Section RENR9348-01 During an engine start sequence, the Starting Motor Magnetic Switch (SMMS) is used by the Electronic Control Module (ECM) to engage the starting motor. Control input voltage for the SMMS is supplied by the ECM. When the ECM supplies the signal to the circuit, the SMMS is energized. This powers the starting solenoid and the starting motor engages. The SMMS is de-energized by the ECM when the engine speed reaches the crank terminate speed.
RENR9348-01 Illustration 100 169 Troubleshooting Section g01210546 Location of the J2/P2 ECM connector (typical engine view) (1) J2/P2 ECM connector Illustration 101 g01210527 Location of the battery disconnect switch and the SMMS (typical left side engine view) (2) Battery disconnect switch (3) SMMS B. Thoroughly inspect connector (1). Also, thoroughly inspect the connections at switches (2) and (3). Refer to Troubleshooting, “Electrical Connectors Inspect” for details.
Troubleshooting Section Results: • OK – The wiring and the connectors appear to be OK. Proceed to Test Step 2. • Not OK – There is a problem with the wiring and/or the connectors. Repair: Repair the connectors and/or the wiring. Replace parts, if necessary. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled. Verify that the repair eliminates the problem. STOP. Test Step 2. Check for Active Diagnostic Codes A.
RENR9348-01 • Not OK – A 444-05 code remained active when the wires were short circuited at the control input for the start relay. There is a open circuit in the harness between the connector and the SMMS. The problem may be in the ECM. Proceed to Test Step 5. Test Step 4. Check for a Short at the Control Input of the SMMS A. Disconnect the wires that are for the control input at the terminals of the SMMS. B. Turn the battery disconnect switch to the ON position. C.
Troubleshooting Section If a 444-05 diagnostic code was originally present, there is an open circuit in the harness or in a connector. If a 444-06 diagnostic code was originally present, there is an short circuit in the harness or in a connector. Repair the harness and/or the connector. Replace parts, if necessary. Verify that the original problem is resolved. STOP. • Not OK – Either of the following conditions exist: The 444-05 diagnostic code is present when the jumper wires are shorted.
RENR9348-01 Repair: The control circuit and the SMMS are OK. The secondary circuit for the relay is not engaging. Replace the SMMS. Verify that the problem is resolved. STOP.
Troubleshooting Section RENR9348-01 Calibration Procedures Results: • OK – No active diagnostic codes are present. If a i02348860 Engine Speed/Timing Sensor Calibrate SMCS Code: 1439-524; 1912-524 System Operation Description: Use this procedure if a 261-13 Engine Timing Calibration required is active. Also use this procedure if any of the following conditions exist: • The Electronic Control Module (ECM) has been replaced. • The ECM software has been updated.
RENR9348-01 Results: • OK – The timing calibration was successful. Repair: Return the engine to service. STOP. • Not OK – The timing calibration was unsuccessful. Repair: The following conditions can cause the timing calibration to fail: • If the crankshaft and camshaft gears have been reassembled incorrectly, the timing will not calibrate. • Verify that the engine speed/timing sensors are installed correctly. • Verify that the engine speed is correct and that the engine speed is stable.
Index Section RENR9348-01 Index Numerics 5 Volt Engine Pressure Sensor Supply Circuit Test ...................................................................... 90 A Air Shutoff System - Test ....................................... Alternator (Charging Problem)............................... Probable Causes ............................................... Recommended Actions...................................... 94 27 27 27 C Calibration Procedures ........................................
RENR9348-01 177 Index Section CID 1785 FMI 10 Intake Manifold Pressure Signal abnormal rate of change...................................... 72 Coolant in Engine Oil............................................. 28 Probable Causes ............................................... 28 Recommended Actions...................................... 28 Coolant Level Sensor Circuit - Test ..................... 109 D Diagnostic Code Cross Reference ........................ Cross-Reference for SPN-FMI Code to CID-FMI.....
Index Section RENR9348-01 I Important Safety Information ................................... 2 Injector Solenoid Circuit - Test............................. 155 Injector Trim File .................................................... 19 Intermittent Engine Shutdown ............................... 41 Probable Causes ............................................... 41 Recommended Actions...................................... 41 Intermittent Low Power or Power Cutout............... 42 Probable Causes .....
RENR9348-01 179 Index Section
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