Cat MEUI Diagnosis

C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure
Page 1 of 4
Shutdown SIS
Previous Screen
Product: PETROLEUM ENGINE
Model: C-15 PETROLEUM ENGINE Z2C
Configuration: C-15 Petroleum Engine Z2C00001-UP
Troubleshooting
C-10 and C-15 Petroleum Engines
Media Number -RENR5061-01
Publication Date -01/02/2005
Date Updated -14/02/2005
i02274766
Can Not Reach Top Engine RPM

SMCS - 1915-035
Note: If this problem occurs only under load, refer to Troubleshooting, "Low Power/Poor or No
Response to Throttle".
The connection of any electrical equipment and the disconnection of any

electrical equipment may cause an explosion hazard which may result
in injury or death. Do not connect any electrical equipment or
disconnect any electrical equipment in an explosive atmosphere.
Probable Causes
Diagnostic codes
Event codes
Programmable parameters
Cold mode
Altitude derate
Throttle signal
"Fuel Position" and/or "FRC Fuel Limit"
Boost pressure sensor
Fuel supply
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 4/8/2010
Air inlet and exhaust system
Accessory equipment
Page 2 of 4
Recommended Actions
Diagnostic Codes and Event Codes
Certain diagnostic codes and/or event codes may cause poor performance. Connect the Caterpillar
Electronic Technician (ET) and check for active codes and logged codes. Troubleshoot any codes that
are present before continuing with this procedure.
Programmable Parameters
Check the values of the following parameters on Cat ET:
"Throttle Position Sensor"
"Direct Fuel Control Mode"
Determine the type of throttle that is used in the application. Program the parameters to match the type
of throttle that is used. Refer to Troubleshooting, "Throttle Position Sensor Circuit - Test" for more
information.
Note: The engine will have poor performance if the parameters are not programmed correctly.
Cold Mode
Use Cat ET to verify that the engine has exited cold mode. A status indicator will appear if the engine is
operating in cold mode. This may limit engine speed.
Altitude Derate
The engine may be derated due to high elevation. Use Cat ET to check for an active engine derate on the
status screens.
Note: There are no event codes that are associated with the altitude derate.
Throttle Signal
View the status for the throttle position on the status screen of Cat ET. Operate the throttle from the
LOW IDLE position to the HIGH IDLE position. The status should be approximately 0 percent at low
idle and the status should be approximately 100 percent at high idle. If either indication is incorrect,
refer to Troubleshooting, "Throttle Position Sensor - Calibrate".
Diagnostic codes that are related to the J1939 data link will prevent correct operation of the throttle if
the throttle position is transmitted over the data link. If there is a problem with the data link, the engine
will remain at low idle until the data link is repaired.
Page 3 of 4
Boost Pressure Sensor, "Fuel Position", and/or "FRC Fuel Limit"

1. With the engine at full load, monitor "Fuel Position" and "Rated Fuel Limit" on the status screen.
If "Fuel Position" does not equal "Rated Fuel Limit" then check the inlet manifold air pressure.
2. Verify that there are no active diagnostic codes that are associated with the boost pressure sensor
or with the atmospheric pressure sensor.
3. Monitor boost pressure and atmospheric pressure on the status screen for normal operation.
Note: Atmospheric pressure is not a default parameter on a status screen. You must manually select the
parameter for the atmospheric pressure in order to monitor the atmospheric pressure sensor.
Fuel Supply
1. Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines. If
problems are found with the fuel lines, repair the lines and/or replace the lines.
2. Check the fuel tank for foreign objects which may block the fuel supply.
3. Check for air in the fuel. Refer to Systems Operation/Testing and Adjusting, "Air in Fuel - Test".
4. Purge trapped air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel
System - Prime" for the correct procedure.
5. 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.
6. Check the fuel pressure. Refer to Systems Operation/Testing and Adjusting, "Fuel System
Pressure - Test". If the fuel pressure is low, replace the fuel filters. If the fuel pressure is still low,
check the following items: fuel transfer pump, fuel transfer pump coupling and fuel pressure
regulating valve.
Air Inlet and Exhaust System

1. Clean plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance
Manual for instructions.
2. Check the air inlet and exhaust system for restrictions and/or for leaks. Refer to Systems
Operation/Testing and Adjusting, "Air Inlet and Exhaust System".
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.
Copyright 1993 - 2010 Caterpillar Inc.
All Rights Reserved.

Private Network For SIS Licensees.
Page 4 of 4
Thu Apr 8 08:09:25 CDT 2010
Page 1 of 4
Shutdown SIS
Previous Screen
Troubleshooting
i02121223
Engine Cranks but Will Not Start

SMCS - 1000-035

Probable Causes
ECM personality module
Electrical power to the Electronic Control Module (ECM)
Remote shutdown switch
Air shutoff circuit
Starting motor solenoid or starting circuit
Engine speed/timing sensors
Electrical connections to the electronic unit injector
Fuel supply
Combustion problem
Recommended Actions
ECM Personality Module
Page 2 of 4
If a new ECM has been installed on the engine, the engine will not start. The ECM will not communicate with
the Caterpillar Electronic Technician (ET) until the correct personality module has been flashed into the
ECM.
1. Verify that the following diagnostic is not active.
253-02 Personality Module mismatch
If the code is active, access the "Winflash" and flash the correct version of the software.
Electrical Power to the ECM

1. Turn the keyswitch OFF.
2. Check the positive battery and negative battery connections to the ECM.
3. Perform a pull test on positive battery wires and negative battery wires.
4. Check the negative battery connection on the ground stud.
5. Turn the keyswitch ON.
6. The warning lamps should illuminate for five seconds.
If the warning lamp illuminates for five seconds, continue with this procedure.
If the warning lamp does not illuminate for five seconds, refer to the diagnostic functional test
Troubleshooting, "Electrical Power Supply Circuit - Test".
Remote Shutdown Switch

Access the screen on Cat ET that displays the remote shutdown switch status. The remote shutdown switch
status on Cat ET is called "User Shutdown".
Table 1
"User Shutdown Status"
Switch Status
Measured Voltage at P61:27
ON
Negative battery
<0.9 VDC
OFF
Open circuit
>10 VDC
If the voltage is not in the proper range, refer to the diagnostic functional test Troubleshooting, "Switch
Circuits - Test".
Air Shutoff Circuit

Refer to the diagnostic functional test Troubleshooting, "Air Shutoff System - Test" for additional
information.
Starting Motor Solenoid or Starting Circuit
Page 3 of 4
1. Test the operation of the starting motor solenoid.

2. Check the engine wiring to the starting motor solenoid.
3. Test the operation of the starting motor.
4. Inspect the starter motor pinion and the flywheel ring gear for damage.
Engine Speed/Timing Sensors

Observe the engine speed on Cat ET while the engine is being cranked.
This situation may require a direct hookup to the batteries in order to power Cat ET while the engine is
cranking. Refer to Illustration 1 for the wiring diagram.
Illustration 1
g00781203
If the engine is cranking and Cat ET displays 0 rpm, a problem exists in the circuits for the engine
speed/timing sensors. Refer to the diagnostic functional test Troubleshooting, "Engine Speed/Timing Sensor
Circuit - Test".
If an engine speed is present, check the sensor installation. If the sensor is not properly installed, the ECM
may read engine speed, but the ECM cannot determine the tooth pattern. The ability for the ECM to read the
tooth pattern is necessary to determine the cylinder position. Engine speed is present when engine speed is
greater than 50 rpm. Refer to the diagnostic functional test Troubleshooting, "Engine Speed/Timing Sensor
Circuit - Test".
Electrical connections to the electronic unit injector

1. Ensure that the electronic unit injector connector (J300/P300) is fully connected and free of corrosion.
2. Check for logged diagnostic codes that are related to the cylinder. Refer to the diagnostic functional test
Page 4 of 4
Troubleshooting, "Injector Solenoid Circuit - Test" if diagnostic codes that are related to the cylinder
are present.
Check the Fuel Supply

1. Check the fuel level.
2. Monitor the exhaust for smoke while the engine is being cranked.
If no smoke is present, there may be a problem with the fuel quality or there may be a problem with the
fuel supply.
3. Check the fuel pressure. Refer to Testing and Adjusting, "Fuel System Pressure - Test".
4. Ensure that the fuel system has been primed. Refer to Testing and Adjusting, "Fuel System - Prime".
5. Check for fuel supply lines that are restricted.
6. Check the fuel filters.
7. If the temperature is below 0 C (32 F), check for solidified fuel (wax).
Check for Combustion Problems

Examples of conditions that may cause combustion problems are shown in the following list:
Cold temperatures
Injector misfiring
Low compression
Mechanical problem
Valve lash settings
Refer to Testing and Adjusting for more information on a particular problem.

Thu Apr 8 08:12:11 CDT 2010
Page 1 of 3
Shutdown SIS
Previous Screen
Troubleshooting
i02291647
Engine Misfires, Runs Rough or Is Unstable

SMCS - 1000-035

Note: If the symptom is intermittent and the symptom cannot be repeated, refer to the diagnostic
procedure 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
Programmable parameters
Electrical connectors
Cold mode
Throttle signal
Unit injectors
Fuel supply
Page 2 of 3
Recommended Actions
Note: If the symptom only occurs under certain operating conditions (high idle, full load, engine
operating temperature, etc), test the engine under those conditions. Troubleshooting the symptom under
other conditions can give misleading results.
Diagnostic Codes
Check for active diagnostic codes on the Caterpillar Electronic Technician (ET). Troubleshoot any
active codes before continuing with this procedure.
Programmable Parameters
Check the following parameters on Cat ET:
"Desired Speed Input Configuration"
of throttle that is used. Refer to the diagnostic functional test Troubleshooting, "Throttle Position Sensor
Circuit - Test" for more information.
Note: If the parameters are not programmed correctly, then the engine will have poor performance.
Electrical Connectors
Check for the correct installation of the J1/P1 and J2/P2 connectors for the Electronic Control Module
(ECM). Check the unit injector connectors. Refer to the diagnostic functional test Troubleshooting,
"Electrical Connectors - Inspect".
Cold Mode
Use Cat ET to verify that the engine has exited cold mode. Cold mode operation may cause the engine to
run rough and the engine power may be limited.
Throttle Signal
Monitor throttle signal on Cat ET. Verify that the throttle signal is stable from the low idle position to
the high idle position.
Unit Injectors
1. Use Cat ET to determine if there are any active diagnostic codes for the unit injectors.
2. Perform the Injector Solenoid Test on Cat ET in order to determine if all of the injector solenoids
are being energized by the ECM.
Page 3 of 3
3. Perform the Cylinder Cutout Test on Cat ET in order to identify any misfiring cylinder(s). Refer
to Troubleshooting, "Injector Solenoid Circuit - Test" for information.
Fuel Supply
3. Check for air in the low pressure fuel supply 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
4. Purge air from the low pressure fuel supply circuit. Refer to Operation and Maintenance Manual,
"Fuel System - Prime" for the complete procedure.
Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel.
5. Check fuel quality. In temperatures below 0 C (32 F), check for solidified fuel (wax). Refer to
Operation and Maintenance Manual for information on cold weather operation.
6. Check the fuel pressure during engine cranking. Check the fuel pressure after the fuel filter. Refer
to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test" 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, fuel transfer pump coupling and fuel pressure
regulating valve.

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 Testing and
Adjusting, "Air Inlet and Exhaust System".

Thu Apr 8 08:13:01 CDT 2010
Page 1 of 2
Shutdown SIS
Previous Screen
Troubleshooting
i02291686
Engine Stalls at Low RPM

SMCS - 1915-035

Probable Causes
Unit injectors
Fuel supply
Accessory equipment
Recommended Actions
Unit Injectors
1. Check for correct installation of the J1/P1 and J2/P2 connectors for the Electronic Control Module
(ECM). Check for correct installation of the connectors for the unit injectors. Refer to
Troubleshooting, "Electrical Connectors - Inspect".
2. Perform the "Injector Solenoid Test" with the Caterpillar Electronic Technician (ET) in order to
determine if all of the injector solenoids are being energized by the ECM.
3. Perform the "Cylinder Cutout Test" with Cat ET in order to identify any injectors that might be
misfiring. Refer to Troubleshooting, "Injector Solenoid Circuit - Test" for the proper procedure.
Page 2 of 2
Fuel Supply
1. Check the pressure of the low pressure fuel system during engine cranking. Check the pressure
while the engine is running. Refer to Systems Operation/Testing and Adjusting, "Fuel System
Pressure - Test" for the correct procedure.
3. Check the fuel tank for debris which may block the fuel supply.
performed:
Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer to
Systems Operation/Testing and Adjusting, "Air in Fuel - Test" for more information.
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.
"Fuel System - Prime" for the correct procedure.
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.

Thu Apr 8 08:13:39 CDT 2010
Service Information System
Page 1 of 3
Troubleshooting
i02291705
Intermittent Engine Shutdown

SMCS - 1000-035

Note: Use this procedure only if the engine shut down completely and it was necessary to restart the
engine.
Probable Causes
Active diagnostic codes or engine events
Incorrect parameters for engine rating
Poor electrical connections to the Electronic Control Module (ECM)
Poor electrical connections to the unit injector connectors
Faulty remote shutdown switch
Tripped circuit breakers
Fuel supply
Faulty overspeed verify switch (if applicable)
Note: If the problem only occurs under certain conditions such as high engine speed, full load or engine
operating temperature, then perform the test under those operating conditions.
Recommended Actions
Active Diagnostic Codes or Engine Events
Certain diagnostic codes and/or event codes may cause the engine to shutdown. Connect the Caterpillar
Electronic Technician (ET) and check for active codes and/or for logged codes. Troubleshoot any codes
https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/mediasear... 4/8/2010
Page 2 of 3
that are present before continuing with this procedure.
Incorrect Parameters for Engine Rating

The engine may be shut down due to low pressure levels or other factors. Connect Cat ET and check for
active shutdowns or diagnostic codes.
If a shutdown is active, "Injection Disabled" will appear on Cat ET.
An engine shutdown event will appear on a CAN J1939 device if the device is capable of displaying
diagnostic codes.
Poor Electrical Connections to the ECM

1. Check the associated wiring for the following conditions: damage, abrasion, corrosion and
incorrect attachment .
J1/P1 and J2/P2 ECM connectors
J61/P61 Customer connector
J401/P401 and J402/P402 Engine Speed/Timing Sensor connectors
Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".

2. Check Cat ET for an active 168-02 "System Voltage intermittent/erratic".
Check the battery connection at the J61 customer connector and the ECM connector. Perform a
pull test on the pin locations at the ECM that are associated with the +Battery and the Battery
connections. Refer to the diagnostic functional test Troubleshooting, " Electrical Connectors Inspect".
Note: Aftermarket engine protection devices usually interrupt power to the ECM. Check for correct
installation and for operation of aftermarket engine protection devices. It may be necessary to bypass
aftermarket devices in order to continue testing.
Poor Electrical Connections to the Unit Injector Connectors

Check the J300/P300 valve cover connectors and associated wiring for the following conditions:
damage, abrasion, corrosion and incorrect attachment. Refer to the diagnostic functional test
Faulty Remote Shutdown Switch

Access a status screen in Cat ET that displays the remote shutdown switch status. The remote shutdown
switch status on Cat ET is called "User Shutdown".
Table 1
Page 3 of 3
"User Shutdown Status"
Switch Status
Measured Voltage at P61-27
ON
Negative battery
<0.9 VDC
OFF
Open circuit
>10 VDC
If the voltage is not in the proper range, refer to the diagnostic functional test Troubleshooting, "Switch
Circuits - Test".
Tripped Circuit Breakers

Check the circuit breakers. The circuit breakers may exceed the trip point due to overheating. Reset the
circuit breakers if the circuit breakers are tripped.
Fuel Supply
Check for a problem with the fuel supply and verify the fuel pressure. Verify that the fuel pressure
sensor is installed. Refer to Systems Operation/Testing and Adjusting for additional information.
Faulty Overspeed Verify Switch

If an overspeed condition has occurred, the air shutoff solenoid(s) must be reset manually. Remove wire
for the overspeed verify switch from the ECM connector and test again. If the problem goes away, there
is a problem in the circuit for the overspeed verify switch. Refer to the diagnostic functional test
Troubleshooting, "Switch Circuits - Test".

Thu Apr 8 08:14:35 CDT 2010
Page 1 of 3
Troubleshooting
i02291707
Intermittent Low Power or Power Cutout

SMCS - 1000-035

Note: Use this procedure only if the engine does not shut down completely.
Probable Causes
Incorrect throttle signal
Poor electrical connections
Fuel supply
Recommended Actions
Electronic Technician (ET) and check for active codes and logged codes. Troubleshoot any codes that
are present before continuing with this procedure.
Incorrect Throttle Signal

Connect Cat ET to the service tool connector. View the status for the throttle position on the status
screen. Operate the throttle from the low idle position to the high idle position. The status should be 0
percent at low idle and the status should be 100 percent at high idle. If the status cannot operate in the
full range, refer to the calibration procedure Troubleshooting, "Throttle Position Sensor - Calibrate".
Page 2 of 3
Poor Electrical Connections

1. Inspect the battery wires from the ECM back to the battery compartment. Refer to the Electrical
System Schematic. Inspect the wires and the power relay. Check the power and ground
connections to the ECM. Refer to the diagnostic functional test Troubleshooting, "Electrical
Power Supply Circuit - Test" for more information.
Fuel Supply
performed:
Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer to
Systems Operation/Testing and Adjusting, "Air in Fuel - Test" for more information.
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.
"Fuel System - Prime" for the correct procedure.
6. Check the fuel pressure after the fuel filter while the engine is being cranked. Refer to Systems
Operation/Testing and Adjusting, "Fuel Pressure - Test" 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, fuel transfer pump coupling and fuel pressure regulating valve.

Thu Apr 8 08:15:09 CDT 2010
Page 3 of 3
Page 1 of 4
Troubleshooting
i02291711
Low Power/Poor or No Response to Throttle

SMCS - 1000-035

Probable Causes
Incorrect engine rating
Incorrectly programmed parameters
Cold mode operation
Poor electrical connections
Incorrect status of PTO enable switch
Incorrect status of intermediate speed switch
Incorrect throttle signal
Poor connections to the electronic unit injectors
Fuel supply
Turbocharger outlet pressure sensor (intake manifold air), rated fuel position and/or FRC fuel
position
Recommended Actions
Note: If the problem only occurs under certain conditions, test the engine under those conditions.
Page 2 of 4
Examples of certain conditions are high rpm, full load and engine operating temperature.
Troubleshooting the symptoms under other conditions can give misleading results.

Electronic Technician (ET) and check for active codes and for logged codes. Troubleshoot any codes
that are present before continuing with this procedure.
Incorrect Engine Rating

Verify that the correct engine rating is being used for the application.
Improperly Programmed Parameters

Check the following parameters on Cat ET:
Verify that the injector codes have been programmed properly.
"Desired Speed Input Configuration"
of throttle that is used. Refer to the diagnostic functional test Troubleshooting, "Throttle Position Sensor
Circuit - Test" for more information.
Note: If the parameters are not programmed correctly, then the engine will have poor performance.
Cold Mode
Monitor the status screen on Cat ET in order to verify that the engine has exited cold mode.
Poor Electrical Connections

Check the associated wiring for damage, abrasion, corrosion or incorrect attachment on the following
connectors: J1/P1 and J2/P2 ECM connectors, customer connector and throttle position sensor
connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for information.
Incorrect Status of PTO Enable Switch

Connect Cat ET and verify that the "PTO enable switch" is not engaged. Remove the wiring for the PTO
enable switch and cycle the power to the ECM. Verify that the problem is still present. If the problem is
still present, reattach the wires and continue to next step. If the problem is resolved, refer to the
diagnostic functional test Troubleshooting, "Switch Circuits - Test".
Incorrect Status of Intermediate Speed Switch
Page 3 of 4
Connect Cat ET and verify that the intermediate speed switch is not engaged. Remove the wiring for
intermediate speed and cycle power to the ECM. Verify that the problem is still present. If the problem
is still present, reattach the wires and continue to next step. If the problem is resolved, refer to the
diagnostic functional test Troubleshooting, "Switch Circuits - Test".
Incorrect Throttle Signal

Connect Cat ET to the service tool connector. View the status for the throttle position on the status
screen. Operate the throttle from the low idle position to the high idle position. The status should be
approximately 0 percent at low idle and the status should be approximately 100 percent at high idle. If
the status cannot operate in the full range, refer to the calibration procedure Troubleshooting, "Throttle
Position Sensor - Calibrate".
Poor Connections to the Electronic Unit Injectors

Inspect the J2/P2 ECM connector and the J300/P300 valve cover connector for proper connections.
Refer to Troubleshooting, " Electrical Connectors - Inspect". Connect Cat ET and cut out each cylinder
in order to isolate the misfiring cylinder or cylinders. If the results are inconclusive, shut off half of the
cylinders and repeat the cylinder cutout test on the active cylinders that are remaining in order to locate
those cylinders that are missing. Refer to the diagnostic functional test Troubleshooting, "Injector
Solenoid Circuit - Test".
Fuel Supply
Check for a problem with the fuel supply and verify the fuel pressure. Verify that a fuel pressure sensor
is installed on the engine. For further information, refer to Systems Operation/Testing and Adjusting,
"Fuel System Pressure - Test".
Turbocharger Outlet Pressure Sensor (Intake Manifold Air), Rated Fuel Position
and/or FRC Fuel Position
1. With the engine at full load, monitor "Fuel Position" and "Rated Fuel Limit" on the status screen.
If "Fuel Position" does not equal "Rated Fuel Limit", then check air inlet manifold pressure.
2. Verify that there are no active diagnostic codes that are associated with the turbocharger outlet
pressure sensor (intake manifold air) or with the atmospheric pressure sensor.
3. Monitor air inlet manifold pressure and atmospheric pressure for normal operation on the status
screen.

Check the air inlet and exhaust systems for restrictions and for leaks. Refer to Systems
Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect". Look for an indication of the
warning lamp or restriction indicators that are tripped if the filters are equipped with these devices.
These indicators are associated with plugged filters. Replace the plugged air filters or clean the plugged
Page 4 of 4
air filters per the guidelines for operation and maintenance. Repair any leaks that are found in the
system.

Thu Apr 8 08:15:33 CDT 2010
Page 1 of 4
Troubleshooting
i02769238
Diagnostic Codes
SMCS - 1900
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.
Suspect Parameter Number (SPN) - The SPN is a three digit code which is assigned to each
component in order to identify data via the data link to the ECM. This is used on the diagnostics for the
CAN data link.
Refer to Troubleshooting, "Diagnostic Code Cross Reference" for the complete list of the diagnostic
codes and a description of each code. There is a troubleshooting procedure for every diagnostic code.
Refer to Troubleshooting, "Troubleshooting With A Diagnostic Code".
When a diagnostic code is activated, the Electronic Control Module (ECM) transmits information about
the code over the J1939 data link. Some J1939 devices may display the code. However, the code will be
displayed with a SPN-FMI code. Refer to Troubleshooting, "Diagnostic Code Cross Reference" for a
cross-reference between SPN-FMI codes and diagnostic codes.
Do not confuse diagnostic codes with event codes. Event codes alert the operator that an abnormal
operating condition such as low oil pressure or high coolant temperature has been detected. Refer to
Troubleshooting, "Troubleshooting with an Event Code" for additional information on event codes.
Illustration 1 is an example of the operating range of a sensor.
View Image
Illustration 1
Page 2 of 4
g01365757
Example of the typical operating range of a sensor

(1) This area represents the normal operating range of the engine parameter.
(2) In these areas, the engine is operating in an unsafe operating range of the monitored parameter. An event code will be
generated for the monitored parameter. The sensor circuit does not have an electronic problem. Refer to Troubleshooting,
Page 3 of 4
"Troubleshooting with an Event Code" for additional information on event codes.

(3) In these areas, the signal from the sensor is outside of the operating range of the sensor. The sensor circuit has an
electronic problem. A diagnostic code will be generated for the sensor circuit.
Active Diagnostic Codes

An active diagnostic code represents a problem with the electronic control system. Correct the
problem as soon as possible.
When the ECM generates an active diagnostic code, the "Active Alarm" indicator ("Engine Control
Alarm Status" on Cat ET) is activated in order to alert the operator. If the condition that generated the
code is momentary, the message disappears from the list of active diagnostic codes. The diagnostic code
becomes logged.
Logged Diagnostic Codes

When 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.

Page 4 of 4
Thu Apr 8 08:16:03 CDT 2010
Page 1 of 4
Troubleshooting
i02292113
Diagnostic Code Cross Reference

SMCS - 1900
Problems with the electronic control system are reported via these types of codes: flash codes, diagnostic
codes and event codes.
For information on flash codes, refer to Troubleshooting, "Flash Codes".
For information on diagnostic codes, refer to Troubleshooting, "Diagnostic Codes".
For information on event codes, refer to Troubleshooting, "Event Codes".
Use Table 1 as a cross-reference between the various types of codes.
Table 1
Cross Reference for Flash Codes
Flash Code
N/A
Diagnostic
or
Event Code
SPN/FMI Code
E443
1835-00
High Auxiliary Pressure
E445
1836-00
High Auxiliary Temperature
545-05
545-05
Ether Start Relay open/short to +batt
545-06
545-06
Ether Start Relay short to ground
1835-03
1835-03
Auxiliary Pressure Sensor open/short to +batt
1835-04
1835-04
Auxiliary Pressure Sensor short to ground
1836-08
1836-08
Auxiliary Temperature Sensor abnormal signal
174-03
174-03
Fuel Temperature open/short to +batt
174-04
174-04
Fuel Temperature short to ground
41-03
N/A
8 Volt DC Supply short to +batt
41-04
N/A
8 Volt DC Supply short to groundt
Description of Code
13
Page 2 of 4
262-03
620-03
5 Volt Sensor DC Power Supply short to +batt
262-04
620-04
263-03
678-03
Digital Sensor Supply short to +batt
263-04
678-04
Digital Sensor Supply short to ground
100-03
100-03
Engine Oil Pressure open/short to +batt
100-04
100-04
Engine Oil Pressure short to ground
273-00
102-00
Turbo Outlet Pressure above normal
273-03
102-03
Turbo Outlet Pressure open/short to +batt
273-04
102-04
Turbo Outlet Pressure short to ground
274-03
108-03
Atmospheric Pressure open/short to +batt
274-04
108-04
Atmospheric Pressure short to ground
110-03
110-03
110-04
110-04
Engine Coolant Temperature short to ground
28
91-13
91-13
Throttle Position calibration required
32
91-08
91-08
Throttle Position signal abnormal
320-02
190-02
Speed/Timing Sensor Loss of Signal
320-11
190-11
Speed/Timing Sensor mechanical failure
342-02
723-02
Loss of Secondary Engine Speed signal
342-11
723-11
Secondary Engine Speed Sensor mechanical

failure
E004
0190-16
Engine Overspeed Shutdown
E190
0190-00
Engine Overspeed Warning
94-03
94-03
Fuel Pressure open/short to +batt
94-04
94-04
Fuel Pressure short to ground
172-03
172-03
Intake Manifold Air Temp open/short to +batt
172-04
172-04
Intake Manifold Air Temp short to ground
22-13
N/A
Timing Sensor calibration required
5 Volt Sensor DC Power Supply short to ground
21
24
25
26
Engine Coolant Temperature open/short to +batt
27
34
35
37
38
42
Page 3 of 4
261-13
228-13
Engine Timing calibration required
E039
0100-18
Low Engine Oil Pressure Derate
E040
100-01
Low Engine Oil Pressure Shutdown
E100
100-17
Low Engine Oil Pressure Warning
51
168-02
168-02
System Voltage intermittent/erratic
53
254-12
N/A
Electronic Control Module Error
253-02
234-02
Personality Module mismatch
268-02
1111-02
Check Programmable Parameters
247-09
639-09
J1939 Data Link communications
E015
110-16
High Engine Coolant Temperature Derate
E016
110-00
High Engine Coolant Temperature Shutdown
E017
110-15
High Engine Coolant Temperature Warning
E057
111-18
Low Engine Coolant Level Derate
E058
111-01
Low Engine Coolant Level Shutdown
E059
111-17
Low Engine Coolant Level Warning
E005
94-15
Fuel Filter Restriction Derate
E006
94-16
Fuel Filter Restriction Shutdown
E095
94-00
Fuel Filter Restriction Warning
E096
94-00
High Fuel Pressure
E025
172-16
High Inlet Air Temperature Derate
E027
172-15
High Inlet Air Temperature Warning
E054
174-16
High Fuel Temperature Derate
E055
174-00
High Fuel Temperature Shutdown
E056
174-15
High Fuel Temperature Warning
1-11
651-11
Injector Cylinder #1 fault
2-11
652-11
3-11
653-11
4-11
654-11
46
56
58
61
62
63
64
65
72
73
Page 4 of 4
5-11
655-11
6-11
656-11
74

Thu Apr 8 08:16:30 CDT 2010
Page 1 of 4
Troubleshooting
i02292113
Diagnostic Code Cross Reference

SMCS - 1900
Problems with the electronic control system are reported via these types of codes: flash codes, diagnostic
codes and event codes.
For information on flash codes, refer to Troubleshooting, "Flash Codes".
For information on diagnostic codes, refer to Troubleshooting, "Diagnostic Codes".
For information on event codes, refer to Troubleshooting, "Event Codes".
Use Table 1 as a cross-reference between the various types of codes.
Table 1
Cross Reference for Flash Codes
Flash Code
N/A
Diagnostic
or
Event Code
SPN/FMI Code
E443
1835-00
High Auxiliary Pressure
E445
1836-00
High Auxiliary Temperature
545-05
545-05
Ether Start Relay open/short to +batt
545-06
545-06
Ether Start Relay short to ground
1835-03
1835-03
Auxiliary Pressure Sensor open/short to +batt
1835-04
1835-04
Auxiliary Pressure Sensor short to ground
1836-08
1836-08
Auxiliary Temperature Sensor abnormal signal
174-03
174-03
Fuel Temperature open/short to +batt
174-04
174-04
Fuel Temperature short to ground
41-03
N/A
8 Volt DC Supply short to +batt
41-04
N/A
8 Volt DC Supply short to groundt
Description of Code
13
Page 2 of 4
262-03
620-03
5 Volt Sensor DC Power Supply short to +batt
262-04
620-04
263-03
678-03
Digital Sensor Supply short to +batt
263-04
678-04
Digital Sensor Supply short to ground
100-03
100-03
Engine Oil Pressure open/short to +batt
100-04
100-04
Engine Oil Pressure short to ground
273-00
102-00
Turbo Outlet Pressure above normal
273-03
102-03
Turbo Outlet Pressure open/short to +batt
273-04
102-04
Turbo Outlet Pressure short to ground
274-03
108-03
Atmospheric Pressure open/short to +batt
274-04
108-04
Atmospheric Pressure short to ground
110-03
110-03
110-04
110-04
Engine Coolant Temperature short to ground
28
91-13
91-13
Throttle Position calibration required
32
91-08
91-08
Throttle Position signal abnormal
320-02
190-02
Speed/Timing Sensor Loss of Signal
320-11
190-11
Speed/Timing Sensor mechanical failure
342-02
723-02
Loss of Secondary Engine Speed signal
342-11
723-11
Secondary Engine Speed Sensor mechanical

failure
E004
0190-16
Engine Overspeed Shutdown
E190
0190-00
Engine Overspeed Warning
94-03
94-03
Fuel Pressure open/short to +batt
94-04
94-04
Fuel Pressure short to ground
172-03
172-03
Intake Manifold Air Temp open/short to +batt
172-04
172-04
Intake Manifold Air Temp short to ground
22-13
N/A
Timing Sensor calibration required
5 Volt Sensor DC Power Supply short to ground
21
24
25
26
Engine Coolant Temperature open/short to +batt
27
34
35
37
38
42
Page 3 of 4
261-13
228-13
Engine Timing calibration required
E039
0100-18
Low Engine Oil Pressure Derate
E040
100-01
Low Engine Oil Pressure Shutdown
E100
100-17
Low Engine Oil Pressure Warning
51
168-02
168-02
System Voltage intermittent/erratic
53
254-12
N/A
Electronic Control Module Error
253-02
234-02
Personality Module mismatch
268-02
1111-02
Check Programmable Parameters
247-09
639-09
J1939 Data Link communications
E015
110-16
High Engine Coolant Temperature Derate
E016
110-00
High Engine Coolant Temperature Shutdown
E017
110-15
High Engine Coolant Temperature Warning
E057
111-18
Low Engine Coolant Level Derate
E058
111-01
Low Engine Coolant Level Shutdown
E059
111-17
Low Engine Coolant Level Warning
E005
94-15
Fuel Filter Restriction Derate
E006
94-16
Fuel Filter Restriction Shutdown
E095
94-00
Fuel Filter Restriction Warning
E096
94-00
High Fuel Pressure
E025
172-16
High Inlet Air Temperature Derate
E027
172-15
High Inlet Air Temperature Warning
E054
174-16
High Fuel Temperature Derate
E055
174-00
High Fuel Temperature Shutdown
E056
174-15
High Fuel Temperature Warning
1-11
651-11
2-11
652-11
3-11
653-11
4-11
654-11
46
56
58
61
62
63
64
65
72
73
Page 4 of 4
5-11
655-11
6-11
656-11
74

Thu Apr 8 08:16:30 CDT 2010
Page 1 of 1
Troubleshooting
i03640720
CID 0001 FMI 11 Cylinder #1 Injector fault

SMCS - 1290-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects an open
circuit or a short circuit in the circuit for the injector.
If the cause of the diagnostic code is a problem in the common wire, two cylinders will be affected
because of the shared common wire for the injectors.
System Response:
The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after
the code has been logged.
The injector may not operate while the condition exists.
Engine misfires
Low power
Test Step 1. Perform the following diagnostic procedure: Injector Solenoid Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:24:04 CDT 2010
Page 1 of 1
Troubleshooting
i02048960
CID 0022 FMI 13 Timing Sensor calibration required

SMCS - 1912-038
The timing has not been calibrated since the Electronic Control Module (ECM) was installed or the
calibration is out of the specification by more than four degrees.
System Response:
The ECM uses the default timing.
The engine may run rough and/or the engine may emit white smoke in the exhaust.
Test Step 1. Perform the following diagnostic procedure: Engine Speed/Timing Sensor - Calibrate
Results:
OK - STOP

Thu Apr 8 08:24:29 CDT 2010
Page 1 of 1
Troubleshooting
i01942631
CID 0041 FMI 03 8 Volt DC Supply short to +batt

SMCS - 5574-038
The Electronic Control Module (ECM) detects all of the following conditions:
The ECM has been powered for at least three seconds.
The ECM reads signal voltage that is above 8.4 VDC for two seconds.
System Response:
The ECM will log the diagnostic code. The ECM flags all digital sensors as invalid data and all digital
sensors are set to the respective default values.
Low power
Test Step 1. Perform the following diagnostic procedure: Digital Sensor Supply Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:24:48 CDT 2010
Page 1 of 1
Troubleshooting
i02419278
CID 0041 FMI 04 8 Volt DC Supply short to ground

SMCS - 5574-038
The voltage level of the 8 volt supply is below normal.
System Response:
The Electronic Control Module (ECM) logs the diagnostic code. The ECM flags all digital sensors as
invalid data and all digital sensors are set to the respective default values.
The engine may experience low power.
Results:
OK - STOP

Thu Apr 8 08:25:03 CDT 2010
Page 1 of 1
Troubleshooting
i02417388
CID 0091 FMI 08 Throttle Position signal abnormal

SMCS - 1913-038
The Electronic Control Module (ECM) detects an incorrect frequency on the throttle signal.
System Response:
The code is logged. The ECM flags the throttle position as invalid data and a default value of zero
percent is used.
The engine speed is limited to low idle.
Test Step 1. Perform the following diagnostic procedure: Throttle Position Sensor Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:25:23 CDT 2010
Page 1 of 1
Troubleshooting
i02426246
CID 0091 FMI 13 Throttle Position calibration required

SMCS - 1913-038
The duty cycle of the signal from the throttle that is connected to the primary throttle input is incorrect.
System Response:
The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags the throttle position
as invalid data and a default value of zero percent is used.
The engine speed is limited to low idle.
Test Step 1. Perform the following diagnostic procedure: Throttle Position Sensor - Calibrate
Results:
OK - STOP

Thu Apr 8 08:25:37 CDT 2010
Page 1 of 1
Troubleshooting
i02424760
CID 0094 FMI 03 Fuel Pressure open/short to +batt

SMCS - 1718-038
The Electronic Control Module (ECM) reads signal voltage that is above normal.
System Response:
The ECM will log the diagnostic code. The ECM flags fuel pressure as invalid data and a default value
is used.
There are no performance effects.
Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:25:57 CDT 2010
Page 1 of 1
Troubleshooting
i02424763
CID 0094 FMI 04 Fuel Pressure short to ground

SMCS - 1718-038
The Electronic Control Module (ECM) reads signal voltage that is below normal.
System Response:
The ECM will log the diagnostic code. The ECM flags fuel pressure as invalid data and a default value
is used.
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:26:36 CDT 2010
Page 1 of 1
Troubleshooting
i02378792
CID 0100 FMI 03 Engine Oil Pressure open/short to +batt

SMCS - 1924-038
The signal voltage from the engine oil pressure sensor is above 4.8 VDC for at least eight seconds.
System Response:
The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags oil pressure as
invalid data and a default value of 600 kPa (87 psi) is used.
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:26:52 CDT 2010
Page 1 of 1
Troubleshooting
i02424648
CID 0100 FMI 04 Engine Oil Pressure short to ground

SMCS - 1924-038
The Electronic Control Module (ECM) detects a signal voltage that is below normal.
System Response:
The code is logged. The ECM flags oil pressure as invalid data and a default value is used.
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:27:07 CDT 2010
Page 1 of 1
Troubleshooting
i02427669
CID 0110 FMI 03 Engine Coolant Temperature open/short to

+batt
SMCS - 1906-038
The signal voltage from the engine coolant temperature sensor is above normal.
System Response:
The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags coolant temperature
as invalid data and a default value is used. The engine will not go into cold mode.
The engine may misfire.
The engine may experience reduced speed (rpm) and/or low power.
Test Step 1. Perform the following diagnostic procedure: Engine Temperature Sensor Open or Short
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:27:21 CDT 2010
Page 1 of 1
Troubleshooting
i02427678
CID 0110 FMI 04 Engine Coolant Temperature short to ground

SMCS - 1906-038
The signal voltage from the engine coolant temperature sensor is below normal.
System Response:
The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags coolant temperature
as invalid data and a default value is used. The engine will not go into cold mode.
The engine may misfire.
The engine may experience reduced speed (rpm) and/or low power.
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:27:40 CDT 2010
Page 1 of 1
Troubleshooting
i02458713
CID 0168 FMI 02 System Voltage intermittent/erratic

SMCS - 1401-038
While the engine is running, the battery voltage drops below 9 VDC intermittently, or the battery
voltage drops below 9 VDC three times in a seven second period.
System Response:
The Electronic Control Module (ECM) will log the diagnostic code.
The engine may misfire and/or shutdown
Test Step 1. Perform the following diagnostic procedure: Electrical Power Supply Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:27:55 CDT 2010
Page 1 of 1
Troubleshooting
i02378820
CID 0172 FMI 03 Intake Manifold Air Temp open/short to +batt

SMCS - 1921-038
The signal voltage from the inlet air temperature sensor exceeds 4.9 VDC for eight seconds.
System Response:
The Electronic Control Module (ECM) logs the diagnostic code. The ECM flags Inlet air temperature as
invalid data and a default temperature of 85 C (185 F) is used.
Low power
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:28:15 CDT 2010
Page 1 of 1
Troubleshooting
i02378836
CID 0172 FMI 04 Intake Manifold Air Temp short to ground

SMCS - 1921-038
The signal voltage from the inlet air temperature sensor dropped below 0.2 VDC for eight seconds.
System Response:
The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags Inlet air
temperature as invalid data and a default value of 85 C (185 F) is used.
Low power
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:28:37 CDT 2010
Page 1 of 1
Troubleshooting
i02385225
CID 0174 FMI 03 Fuel Temperature open/short to +batt

SMCS - 1922-038
The Electronic Control Module (ECM) detects signal voltage that is above normal.
System Response:
The ECM will log the diagnostic code. The ECM flags fuel temperature as invalid data and a default
value is used.
Low power
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:28:53 CDT 2010
Page 1 of 1
Troubleshooting
i02424798
CID 0174 FMI 04 Fuel Temperature short to ground

SMCS - 1922-038
The Electronic Control Module (ECM) detects signal voltage that is below normal.
System Response:
The ECM will log the diagnostic code. The ECM flags fuel temperature as invalid data and a default
value is used.
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:29:12 CDT 2010
Page 1 of 1
Troubleshooting
i02490447
CID 0247 FMI 09 J1939 Data Link communications

SMCS - 1901-038
The Electronic Control Module (ECM) has detected a loss of communications with the J1939 data link.
Ensure that all flash files in the control system are current.
System Response:
The ECM will log the diagnostic code.
The engine may not operate properly and/or the equipment may not have engine speed control.
Test Step 1. Perform the following diagnostic procedure: CAN Data Link Circuit - Test
Results:
OK - STOP
Page 1 of 2
Troubleshooting
i02428636
CID 0253 FMI 02 Personality Module mismatch

SMCS - 1902-038
The flash file that is used for replacement is for a different engine family or for a different engine
application.
System Response:
Caterpillar Electronic Technician (ET) will not be able to clear the code.
The fuel injection system is disabled and the engine will not start.
Test Step 1. Check the Part Number of the Flash File

A. Restore the electrical power to the Electronic Control Module (ECM).
B. Verify that the part number for the flash file agrees with the latest update that is available on
Service Technician Workbench (STW), or on SIS Web.
Expected Result:
The correct flash file is installed in the ECM.
Results:
OK - The correct flash file is installed in the ECM.

Repair: The engine will not start until the 253-02 diagnostic code is cleared. Clearing this code
requires factory passwords.Acquire factory passwords. Clear the 253-02 diagnostic code. Return
the engine to service.
STOP
Not OK - The correct flash file is not installed in the ECM.

Repair: Flash program the ECM with the correct flash file. Refer to programming parameters
Troubleshooting, "Flash Programming". Verify that the problem is resolved.
STOP

Page 2 of 2
Thu Apr 8 08:30:18 CDT 2010
Page 1 of 1
Troubleshooting
i02125661
CID 0254 FMI 12 Electronic Control Module Error

SMCS - 1901-038
The Electronic Control Module (ECM) has detected an internal fault.
System Response:
Engine power and engine performance may be affected.
Any normal ECM function may be affected.
Engine shutdown
Test Step 1.
Replace the ECM. Ensure that the new ECM serial number ends with the same two characters as the old
ECM serial number. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM.
Results:
OK - STOP

Thu Apr 8 08:30:56 CDT 2010
Page 1 of 1
Troubleshooting
i02348802
CID 0261 FMI 13 Engine Timing Calibration required

SMCS - 1912-038
The timing has not been calibrated since the Electronic Control Module (ECM) was installed or the
calibration is incorrect.
System Response:
The ECM uses default timing.
Engine misfires
Low power
Reduced engine speed
White exhaust smoke
Increased exhaust emissions
Test Step 1. Perform the following diagnostic procedure: Engine Speed/Timing Sensor - Calibrate
Results:
OK - STOP

Thu Apr 8 08:31:29 CDT 2010
Page 1 of 1
Troubleshooting
i02121647
CID 0262 FMI 03 5 Volt Sensor DC Power Supply short to +batt

SMCS - 5574-038
The Electronic Control Module (ECM) detects the following condition:
The analog sensor supply voltage is greater than 5.2 VDC for one second.
System Response:
The ECM will log the diagnostic code. The ECM flags all analog sensors as invalid data and all analog
Low power
Test Step 1. Perform the following diagnostic procedure: 5 Volt Engine Pressure Sensor Supply
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:32:01 CDT 2010
Page 1 of 1
Troubleshooting
i02121649
CID 0262 FMI 04 5 Volt Sensor DC Power Supply short to

ground
SMCS - 5574-038
The Electronic Control Module (ECM) detects the following condition:
The analog sensor supply voltage is less than 4.8 VDC for one second.
System Response:
The ECM will log the diagnostic code. The ECM flags all analog sensors as invalid data and all analog
Low power
Test Step 1. Perform the following diagnostic procedure: 5 Volt Engine Pressure Sensor Supply
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:32:41 CDT 2010
Page 1 of 1
Troubleshooting
i02461066
CID 0263 FMI 03 Digital Sensor Supply short to +batt

SMCS - 5574-038
The Electronic Control Module (ECM) detects supply voltage that is above normal.
System Response:
Results:
OK - STOP

Thu Apr 8 08:33:20 CDT 2010
Page 1 of 1
Troubleshooting
i02461080
CID 0263 FMI 04 Digital Sensor Supply short to ground

SMCS - 5574-038
The Electronic Control Module (ECM) detects supply voltage that is below normal.
System Response:
Results:
OK - STOP

Thu Apr 8 08:33:54 CDT 2010
Page 1 of 1
Troubleshooting
i02713570
CID 0268 FMI 02 Check Programmable Parameters

SMCS - 1901-038
The Electronic Control Module (ECM) detects that one or more of the programmable parameters have
not been programmed.
System Response:
The diagnostic code is not logged. Any unprogrammed parameters are set to the default value. Engine
performance may be affected. This is dependent on the unprogrammed parameters.
Low power
Test Step 1.
Use Caterpillar Electronic Technician (ET) to reprogram the system configuration parameters. Refer to
Troubleshooting, "System Configuration Parameters" for additional information.
Results:
A 0268-2 code is active Repair: Identify the condition that is displayed beneath the code:If a programmable parameter is
displayed, program that parameter with the correct value.If "Injector Code" is displayed, load the
missing injector trim file into the ECM.
STOP

Thu Apr 8 08:34:36 CDT 2010
Page 1 of 1
Troubleshooting
i02071664
CID 0273 FMI 00 Turbo Outlet Pressure above normal

SMCS - 1917-038
The outlet pressure of the turbocharger is greater than 200 kPa (29 psi).
The engine speed is within 50 rpm of low idle for five seconds.
System Response:
The ECM flags turbocharger compressor outlet pressure as invalid data and a default value of 0 kPa (0
psi) is used.
Low power
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:34:56 CDT 2010
Page 1 of 1
Troubleshooting
i02378875
CID 0273 FMI 03 Turbo Outlet Pressure open/short to +batt

SMCS - 1917-038
With an engine speed of zero rpm, the signal voltage for the turbocharger outlet pressure sensor exceeds
4.95 VDC for at least two seconds.
System Response:
The Electronic Control Module (ECM) logs the diagnostic code. The ECM flags the turbocharger outlet
pressure as invalid data. A default value of 100 kPa (14.5 psi) is used.
Low power
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:35:22 CDT 2010
Page 1 of 1
Troubleshooting
i02378876
CID 0273 FMI 04 Turbo Outlet Pressure short to ground

SMCS - 1917-038
The signal voltage for the turbocharger outlet pressure sensor falls below 0.5 VDC for two seconds.
System Response:
The Electronic Control Module (ECM) logs the diagnostic code. The ECM flags turbocharger outlet
pressure as invalid data. A default value of 100 kPa (14.5 psi) is used.
Low power
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:35:36 CDT 2010
Page 1 of 1
Troubleshooting
i02281091
CID 0274 FMI 03 Atmospheric Pressure open/short to +batt

SMCS - 1923-038
The signal voltage from the atmospheric pressure sensor is above 4.8 VDC for at least eight seconds.
System Response:
The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags atmospheric
pressure as invalid data and a default value of 100 kPa (15 psi) is used.
Low power
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:35:51 CDT 2010
Page 1 of 1
Troubleshooting
i02473210
CID 0274 FMI 04 Atmospheric Pressure short to ground

SMCS - 1923-038
The signal voltage from the atmospheric pressure sensor is below normal.
System Response:
The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags atmospheric
pressure as invalid data and a default value is used.
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:36:05 CDT 2010
Page 1 of 1
Troubleshooting
i02085690
CID 0320 FMI 02 Speed/Timing Sensor Loss of Signal

SMCS - 1912-038
The signal for the primary engine speed/timing sensor is intermittent or lost for less than one second.
System Response:
The Electronic Control Module (ECM) will use the secondary engine speed/timing sensor in order to
determine engine speed. The ECM will log the diagnostic code.
There may be a slight change in engine response when the ECM is switched to the secondary engine
speed/timing sensor.
Test Step 1. Perform the following diagnostic procedure: Engine Speed/Timing Sensor Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:36:20 CDT 2010
Page 1 of 1
Troubleshooting
i02085691
CID 0320 FMI 11 Speed/Timing Sensor mechanical failure

SMCS - 1912-038
The signal for the primary engine speed/timing sensor is lost for more than one second.
System Response:
The Electronic Control Module (ECM) will use the secondary engine speed/timing sensor in order to
determine engine speed. The ECM will log the diagnostic code.
There may be a slight change in engine response when the ECM is switched to the secondary engine
speed/timing sensor.
Results:
OK - STOP

Thu Apr 8 08:36:36 CDT 2010
Page 1 of 1
Troubleshooting
i02085693
CID 0342 FMI 02 Loss of Secondary Engine Speed signal

SMCS - 1907-038
The signal from the secondary engine speed/timing sensor is intermittent or lost for less than one
second.
System Response:
Engine misfires during starting
Engine shutdown
Note: The engine will shut down only if the primary engine speed/timing sensor and the secondary
engine speed/timing sensor fail.
Results:
OK - STOP

Thu Apr 8 08:36:51 CDT 2010
Page 1 of 1
Troubleshooting
i02085697
CID 0342 FMI 11 Secondary Engine Speed Sensor mechanical

failure
SMCS - 1907-038
The signal for the secondary engine speed/timing sensor is lost for more than one second.
System Response:
Engine misfires during starting
Engine shutdown
Note: The engine will shut down only if the primary engine speed/timing sensor and the secondary
engine speed/timing sensor fail.
Results:
OK - STOP

Thu Apr 8 08:37:05 CDT 2010
Page 1 of 1
Troubleshooting
i01939089
CID 0545 FMI 05 Ether Start Relay open/short to +batt

SMCS - 4493-038
An open circuit or a short to +Battery condition is detected at the ether relay output for at least
two seconds.
The driver output is off.
Battery voltage is greater than 9 VDC for the last two seconds.
System Response:
The ECM will log the diagnostic code. Ether injection is disabled.
Hard starting
Test Step 1. Perform the following diagnostic procedure: Ether Injection System - Test
Results:
OK - STOP

Thu Apr 8 08:37:18 CDT 2010
Page 1 of 1
Troubleshooting
i01942702
CID 0545 FMI 06 Ether Start Relay short to ground

SMCS - 4493-038
The ECM has detected an open or a short to ground at the output for the ether relay for at least
two seconds.
The driver output is on.
Battery voltage is greater than 9 VDC for the last two seconds.
System Response:
The ECM will log the diagnostic code. Ether injection is disabled.
Hard starting
Test Step 1. Perform the following diagnostic procedure: Ether Injection System - Test
Results:
OK - STOP

Thu Apr 8 08:37:36 CDT 2010
Page 1 of 1
Troubleshooting
i02427110
CID 1835 FMI 03 Auxiliary Pressure Sensor open/short to +batt

SMCS - 5574-038-PX
The Electronic Control Module (ECM) detects a signal voltage that is above normal.
System Response:
The ECM logs the diagnostic code. The value of the auxiliary pressure is set to a default value.
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:37:48 CDT 2010
Page 1 of 1
Troubleshooting
i02427111
CID 1835 FMI 04 Auxiliary Pressure Sensor short to ground

SMCS - 5574-038-PX
The Electronic Control Module (ECM) detects a signal voltage from the auxiliary pressure sensor that is
below normal.
System Response:
The ECM logs the diagnostic code. The value of the auxiliary pressure is set to a default value.
Circuit - Test
Results:
OK - STOP

Thu Apr 8 08:38:02 CDT 2010
Page 1 of 1
Troubleshooting
i02107196
CID 1836 FMI 08 Auxiliary Temperature Sensor signal

abnormal
SMCS - 5574-038-TA
Either the duty cycle is greater than 95 percent or less than 5 percent for one second, or the sensor
frequency is greater than 1000 Hz or less than 150 Hz for two seconds.
There are no active diagnostic codes for the digital sensor supply (8 Volt DC).
System Response:
The ECM will log the diagnostic code. The auxiliary temperature will be set to a default value.
None
Test Step 1. Perform the following diagnostic procedure: Auxiliary Temperature Sensor Circuit Test
Results:
OK - STOP

Thu Apr 8 08:38:20 CDT 2010
Page 1 of 5
Troubleshooting
i02275527
Event Codes
SMCS - 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, the event is active.
Active Event Codes

An active event code represents a problem with engine operation. Correct the problem as soon as
possible.
Active event codes are listed in ascending numerical order. The code with the lowest number is listed
first.
When certain event codes are activated, the Electronic Control Module (ECM) also generates a flash
code that will be displayed on the diagnostic lamp. Refer to Troubleshooting, "Diagnostic Code Cross
Reference" for a cross-reference between event codes and flash codes.
Illustration 1 is an example of the operating range of an oil temperature sensor. Do not use the
Illustration to troubleshoot the oil temperature sensor.
View Image
Illustration 1
Page 2 of 5
g01139661
Example of the typical operating range of an oil temperature sensor

(1) This area represents the normal temperature range for the engine oil. The normal output voltage of the sensor is between
0.2 VDC and 4.2 VDC.
(2) In this area, the oil temperature above 107 C (225 F) is higher than normal. The output voltage of the sensor will
Page 3 of 5
generate an event code. The sensor does not have an electronic problem.
(3) In these areas, the output voltage of the sensor is too high or too low. The voltage is outside of the normal range. The
electronic problem will generate a diagnostic code. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code" for
additional information on diagnostic codes.
The following format is used for event codes:

"EXXX (Y) Description of the event"
The "E" means that the code is an event code. The "XXX" represents a numeric identifier for the event
code. The "(Y)" represents a numeric identifier for the severity of the event. This is followed by a
description of the event. Refer to the following example:
"E004 (3) Engine Overspeed Shutdown"
In this example, the number 3 indicates the severity of the event. The ECM has three levels of response
to events:
Warning (1) - This condition represents a serious problem with engine operation. However, this
condition does not require a derate or a shutdown.
Derate (2) - For this condition, the ECM reduces the engine's power in order to help prevent possible
engine damage.
Shutdown (3) - For this condition, the ECM shuts down the engine in order to help prevent possible
engine damage.
Responses to certain events may be programmed into the ECM. Refer to Troubleshooting, "System
Configuration Parameters".
Logged Event Codes

When the ECM generates an event code the ECM logs the code in permanent memory. The ECM has an
internal diagnostic clock. The ECM will record the following information when an event 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
Logged events are listed in chronological order. The most recent event code is listed first.
This information can be helpful for troubleshooting intermittent problems. Logged codes can also be
used to review the performance of the engine.
Clearing Event Codes
Page 4 of 5
A code is cleared from memory when one of the following conditions occur:
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.
The service technician manually clears the code.
Always clear logged event codes after investigating and correcting the problem which generated the
code.
Troubleshooting
For basic troubleshooting of the engine, perform the following steps in order to diagnose a malfunction:
1. Obtain the following information about the complaint from the operator:
The event and the time of the event
Determine the conditions for the event. The conditions will include the engine rpm and the
load.
Determine if there are any systems that were installed by the dealer or by the customer that
could cause the event.
Determine whether any additional events occurred.
2. Verify that the complaint is not due to normal engine operation. Verify that the complaint is not
due to error of the operator.
3. Narrow the probable cause. Consider the operator information, the conditions of operation, and
the history of the engine.
4. Perform a visual inspection. Inspect the following items:
Fuel supply
Oil level
Oil supply
Wiring
Connectors
Be sure to check the connectors. This is very important for problems that are intermittent. Refer to
Page 5 of 5
If these steps do not resolve the problem, identify the procedures in this manual that best describe the
event. Check each probable cause according to the tests that are recommended.

Thu Apr 8 08:38:40 CDT 2010
Page 1 of 1
Troubleshooting
i02235554
E004 Engine Overspeed Shutdown

SMCS - 7427-038
Engine speed has exceeded the trip point for engine overspeed.
System Response:
The Electronic Control Module (ECM) will log the event.
Caterpillar Electronic Technician (ET) displays "Injection Disabled" on the status screen.
The engine is shutdown.
The operator may be operating the engine incorrectly.
The "Engine Overspeed" parameter may be incorrectly programmed for the application. Use Cat ET to
view the parameter setting for engine overspeed. Refer to Troubleshooting, "System Configuration
Parameters" for the rpm range that is available for this parameter.
Test Step 1. Interview the Operator
Determine the events that caused the overspeed of the engine. Make corrections in order to prevent the
overspeed from recurring.
Results:
OK - STOP

Thu Apr 8 08:38:56 CDT 2010
Page 1 of 2
Troubleshooting
i02373037
E005 Fuel Filter Restriction Derate

SMCS - 1261-038
The engine has been running for 60 seconds and the Electronic Control Module (ECM) has identified
fuel pressure that is less than 225 kPa (33 psi) for 10 seconds.
System Response:
The ECM will log the event.
Caterpillar Electronic Technician (ET) will display "Engine Derate" on any Cat ET status screen. The
ECM derates the engine power by 17.5 percent per second. The maximum derate is 39 percent. The
ECM will restore full power when the fuel pressure rises above 235 kPa (34 psi) for four seconds.
The engine power is derated.
Test Step 1. Replace the Fuel Filter
A. Replace the engine's fuel filter. Prime the fuel system.
Refer to the engine's Operation and Maintenance Manual for the correct procedure.
B. Start the engine. Use Cat ET to check for another occurrence of the event.
Expected Result:
The event does not recur.
Results:
OK - The event does not recur. Stop.
NOT OK - The ECM is detecting an abnormal fuel pressure in the fuel system.
Repair: Refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test" for
information that relates to testing the fuel system.
Stop.

Page 2 of 2
Thu Apr 8 08:39:11 CDT 2010
Page 1 of 2
Troubleshooting
i02353654
E006 Fuel Filter Restriction Shutdown

SMCS - 1261-038
The engine has been running for 60 seconds and the Electronic Control Module (ECM) has identified a
restriction of the fuel filter.
System Response:
The Caterpillar Electronic Technician (ET) will display "No Engine Speed" on the status screen.
The engine is shut down.
This event code indicates a restriction in the fuel filter.
B. Start the engine. Use Cat ET to check for another occurrence of the event.
Expected Result:
Results:
OK - STOP
Not OK - The ECM is detecting an abnormal fuel pressure in the fuel system.
STOP

Page 2 of 2
Thu Apr 8 08:39:27 CDT 2010
Page 1 of 2
Troubleshooting
i02235951
E015 High Engine Coolant Temperature Derate

SMCS - 1395-038-TA
The engine has been running for three minutes and the coolant temperature has exceeded the derate trip
point for coolant temperature protection.
System Response:
Caterpillar Electronic Technician (ET) displays "Engine Derate" on the status screen.
The ECM will derate engine power by 12.5 percent. The ECM will derate engine power by a maximum
of 25 percent for coolant temperatures that exceed 109 C (228 F). The engine power will be derated at
a rate of one percent per second.
Test Step 1. Check the Monitoring System Parameter
The "High Engine Coolant Temperature" parameter may be incorrectly programmed. Use Cat ET to
view the parameter setting for "High Engine Coolant Temperature". Ensure that the parameter setting is
correct for the application of the engine.
Expected Result:
The "High Engine Coolant Temperature" parameter is programmed correctly.
Results:
OK - An overheating condition exists for the engine.

Repair: Refer to Systems Operation/Testing and Adjusting, "Cooling System - Check".
STOP
Not OK - The parameter is incorrectly programmed.

Repair: Refer to Troubleshooting, "System Configuration Parameters" for the temperature range
that is available for the "High Engine Coolant Temperature" parameter.Verify that the repair
eliminates the problem.
STOP

Page 2 of 2
Thu Apr 8 08:39:42 CDT 2010
Page 1 of 2
Troubleshooting
i02291786
E016 High Engine Coolant Temperature Shutdown

SMCS - 1395-038-TA
The engine has been running for three minutes and the coolant temperature has exceeded the shutdown
trip point for coolant temperature protection.
System Response:
The "High Engine Coolant Temperature" parameter may be incorrectly programmed. Use Caterpillar
Electronic Technician (ET) to view the parameter setting for "High Engine Coolant Temperature".
Ensure that the parameter setting is correct for the application of the engine.
Expected Result:
Results:
OK - The monitoring system parameter is programmed correctly.

Repair: An overheating condition exists for the engine. Refer to Systems Operation/Testing and
Adjusting, "Cooling System - Check".
STOP

that is available for the "High Engine Coolant Temperature" parameter. Verify that the repair
STOP

Page 2 of 2
Thu Apr 8 08:39:53 CDT 2010
Page 1 of 2
Troubleshooting
i02291787
E017 High Engine Coolant Temperature Warning

SMCS - 1395-038-TA
The engine has been running for three minutes and the coolant temperature has exceeded the warning
trip point for coolant temperature protection.
System Response:
Engine operation is not affected.
The "High Engine Coolant Temperature" parameter may be incorrectly programmed. Use Caterpillar
Electronic Technician (ET) to view the parameter setting for "High Engine Coolant Temperature".
Ensure that the parameter setting is correct for the application of the engine.
Expected Result:
Results:
OK - An overheating condition exists for the engine.

Repair: Refer to Systems Operation/Testing and Adjusting, "Cooling System - Check".
STOP

that is available for the "High Engine Coolant Temperature" parameter. Verify that the repair
STOP
Page 2 of 2

Thu Apr 8 08:40:07 CDT 2010
Page 1 of 2
Troubleshooting
E025 High Inlet Air Temperature Derate

SMCS - 1050-038-TA
The inlet air system has exceeded the derate trip point for overtemperature protection.
System Response:
The ECM will derate engine power by three percent for an inlet air temperature of 80 C (176 F). The
ECM will continue to derate engine power by an additional three percent for each 1 C (2 F) that is
beyond the trip point. The ECM will derate engine power for a maximum of 20 percent. The engine
power will be derated at a rate of one percent per second.
The derate will be cancelled if the inlet air temperature drops below 79 C (174 F) for 20 seconds.
The "High Intake Air Temperature" parameter may be incorrectly programmed. Use Cat ET to view the
parameter setting for "High Intake Air Temperature". Ensure that the parameter setting is correct for the
application of the engine.
Expected Result:
The "High Intake Air Temperature" parameter is programmed correctly.
Results:
OK - There is a problem with the air inlet or the exhaust system.

Repair: Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System".
STOP

that is available for the "High Intake Air Temperature" parameter. Verify that the repair eliminates
the problem.
Page 2 of 2
STOP

Thu Apr 8 08:40:24 CDT 2010
Page 1 of 2
Troubleshooting
i02236416
E027 High Inlet Air Temperature Warning

SMCS - 1050-038-TA
The inlet air system has exceeded the warning trip point for overtemperature protection.
System Response:
The "High Intake Air Temperature" parameter may be incorrectly programmed. Use Caterpillar
Electronic Technician (ET) to view the parameter setting for "High Intake Air Temperature". Ensure that
the parameter setting is correct for the application of the engine.
Expected Result:
The "High Intake Air Temperature" parameter is programmed correctly.
Results:
OK - There is a problem with the air inlet or the exhaust system.

Repair: Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System".
STOP

that is available for the "High Intake Air Temperature" parameter. Verify that the repair eliminates
the problem.
STOP

Thu Apr 8 08:40:41 CDT 2010
Page 2 of 2
Page 1 of 2
Troubleshooting
E039 Low Engine Oil Pressure Derate

SMCS - 1348-038-LP
The engine has been running for thirty seconds and the oil pressure has dropped below the derate trip
point for low oil pressure protection.
System Response:
The ECM will derate engine power by 35 percent.
Note: The derate will be cancelled if the engine oil pressure rises above 70 kPa (10 psi) for two seconds.
There may be a problem with the engine lubrication system.
Test Step 1. Check the Engine Oil Level

A. Turn the keyswitch to the OFF position.
B. Check the engine oil level.
Refer to Operation and Maintenance Manual, "Engine Oil Level - Check".
Expected Result:
The engine oil level is OK.
Results:
OK - The engine oil level is OK. There may be a problem with the engine's lubrication system.
Repair: Refer to Testing and Adjusting, "Engine Oil Pressure - Test".
STOP
Not OK - The engine oil level is low.

Repair: Add engine oil to the proper level. Verify that the repair eliminates the problem.
Page 2 of 2
STOP

Thu Apr 8 08:40:57 CDT 2010
Page 1 of 2
Troubleshooting
i02236634
E040 Low Engine Oil Pressure Shutdown

SMCS - 1348-038-LP
The engine has been running for thirty seconds and the oil pressure has dropped below the shutdown trip
System Response:
Expected Result:
Results:
STOP

STOP
Page 2 of 2

Thu Apr 8 08:41:15 CDT 2010
Page 1 of 3
Troubleshooting
i02291735
E054 High Fuel Temperature Derate

SMCS - 1250-038-TA
The fuel temperature has exceeded the derate trip point.
System Response:
Engine power is derated by 30 percent.

Test Step 1. Perform a Check of the Fuel Heater and Related Equipment
A. If the engine is equipped with a fuel heater, perform a check of the fuel heater and thermostat.
Expected Result:
There are no problems with the fuel heater or the thermostat.
Results:
OK - The fuel heater and the thermostat are OK. Proceed to Test Step 2.
Not OK - A problem was found with the fuel heater or the thermostat.
Repair: Repair the problem. Ensure that the repair eliminates the problem.
STOP
Test Step 2. Inspect the Fuel Return Line for Restrictions

A. Inspect the fuel return line for restrictions. Check for collapsed fuel lines.
Note: A restriction in the return fuel line will decrease fuel flow from the fuel manifold. The
Page 2 of 3
decrease in fuel flow will cause the fuel in the fuel manifold to increase in temperature.
Expected Result:
There are no problems with the fuel return lines.
Results:
OK - The fuel return lines are OK. Proceed to Test Step 3.
Not OK - A problem was found with the fuel return lines.

STOP
Test Step 3. Check the Level of Fuel in the Fuel Tank

A. Fuel is continuously cycled from the fuel tank through the fuel system back to the fuel tank. The
quantity of fuel in the fuel tank may affect fuel temperature. If the quantity of fuel in the fuel tank
becomes low, there may be insufficient volume to aid in the dissipation of heat. As a result, the
fuel temperature will rise.
Expected Result:
The fuel level in the fuel tank is OK.
Results:
OK - The fuel level in the tank is OK.

Repair: Verify that the Caterpillar Electronic Technician (ET) is providing the correct fuel
temperature. Check the actual fuel temperature. If the two temperatures are different, check the
fuel temperature sensor for proper operation. Refer to the diagnostic functional test
Troubleshooting, "Engine Temperature Sensor Open or Short Circuit - Test".
STOP
Not OK - The fuel level was low.

Repair: Check the fuel in the fuel tank for excessive heat. If necessary, add fuel to aid in
dissipating heat from the fuel system. Ensure that the repair eliminates the problem.
STOP

Thu Apr 8 08:41:34 CDT 2010
Page 3 of 3
Page 1 of 3
Troubleshooting
i02291738
E055 High Fuel Temperature Shutdown

SMCS - 1250-038-TA
The fuel temperature has exceeded the shutdown trip point.
System Response:

Expected Result:
Results:
STOP

Page 2 of 3
Expected Result:
Results:

STOP

Expected Result:
Results:

STOP

STOP

Thu Apr 8 08:41:50 CDT 2010
Page 3 of 3
Page 1 of 3
Troubleshooting
i02291742
E056 High Fuel Temperature Warning

SMCS - 1250-038-TA
The fuel temperature is above the warning trip point.
System Response:
The event is logged.

Expected Result:
Results:
STOP

Page 2 of 3
Expected Result:
Results:

STOP

Expected Result:
Results:

STOP

STOP

Thu Apr 8 08:42:06 CDT 2010
Page 3 of 3
Page 1 of 2
Troubleshooting
i02370276
E057 Low Engine Coolant Level Derate

SMCS - 1395-038-LO
The engine has been running for one minute and the coolant level is not being detected by the coolant
level sensor.
System Response:
The Caterpillar Electronic Technician (ET) displays "Engine Derate" on the status screen.
The ECM will derate engine power by 35 percent. The engine power will be derated at a rate of one
percent per second.
Test Step 1. Check the Engine Coolant Level
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.
A. Check the coolant level of the engine. Refer to Operation and Maintenance Manual, "Cooling
System Coolant Level - Check".
Expected Result:
The coolant level is OK.
Results:
OK - The coolant is at the appropriate level. There may be a problem with the coolant level
sensor.
Repair: Test the operation of the coolant level sensor. Refer to Troubleshooting, "Coolant Level
Sensor Circuit - Test".
Page 2 of 2
STOP
Not OK - The coolant level is low.

Repair: Fill the cooling system with the appropriate coolant. Verify that the repair eliminates the
problem.
STOP

Thu Apr 8 08:42:19 CDT 2010
Page 1 of 2
Troubleshooting
i02236801
E058 Low Engine Coolant Level Shutdown

SMCS - 1395-038-LO
level sensor.
System Response:
Caterpillar Electronic Technician (ET) displays "Injection Disabled" on the status screen.
A. Check the coolant level of the engine. Refer toOperation and Maintenance Manual, "Cooling
Expected Result:
Results:
sensor.
STOP
Page 2 of 2

problem.
STOP

Thu Apr 8 08:42:32 CDT 2010
Page 1 of 2
Troubleshooting
i02236927
E059 Low Engine Coolant Level Warning

SMCS - 1395-038-LO
level sensor.
System Response:
A. Check the coolant level of the engine. Refer toOperation and Maintenance Manual, "Cooling
Expected Result:
Results:
sensor.
STOP
Page 2 of 2
problem.
STOP

Thu Apr 8 08:42:50 CDT 2010
Page 1 of 2
Troubleshooting
i02373025
E095 Fuel Filter Restriction Warning

SMCS - 1261-038
The engine has been running for 60 seconds and the Electronic Control Module (ECM) has identified
fuel pressure less than 250 kPa (36 psi) for 10 seconds.
System Response:
The low fuel pressure warning will deactivate when the fuel pressure rises above 260 kPa (37 psi) for
four seconds.
B. Start the engine. Use Caterpillar Electronic Technician (ET) to check for another occurrence of the
event.
Expected Result:
Results:
OK - The event does not recur. Stop.
NOT OK - The ECM is detecting an abnormal fuel pressure in the fuel system.
Stop.

Page 2 of 2
Thu Apr 8 08:43:05 CDT 2010
Page 1 of 2
Troubleshooting
i02237317
E096 High Fuel Pressure

SMCS - 1250-038-HQ
The engine has been running for 60 seconds and the fuel pressure exceeds the warning trip point for fuel
system protection.
System Response:
Test Step 1. Check for Diagnostic Codes
A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
B. Turn the keyswitch to the ON position (engine off).
C. Check for active diagnostic codes or logged diagnostic codes.
Expected Result:
No other codes are active or logged.
Results:
OK - No other codes are active or logged. A mechanical problem exists in the low pressure fuel
system.
STOP
Not OK - There are diagnostic codes that are active or logged.

Repair: Correct the other codes that are active or logged first. Refer to the appropriate topic in the
"Troubleshooting With a Diagnostic Code" section of this manual. Verify that the repair
STOP

Page 2 of 2
Thu Apr 8 08:43:23 CDT 2010
Page 1 of 2
Troubleshooting
i02237386
E100 Low Engine Oil Pressure Warning

SMCS - 1348-038-LP
The engine has been running for thirty seconds and the oil pressure has dropped below the warning trip
System Response:
Engine operation will not be affected.
Note: The warning will be cancelled if the engine oil pressure rises above 70 kPa (10 psi) for twenty
seconds.
Expected Result:
Results:
STOP

STOP

Page 2 of 2
Thu Apr 8 08:43:39 CDT 2010
Page 1 of 1
Troubleshooting
i02291765
E190 Engine Overspeed Warning

SMCS - 7427-038
The trip point has been exceeded for engine overspeed protection.
System Response:
Note: The warning will be cancelled if the engine rpm drops 200 rpm below the trip point that is
programmed for this parameter.
Engine operation is not affected unless engine speed exceeds the maximum governed engine speed. If
the maximum engine speed is exceeded, the injection will be disabled until the engine speed drops
below the maximum engine speed.
The operator may be operating the engine incorrectly.
The "Engine Overspeed" parameter may be incorrectly programmed for the application. Use Caterpillar
Electronic Technician (ET) to view the parameter setting for engine overspeed. Refer to
Troubleshooting, "System Configuration Parameters" for the rpm range that is available for this
parameter.
Test Step 1. Interview the Operator
Determine the events that caused the overspeed of the engine. Make corrections in order to prevent the
overspeed from recurring.
Results:
OK - STOP

Thu Apr 8 08:43:53 CDT 2010
Page 1 of 2
Troubleshooting
i02121632
E443 High Auxiliary Pressure

SMCS - 5095-038-AX
The Electronic Control Module (ECM) has detected an auxiliary pressure that is higher than the trip
points that are programmed into the monitoring system.
System Response:
The ECM will log the code.
The level of response is determined by the monitoring system. There is no loss of performance if the
monitoring system is programmed to "Warning". If the monitoring system is programmed to "Derate",
the ECM will derate power by 25 percent. If the engine is programmed to "Shutdown", the engine will
be shutdown.

Test Step 1. Verify the Trip Points
B. Access the monitoring system on Cat ET.
C. Verify that the trip points for auxiliary pressure are valid for the application.
Expected Result:
The trip points for the auxiliary pressure are valid.
Results:
OK - The trip points are valid.

Repair: There is a mechanical problem.
Page 2 of 2
STOP
Not OK - The trip points are not valid.

Repair: Program the trip points to the proper level.Verify that the repair eliminates the problem.
STOP

Thu Apr 8 08:44:08 CDT 2010
Page 1 of 2
Troubleshooting
i02121634
E445 High Auxiliary Temperature

SMCS - 5095-038-AX
The Electronic Control Module (ECM) has detected an auxiliary temperature that is higher than the trip
points that are programmed into the monitoring system.
System Response:
The ECM will log the code.
The level of response is determined by the monitoring system. There is no loss of performance if the
monitoring system is programmed to "Warning". If the monitoring system is programmed to "Derate",
the ECM will derate power by 25 percent. If the monitoring system is programmed to "Shutdown", the
engine will be shutdown.

Test Step 1. Verify the Trip Points
B. Access the monitoring system on Cat ET.
C. Verify that the trip points for auxiliary temperature are valid for the application.
Expected Result:
The trip points for the auxiliary temperature are valid.
Results:
OK - The trip points are valid.

Repair: There is a mechanical problem.
Page 2 of 2
STOP
Not OK - The trip points are not valid.

Repair: Program the trip points to the proper level.Verify that the repair eliminates the problem.
STOP

Thu Apr 8 08:44:23 CDT 2010

Cat MEUI Diagnosis

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Cat MEUI Diagnosis

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C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure

Publication Date -01/02/2005

Date Updated -14/02/2005

Can Not Reach Top Engine RPM

The connection of any electrical equipment and the disconnection of any

"Fuel Position" and/or "FRC Fuel Limit"

Boost pressure sensor

C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure

Air inlet and exhaust system

"Throttle Position Sensor"

"Direct Fuel Control Mode"

C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure

Boost Pressure Sensor, "Fuel Position", and/or "FRC Fuel Limit"

Air Inlet and Exhaust System

Copyright 1993 - 2010 Caterpillar Inc.

C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure

All Rights Reserved.

Thu Apr 8 08:09:25 CDT 2010

C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure

Publication Date -01/02/2005

Date Updated -14/02/2005

Engine Cranks but Will Not Start

The connection of any electrical equipment and the disconnection of any

ECM personality module

Electrical power to the Electronic Control Module (ECM)

Remote shutdown switch

Air shutoff circuit

Starting motor solenoid or starting circuit

Engine speed/timing sensors

Electrical connections to the electronic unit injector

C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure

253-02 Personality Module mismatch

Electrical Power to the ECM

Remote Shutdown Switch

Measured Voltage at P61:27

Air Shutoff Circuit

Starting Motor Solenoid or Starting Circuit

C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure

1. Test the operation of the starting motor solenoid.

Engine Speed/Timing Sensors

Electrical connections to the electronic unit injector

C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure

Check the Fuel Supply

Check for Combustion Problems

Valve lash settings

Refer to Testing and Adjusting for more information on a particular problem.

Copyright 1993 - 2010 Caterpillar Inc.

Thu Apr 8 08:12:11 CDT 2010

C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure

Publication Date -01/02/2005

Date Updated -14/02/2005

Engine Misfires, Runs Rough or Is Unstable

The connection of any electrical equipment and the disconnection of any

Air inlet and exhaust system

C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure

"Throttle Position Sensor"

"Desired Speed Input Configuration"

"Direct Fuel Control Mode"

C-15 Petroleum Engine Z2C00001-UP(SEBP4170 - 08) - Document Structure

Replacement of the fuel filters

Service on the low pressure fuel supply circuit

Replacement of unit injectors

Air Inlet and Exhaust System

Copyright 1993 - 2010 Caterpillar Inc.