Renr5059!14!00 Manuals Service Modules Troubleshooting Ceterpilar

RENR5059-14 (en-us)
February 2017
Troubleshooting
3500B and 3500C Generator Set
Engines
LD9 1-UP (Engine) GAR 1-UP (Generator Set) JM4 1-UP (Generator Set)
CNB 1100-UP (Generator PBR 1-UP (Generator Set) YBD 1-UP (Generator Set)
Set) SBJ 1-UP (Generator Set) LD4 1-UP (Generator Set)
CMC 1107-UP (Generator SBG 1-UP (Generator Set) YBT 1-UP (Generator Set)
Set) SBK 1-UP (Generator Set) ZBP 1-UP (Generator Set)
FDN 1515-UP (Generator YAL 1-UP (Generator Set) PDR 1-UP (Generator Set)
Set) YAP 1-UP (Generator Set) YBW 1-UP (Generator Set)
BGX 120-UP (Generator YAR 1-UP (Generator Set) ZBR 1-UP (Generator Set)
Set) YBR 1-UP (Generator Set) SEK 1-UP (Generator Set)
BLF 166-UP (Generator Set) YAM 1-UP (Generator Set) SFJ 1-UP (Generator Set)
BMB 132-UP (Generator YAY 1-UP (Generator Set) GD3 1-UP (Generator Set)
Set) YAN 1-UP (Generator Set) LYP 1-UP (Generator Set)
BPJ 472-UP (Generator Set) YAZ 1-UP (Generator Set) RRM 1-UP (Generator Set)
BRK 287-UP (Generator YAT 1-UP (Generator Set) LY7 1-UP (Generator Set)
Set) YAW 1-UP (Generator Set) LY8 1-UP (Generator Set)
CPA 182-UP (Generator JCG 1-UP (Generator Set) LY9 1-UP (Generator Set)
Set) JCY 1-UP (Generator Set) LYH 1-UP (Generator Set)
ZAD 1-UP (Generator Set) JCH 1-UP (Generator Set)
ZAH 1-UP (Generator Set) JDE 1-UP (Generator Set)
YAH 1-UP (Generator Set) JCN 1-UP (Generator Set)
ZAJ 1-UP (Generator Set) JDH 1-UP (Generator Set)
ZAP 1-UP (Generator Set) JDJ 1-UP (Generator Set)
ZAR 1-UP (Generator Set) JM2 1-UP (Generator Set)
GZY 1-UP (Generator Set) YBB 1-UP (Generator Set)
GZT 1-UP (Generator Set) JM3 1-UP (Generator Set)
GZS 1-UP (Generator Set) YBC 1-UP (Generator Set)
SAFETY.CAT.COM
i06558969
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, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR5059-14 3
Table of Contents
Table of Contents MID 036 - CID 0002 - FMI 06 Injector Cylinder 2

short............................................................... 116
MID 036 - CID 0003 - FMI 05 Injector Cylinder 3 open
Troubleshooting Section circuit ............................................................. 117
MID 036 - CID 0003 - FMI 06 Injector Cylinder 3
short............................................................... 118
Electronic Troubleshooting MID 036 - CID 0004 - FMI 05 Injector Cylinder 4 open
System Overview ..................................................6 circuit ............................................................. 119
Self-Diagnostics..................................................17 MID 036 - CID 0004 - FMI 06 Injector Cylinder 4
Electrical Connectors and Functions.....................19 short............................................................... 120
Electronic Service Tools.......................................21 MID 036 - CID 0005 - FMI 05 Injector Cylinder 5 open
circuit ............................................................. 121
Programming Parameters MID 036 - CID 0005 - FMI 06 Injector Cylinder 5
Programming Parameters....................................28 short............................................................... 122
Factory Passwords..............................................29 MID 036 - CID 0006 - FMI 05 Injector Cylinder 6 open
Flash Programming .............................................30 circuit ............................................................. 123
System Configuration Parameters ........................32 MID 036 - CID 0006 - FMI 06 Injector Cylinder 6
Customer Parameters Worksheet.........................36 short............................................................... 124
Replacing the ECM .............................................37 MID 036 - CID 0007 - FMI 05 Injector Cylinder 7 open
circuit ............................................................. 125
Troubleshooting without a Diagnostic Code MID 036 - CID 0007 - FMI 06 Injector Cylinder 7
Symptoms ..........................................................40 short............................................................... 126
Alternator (Charging Problem and/or Noisy MID 036 - CID 0008 - FMI 05 Injector Cylinder 8 open
Operation) ........................................................41 circuit ............................................................. 127
Can Not Reach Top Engine RPM..........................44 MID 036 - CID 0008 - FMI 06 Injector Cylinder 8
Coolant Temperature Is Too High .........................45 short............................................................... 128
ECM Will Not Accept Factory Passwords ..............47 MID 036 - CID 0009 - FMI 05 Injector Cylinder 9 open
ECM Will Not Communicate with Other Systems or circuit ............................................................. 129
Display Modules ................................................49 MID 036 - CID 0009 - FMI 06 Injector Cylinder 9
Electronic Service Tool Will Not Communicate with short............................................................... 130
ECM.................................................................50 MID 036 - CID 0010 - FMI 05 Injector Cylinder 10
Engine Cranks but Will Not Start...........................52 open circuit ..................................................... 132
Engine Has Early Wear........................................54 MID 036 - CID 0010 - FMI 06 Injector Cylinder 10
Engine Has Early Wear........................................56 short............................................................... 133
Engine Misfires, Runs Rough or Is Unstable..........59 MID 036 - CID 0011 - FMI 05 Injector Cylinder 11
Engine Oil in Cooling System ...............................62 open circuit ..................................................... 134
Engine Stalls at Low RPM....................................64 MID 036 - CID 0011 - FMI 06 Injector Cylinder 11
Engine Stalls at Low RPM....................................66 short............................................................... 135
Engine Will Not Crank..........................................68 MID 036 - CID 0012 - FMI 05 Injector Cylinder 12
Excessive Engine Oil Consumption ......................70 open circuit ..................................................... 136
Excessive Black Smoke.......................................71 MID 036 - CID 0012 - FMI 06 Injector Cylinder 12
Excessive White Smoke ......................................73 short............................................................... 137
Exhaust Temperature Is Too High .........................75 MID 036 - CID 0013 - FMI 05 Injector Cylinder 13
Fuel Dilution of Engine Oil....................................77 open circuit ..................................................... 138
Fuel in Cooling System ........................................79 MID 036 - CID 0013 - FMI 06 Injector Cylinder 13
Intermittent Engine Shutdown ..............................81 short............................................................... 139
Intermittent Low Power or Power Cutout ...............83 MID 036 - CID 0014 - FMI 05 Injector Cylinder 14
Low Engine Oil Pressure .....................................85 open circuit ..................................................... 140
Low Power/Poor or No Response to Throttle .........86 MID 036 - CID 0014 - FMI 06 Injector Cylinder 14
Mechanical Noise (Knock) in Engine.....................89 short............................................................... 141
Noise Coming from Cylinder ................................90 MID 036 - CID 0015 - FMI 05 Injector Cylinder 15
Oil Contains Coolant ...........................................91 open circuit ..................................................... 142
Poor Fuel Consumption ..................................... 103 MID 036 - CID 0015 - FMI 06 Injector Cylinder 15
Too Much Valve Lash ........................................ 104 short............................................................... 143
Too Much Vibration............................................ 106 MID 036 - CID 0016 - FMI 05 Injector Cylinder 16
Valve Rotocoil or Spring Lock Is Free.................. 107 open circuit ..................................................... 144
Troubleshooting with a Diagnostic Code short............................................................... 145
Diagnostic Codes.............................................. 109 MID 036 - CID 0091 - FMI 08 Throttle Position signal
MID 036 - CID 0001 - FMI 05 Injector Cylinder 1 open abnormal ........................................................ 146
circuit ............................................................. 113 MID 036 - CID 0094 - FMI 03 Fuel Pressure open/
MID 036 - CID 0001 - FMI 06 Injector Cylinder 1 short to +batt................................................... 147
short............................................................... 114 MID 036 - CID 0094 - FMI 04 Fuel Pressure short to
MID 036 - CID 0002 - FMI 05 Injector Cylinder 2 open ground............................................................ 148
circuit ............................................................. 115
4 RENR5059-14
Table of Contents
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure MID 036 - CID 0276 - FMI 04 Left Turbo Inlet
open/short to +batt .......................................... 149 Pressure short to ground.................................. 184
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure MID 036 - CID 0279 - FMI 03 Aftercooler
short to ground ................................................ 150 Temperature open/short to +batt ....................... 185
MID 036 - CID 0101 - FMI 03 Crankcase Pressure MID 036 - CID 0279 - FMI 04 Aftercooler
open/short to +batt .......................................... 151 Temperature short to ground ............................ 186
MID 036 - CID 0101 - FMI 04 Crankcase Pressure MID 036 - CID 0289 - FMI 02 Unfiltered Fuel
short to ground ................................................ 152 Pressure misinstalled....................................... 187
MID 036 - CID 0105 - FMI 03 Inlet Manifold Temp MID 036 - CID 0289 - FMI 03 Unfiltered Fuel
Sensor open/short to +batt ............................... 153 Pressure open/short to +batt ............................ 188
MID 036 - CID 0105 - FMI 04 Inlet Manifold Temp MID 036 - CID 0289 - FMI 04 Unfiltered Fuel
Sensor short to ground..................................... 155 Pressure short to ground.................................. 189
MID 036 - CID 0110 - FMI 03 Engine Coolant MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
Temperature open/short to +batt ....................... 156 inputs ............................................................. 190
MID 036 - CID 0110 - FMI 04 Engine Coolant MID 036 - CID 0337 - FMI 02 Incorrect Remote E-
Temperature short to ground ............................ 157 Stop Switch inputs ........................................... 191
MID 036 - CID 0168 - FMI 00 System Voltage MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open
High ............................................................... 158 circuit ............................................................. 192
MID 036 - CID 0168 - FMI 01 System Voltage MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short to
Low ................................................................ 159 ground............................................................ 193
MID 036 - CID 0168 - FMI 02 System Voltage MID 036 - CID 0446 - FMI 05 Air Shutoff Relay
intermittent/erratic............................................ 160 open............................................................... 194
MID 036 - CID 0175 - FMI 03 Engine Oil Temperature MID 036 - CID 0446 - FMI 06 Air Shutoff Relay
open/short to +batt .......................................... 161 short............................................................... 195
MID 036 - CID 0175 - FMI 04 Engine Oil Temperature MID 036 - CID 0542 - FMI 02 Unfiltered Engine Oil
short to ground ................................................ 162 Pressure misinstalled....................................... 196
MID 036 - CID 0190 - FMI 02 Loss of Engine Speed MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil
signal ............................................................. 163 Pressure open/short to +batt ............................ 197
MID 036 - CID 0190 - FMI 03 Engine Speed open/ MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil
short to +batt ................................................... 164 Pressure short to ground.................................. 198
MID 036 - CID 0248 - FMI 09 Cat Data Link not MID 036 - CID 0546 - FMI 05 Ether Hold Relay open/
communicating................................................ 165 short to ground ................................................ 199
MID 036 - CID 0253 - FMI 02 Personality Module MID 036 - CID 0546 - FMI 06 Ether Hold Relay short
mismatch ........................................................ 166 to +batt ........................................................... 200
MID 036 - CID 0254 - FMI 12 Electronic Control MID 036 - CID 0799 - FMI 12 Need Service tool
Module Error ................................................... 168 update ............................................................ 201
MID 036 - CID 0261 - FMI 13 Engine Timing MID 036 - CID 0827 - FMI 08 Left Exhaust
calibration required .......................................... 169 Temperature signal abnormal ........................... 203
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC MID 036 - CID 0828 - FMI 08 Right Exhaust
Power Supply short to +batt.............................. 170 Temperature signal abnormal ........................... 204
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC MID 036 - CID 1495 - FMI 02 Injector Trim Codes Not
Power Supply short to ground........................... 171 Programmed ................................................... 205
MID 036 - CID 0263 - FMI 03 Digital Sensor Supply
short to +batt ................................................... 172 Troubleshooting with an Event Code
MID 036 - CID 0263 - FMI 04 Digital Sensor Supply Event Codes .................................................... 207
short to ground ................................................ 173 E004 Engine Overspeed Shutdown .................... 211
MID 036 - CID 0268 - FMI 02 Check Programmable E007 High Aftercooler Temperature Derate ......... 212
Parameters ..................................................... 174 E008 High Aftercooler Temperature Shutdown .... 213
MID 036 - CID 0273 - FMI 00 Turbo Outlet Pressure E009 High Altitude Derate.................................. 215
above normal .................................................. 175 E012 High Crankcase Pressure Derate............... 216
MID 036 - CID 0273 - FMI 03 Turbo Outlet Pressure E013 High Crankcase Pressure Shutdown.......... 217
open/short to +batt .......................................... 176 E015 High Engine Coolant Temperature Derate .. 219
MID 036 - CID 0273 - FMI 04 Turbo Outlet Pressure E016 High Engine Coolant Temperature
short to ground ................................................ 177 Shutdown ....................................................... 221
MID 036 - CID 0274 - FMI 03 Atmospheric Pressure E017 High Engine Coolant Temperature Warning 223
open/short to +batt .......................................... 178 E021 High Exhaust Temperature Derate ............. 225
MID 036 - CID 0274 - FMI 04 Atmospheric Pressure E031 Air Inlet Restriction Derate......................... 227
short to ground ................................................ 179 E038 Low Engine Coolant Temperature Warning . 228
MID 036 - CID 0275 - FMI 03 Right Turbo Inlet E040 Low Engine Oil Pressure Shutdown ........... 230
Pressure open/short to +batt ............................ 180 E043 Low System Voltage Warning .................... 231
MID 036 - CID 0275 - FMI 04 Right Turbo Inlet E095 Fuel Filter Restriction Warning................... 233
Pressure short to ground.................................. 181 E099 Engine Oil Filter Restriction Warning .......... 235
MID 036 - CID 0276 - FMI 03 Left Turbo Inlet E100 Low Engine Oil Pressure Warning.............. 236
Pressure open/short to +batt ............................ 182 E101 High Crankcase Pressure Warning ............ 238
E162 High Boost Pressure ................................. 239
RENR5059-14 5
Table of Contents
E173 High Exhaust Temperature Warning........... 241

E190 Engine Overspeed Warning....................... 242
E198 Low Fuel Pressure.................................... 243
E255 Diagnostic Reset ...................................... 244
E264 Emergency Stop Activated ........................ 245
E272 Inlet Air Restriction Warning ...................... 247
E279 High Aftercooler Temperature Warning....... 248
E552 Low Aftercooler Coolant Level ................... 250
E2087 Air Intake Shutoff Closed ......................... 251
E2088 Air Intake Shutoff Detection Circuit Detected
but Not Installed .............................................. 252
E2143 Low Engine Coolant Level ....................... 254
Diagnostic Functional Tests

Air Shutoff System ............................................ 256
Analog Sensor Supply ....................................... 261
CAN Data Link .................................................. 268
Cat Data Link .................................................... 271
Coolant Level Sensor ........................................ 274
Digital Sensor Supply ........................................ 281
Direct Fuel Control Mode ................................... 287
Electrical Power Supply ..................................... 291
Emergency Stop Switch..................................... 295
Engine Control Switch (ECS) ............................. 299
Engine Sensor Open/Short Test ......................... 302
Engine Speed/Timing Sensor............................. 310
Ether Injection System....................................... 316
Injector Solenoids ............................................. 324
Inspecting Electrical Connectors ........................ 331
Prelubrication System........................................ 337
Speed Control................................................... 344
Starting Motor System ...................................... 348
Calibration Procedures
Analog Sensor - Calibrate .................................. 354
Engine Speed/Timing Sensor - Calibrate............. 356
Index Section
Index................................................................ 359
6 RENR5059-14
Electronic Troubleshooting
Troubleshooting Section S/N: SFJ1–Up

S/N: ZAJ1–Up
S/N: BRK287–Up
Electronic Troubleshooting S/N: SBK1–Up
S/N: SEK1–Up
S/N: YAL1–Up
i02385288
S/N: YAM1–Up
System Overview S/N: FDN1515–Up
SMCS Code: 1901-038; 1924 S/N: JCN1–Up
S/N: JM21–Up S/N: YAN1–Up
S/N: GD31–Up S/N: LYP1–Up
S/N: JM31–Up S/N: YAP1–Up
S/N: JM41–Up S/N: ZAP1–Up
S/N: LD41–Up S/N: ZBP1–Up
S/N: LY71–Up S/N: GAR1–Up
S/N: LY81–Up S/N: PBR1–Up
S/N: LD91–Up S/N: PDR1–Up
S/N: LY91–Up S/N: YAR1–Up
S/N: CPA182–Up S/N: YBR1–Up
S/N: BMB132–Up S/N: ZAR1–Up
S/N: CNB1100–Up S/N: ZBR1–Up
S/N: YBB1–Up S/N: GZS1–Up
S/N: CMC1107–Up S/N: GZT1–Up
S/N: YBC1–Up S/N: YAT1–Up
S/N: YBD1–Up S/N: YBT1–Up
S/N: ZAD1–Up S/N: YAW1–Up
S/N: JDE1–Up S/N: YBW1–Up
S/N: BLF166–Up S/N: BGX120–Up
S/N: JCG1–Up S/N: GZY1–Up
S/N: SBG1–Up S/N: JCY1–Up
S/N: JCH1–Up S/N: YAY1–Up
S/N: JDH1–Up S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up
S/N: ZAH1–Up
S/N: BPJ472–Up
S/N: JDJ1–Up
S/N: SBJ1–Up
RENR5059-14 7
The engine is designed for electronic control of most • The operator places the control in the AUTO mode
engine operating functions. The electronic system and the remote initiate input becomes active.
consists of the following components: Electronic
Control Module (ECM), wiring harness, switches, • The operator places the control in the AUTO mode
sensors and fuel injectors.The engine ECM receives and a start command is sent via the data link.
information from the sensors and from the switches
on the engine. The engine ECM also receives 2) The generator control module performs the
information from the generator control module. The following system checks:
engine ECM and the generator control module
continuously share information that enables both • No system faults are present.
control modules to process information so it is
possible to make decisions on the control of the • All previous shutdown faults have been reset.
overall genset. The engine ECM processes the
information that is collected in order to make • The engine is not already running.
decisions on the control of the engine. The generator
control module processes the information that is • If the prelube (if equipped) is not complete, the
collected in order to make decisions on the control of generator control module will not crank the engine.
the generator.
3) The generator control module begins the following
Electronic Controls cranking sequence:
• Activate the Starting Motor Relay (SMR).
Electronic Control Module
• A start signal is sent to the engine ECM via the
The ECM consists of two main components, the Cat Data Link and the fuel control relay is
control computer (hardware) and the flash file. The activated.
control computer consists of a microprocessor and of
electronic circuitry. The flash file contains the 4) The generator control enables cranking the engine
engine's operational characteristics. The operating until the cycle crank time reaches the setpoint for
maps influence the engine's performance. total crank time or until the engine starts.
Engine Governor 5) The generator control module deactivates the

SMR when the engine speed reaches the setpoint for
crank terminate speed.
The engine ECM governs engine speed. The engine
ECM and the flash file work together by controlling
the amount of fuel that is delivered by the injectors. Engine Stopping Procedure
Desired engine rpm is determined by the throttle
position sensor signal and by certain sensor 1) The generator control module receives one of the
readings. Actual engine rpm is detected by the following engine stop signal:
engine speed/timing sensor.
• The operator places the control in the STOP
Fuel Injection mode.
• The operator places the control in the AUTO mode
The engine ECM controls the timing and the duration and the remote initiate input becomes inactive.
of the fuel that is injected. The engine ECM varies the
signals to the fuel injectors. Fuel is injected only while • The generator control module begins the
an injector solenoid is energized by a 105 volt signal cooldown period. Place the generator control in
from the engine ECM. The timing of the injection
the STOP mode in order to bypass the cooldown .
signal determines the engine timing. The length of
the injection signal determines engine speed. By “PRESS ENTER TO BYPASS” and “PRESS
controlling the timing and duration of the 105 volt ESCAPE TO CONTINUE” will be shown on the
signal, the ECM controls the engine speed. display.
2) After the cooldown period, the generator control
Engine Starting and Stopping module sends a shutdown signal to the engine ECM.
Procedures The engine ECM deactivates the fuel control relay
which shuts down the engine.
Engine Starting Sequence
1) The generator control module will receive one of
the following start signals:
• The operator places the control in the RUN mode.
8 RENR5059-14
Block Diagram for the 3500B Engine

RENR5059-14 9
Illustration 1 g01189813
10 RENR5059-14
Typical components
Typical block diagram for the generator control
RENR5059-14 11
Typical block diagram for communications
12 RENR5059-14
Location Of The 3512B and 3516B Engine Sensors
Typical left side view
(1) Left turbocharger inlet pressure sensor (5) Engine speed/timing sensor (9) Filtered engine oil pressure sensor
(2) Exhaust temperature sensor (LH) (6) Unfiltered engine oil pressure sensor (10) Atmospheric pressure sensor
(3) Connector for the CAN data link (7) Low oil level switch (11) ECM connector J2/P2
(4) Engine ECM (8) Very low oil level switch (12) ECM connector J1/P1
RENR5059-14 13
Typical right side view
(13) Connector for the timing calibration (15) Crankcase pressure sensor (17) Electric fuel priming pump
sensor (16) Connector for the continuous oil (18) Coolant flow switch
(14) Exhaust temperature sensor (RH) renewal solenoid
14 RENR5059-14
Typical front and rear view
(19) Connector for the engine fan speed (20) Turbocharger outlet pressure sensor
sensor (21) Rear aftercooler temperature sensor
RENR5059-14 15
Location Of The 3508B Engine Sensors
Typical left side view
(1) Unfiltered fuel pressure sensor (6) Left turbocharger compressor inlet (10) Engine speed/timing sensor
(2) Filtered fuel pressure sensor pressure sensor (11) Ether starting aid
(3) Unfiltered oil pressure sensor (7) Coolant temperature sensor (12) Power distribution box
(4) Filtered oil pressure sensor (8) Atmospheric pressure sensor (13) Starting motors
(5) Left air shutoff solenoid (9) Aftercooler temperature sensor
16 RENR5059-14
Typical right side view
(14) Right turbocharger compressor inlet (15) Right air shutoff solenoid (17) Alternator
pressure sensor (16) Air start solenoid (18) Crankcase pressure sensor
RENR5059-14 17
Typical front and rear view
(19) Turbocharger compressor outlet (1) Unfiltered fuel pressure sensor (6) Left turbocharger compressor inlet
pressure sensor (8) Atmospheric pressure sensor pressure sensor
(20) Electronic control module (ECM) (14) Right turbocharger compressor inlet (10) Engine speed/timing sensor
(21) ECM connector J1/P1 pressure sensor
(22) ECM connector J2/P2
i01977688 S/N: LY81–Up

S/N: LD91–Up
Self-Diagnostics
S/N: LY91–Up
SMCS Code: 1901-038
S/N: CPA182–Up
S/N: JM21–Up
S/N: BMB132–Up
S/N: GD31–Up
S/N: CNB1100–Up
S/N: JM31–Up
S/N: YBB1–Up
S/N: JM41–Up
S/N: CMC1107–Up
S/N: LD41–Up
S/N: YBC1–Up
S/N: LY71–Up
S/N: YBD1–Up
18 RENR5059-14

S/N: LYH1–Up The Electronic Control Module (ECM) has the ability
to detect problems with the electronic system and
S/N: YAH1–Up with engine operation. When a problem is detected, a
S/N: ZAH1–Up code is generated. An alarm may also be generated.
There are two types of codes:
S/N: BPJ472–Up
• Diagnostic
S/N: JDJ1–Up
• Event
S/N: SBJ1–Up
Diagnostic Code – When a problem with the
S/N: SFJ1–Up electronic system is detected, the ECM generates a
S/N: ZAJ1–Up diagnostic code. This indicates the specific problem
with the electronic control system.
S/N: BRK287–Up
Event Code – An event code is generated by the
S/N: SBK1–Up detection of an abnormal engine operating condition.
For example, an event code will be generated if the
S/N: SEK1–Up oil pressure is too low. In this case, the event code
indicates the symptom of a problem.
S/N: YAL1–Up
S/N: YAM1–Up The codes can have two different states:
S/N: FDN1515–Up • Active
S/N: JCN1–Up
• Logged
S/N: YAN1–Up
Active Code – An active diagnostic code or an active
S/N: LYP1–Up event code indicates that an active problem has been
detected. Active codes require immediate attention.
S/N: YAP1–Up Always service active codes prior to servicing logged
codes.
S/N: ZAP1–Up
Logged Code – Every generated code is stored in
S/N: ZBP1–Up the permanent memory of the ECM. The codes are
S/N: GAR1–Up logged.
S/N: PBR1–Up
Logged codes may not indicate that a repair is
S/N: PDR1–Up needed. The problem may have been temporary. The
problem may have been resolved since the logging of
S/N: YAR1–Up the code. If the system is powered, it is possible to
generate an active diagnostic code whenever a
S/N: YBR1–Up component is disconnected. When the component is
S/N: ZAR1–Up reconnected, the code is no longer active. Logged
codes may be useful to help troubleshoot intermittent
S/N: ZBR1–Up problems. Logged codes can also be used to review
the performance of the engine and of the electronic
S/N: GZS1–Up system.
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
RENR5059-14 19
i02385530 S/N: SEK1–Up

S/N: YAL1–Up
Electrical Connectors and
Functions S/N: YAM1–Up
S/N: FDN1515–Up
SMCS Code: 1408-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up
S/N: ZAH1–Up
S/N: BPJ472–Up
S/N: JDJ1–Up
S/N: SBJ1–Up
S/N: SFJ1–Up
S/N: ZAJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
20 RENR5059-14
Electronic Control Module (ECM)
2-pin connector
RENR5059-14 21
3-pin connectors
i06844639 S/N: CNB1100–Up

S/N: YBB1–Up
Electronic Service Tools
S/N: CMC1107–Up
SMCS Code: 1901-038
S/N: YBC1–Up
S/N: JM21–Up
S/N: YBD1–Up
S/N: GD31–Up
S/N: ZAD1–Up
S/N: JM31–Up
S/N: JDE1–Up
S/N: JM41–Up
S/N: BLF166–Up
S/N: LD41–Up
S/N: JCG1–Up
S/N: LY71–Up
S/N: SBG1–Up
S/N: LY81–Up
S/N: JCH1–Up
S/N: LD91–Up
S/N: JDH1–Up
S/N: LY91–Up
S/N: LYH1–Up
S/N: CPA182–Up
S/N: YAH1–Up
S/N: BMB132–Up
22 RENR5059-14
S/N: ZAH1–Up Service Tools

S/N: BPJ472–Up Most of the tools that are listed in Table 1 are
required to enable a service technician to perform the
S/N: JDJ1–Up test procedures in this manual. Some of the devices
may be specific to the type of Electronic Control
S/N: SBJ1–Up Module (ECM) that is being used.
S/N: SFJ1–Up Table 1
S/N: ZAJ1–Up Service Tools
S/N: BRK287–Up Part Description

Number
S/N: SBK1–Up 349-4200 Thermometer
S/N: SEK1–Up 360-0774 Refractometer
S/N: YAL1–Up 431-7087 Tool Gp (REFRACTOMETER (DEF))
S/N: YAM1–Up N/A 4 mm Allen Wrench
S/N: FDN1515–Up 1U-5805 Wire Removal Tool (14-GA, GREEN)
S/N: JCN1–Up Magnetic Transducer As (TIMING

6V-2197
CALIBRATION)
S/N: YAN1–Up
121-9588 Wire Removal Tool (16-GA, BLUE)
S/N: LYP1–Up
147-6456 Wedge Removal Tool
S/N: YAP1–Up 151-6320 Wire Removal Tool (14-GA TO 18-GA, RED)
S/N: ZAP1–Up 1U-5804 Crimp Tool (12−AWG TO 18−AWG)
S/N: ZBP1–Up 6V-2197 Transducer
S/N: GAR1–Up 7X-1171 Transducer Adapter
S/N: PBR1–Up 7X-1695 Cable As
S/N: PDR1–Up 146-4080 Digital Multimeter Gp (RS232)
S/N: YAR1–Up 7X-1710 Multimeter Probes

326-4904 Adapter Cable As (3-PIN BREAKOUT)
S/N: YBR1–Up
S/N: ZAR1–Up 7X-1715 Adapter Cable As (40-PIN BREAKOUT)
134-5195 Harness (40-PIN)
S/N: ZBR1–Up (For ADEM 2 ECM (two 40-pin connectors))
S/N: GZS1–Up 208-0059 Adapter Cable As (70-PIN BREAKOUT)

(For ADEM 3 ECM (two 70-pin connectors) and
S/N: GZT1–Up for ADEM 4 ECM (one 70-pin connector and one
120-pin connector))
S/N: YAT1–Up
257-8718 The 257-8718 Adapter Cable As is not appli-
S/N: YBT1–Up cable with Tier IV Engines.
Adapter Cable As (120-PIN BREAKOUT)
S/N: YAW1–Up
(For ADEM 4 ECM (one 70-pin connector and one
S/N: YBW1–Up 120-pin connector))
S/N: BGX120–Up N/A Torque Wrench (capable of applying 1.5 N·m

(13.3 lb in))
S/N: GZY1–Up
Repair Kits for Connectors
S/N: JCY1–Up
362-3555 Connector Repair Kit (AMPSEAL)
S/N: YAY1–Up Connector Repair Kit (Deutsch connector)
175-3700
S/N: YAZ1–Up Bypass Harnesses for the ECM
(continued)
RENR5059-14 23
(Table 1, contd) (Table 2, contd)

Service Tools Optional Service Tools
Part Description Part Number Description
Number
348-5430 Multi-Tool Gp
129-2018 Power Cable
(Stand alone cable for ADEM 2 ECM) 8T-8726 Adapter Cable As
217-0113 Wiring Harness (ECM BYPASS) 163-5443 Adapter Cable As (3-PIN BREAKOUT)
(The bypass harness connects to the battery. The
bypass harness is used with the following har- 177-2330 Battery Analyzer (DIGITAL)
nesses for different types of electronic control
190-8900 Connector Repair Kit
modules.)
225-5985 Parallel Port Cable (COMMUNICATION
328-2292 Harness (ENGINE ECM BYPASS)
ADAPTER)
(For ADEM 3 ECM and ADEM 4 ECM)
391-8170 EMISSIONS ANALYZER TOOL GP (Bluetooth
277-4734 Harness (ENGINE ECM BYPASS)
Module)
(For A4:E2 ECM (Two 64-pin connectors))
393-0673 EMISSIONS ANALYZER TOOL GP
276-7273 Sensor Test Box (1)
(1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911 Bat-
(1) Instrument used to test Cylinder Position sensors. tery Load Tester for 6, 8, and 12 v Lead Acid Batteries” and
Special Instructions, SEHS7633, “Battery Test Procedure”.
Two short jumper wires may be needed to check the (2) Refer to Special Instructions, SEHS8382, “Use of the 6V-9130
continuity of some wiring harness circuits by shorting Temperature Adapter Group”.
two adjacent terminals together in a connector. A
long extension wire may also be needed to check the
continuity of some wiring harness circuits. Cat Electronic Technician (ET)
Except for harness tests, the use of certain test Cat ET can be used by the technician to help perform
equipment is not recommended for use on modern the following procedures:
Caterpillar electrical circuits. Such testers include the
following examples: the 8T-0500 Continuity Tester • Diagnostic testing
and 5P-7277 Voltage Tester.
• Calibrations
Note: A procedure has been developed to test "In
Cylinder" Position Sensors. Reference Special • Flash programming
Instruction REHS7338, “Procedure to Test the • Configuration of the ECM
Position Sensor of a Hydraulic Cylinder”.
• Print various reports
Optional Service Tools
Cat ET can display the following information:
Table 2 lists the optional service tools that may be
needed during testing or repair. • Status parameters
Table 2
• Event codes
Optional Service Tools
• Diagnostic codes
Part Number Description
• ECM settings
198-4240 Digital Pressure Indicator
or or • Engine configuration
1U-5470 Engine Pressure Group
Always use the latest revision of Cat ET. The media
4C-4075 Crimp Tool (4−AWG TO 10−AWG)
is available on CD and the media can also be
4C-4911(1) Battery Load Tester downloaded from various Caterpillar web sites.
Table 3
5P-7277 Voltage Tester
Software, JEBD3003, “CATERPILLAR ELECTRONIC
6V-9130(2) Temperature Adapter (MULTIMETER) TECHNICIAN”
8T-5319 Connector Tool Group

Once you have downloaded Cat ET onto your PC,
349-4199 AC/DC Current Probe you will need a license from your Caterpillar dealer to
use the software. Various licenses are available for
different users with different requirements. Consult
(continued) your Caterpillar dealer.
24 RENR5059-14
Note: For more information regarding the use of Cat

ET and PC requirements, refer to the documentation
that accompanies your Cat ET program software.
Connecting Cat ET
Connecting the Communication Adapter

Note: The 466-6258 is the latest version of the
Communication Adapter Group. Older service tool
versions can still be used.
Table 4 lists the standard hardware that is required to
connect Cat ET.
Table 4
Standard Hardware for Connecting with Cat ET
N/A Personal Computer (PC)
466-6258 Communication Adapter Gp

317-7492 Radio Kit (NACD only)
(1) PC
349-1206 Radio Kit (EAME only) (2) 353-5083 Cable As (USB)
(3) 317-7485 Communication Adapter (3)
Components of the 466-6258 Communication Adapter Gp (4) 327-8981 Cable As (DATA LINK)
317-7485 Communication Adapter (3)

2. Connect cables (2) and (4) to communication
370-4617 Cable As (USB) adapter (3).
457-6114 Cable As (DATA LINK) Note: The communication adapter will power up
Components of the 317-7492 Radio Kit
when the adapter is connected to a PC or to an ECM
that is powered up.
317-7493 Wireless Communication Radio
3. Connect cable (2) to the USB port of the PC.
317-7496 Computer Cable As
4. Connect cable (4) to a service tool connector.
317-7510 Radio Cable Assembly
Antenna (2)
5. Restore electrical power to the ECM. Verify that
326-9606
the “POWER” indicator on the communication
Components of the 349-1206 Radio Kit adapter is illuminated. Make sure that the PC is
348-9250 Communication Radio Gp powered up.
317-7496 Computer Cable As 6. Establish communication between Cat ET and the

ECM. If Cat ET indicates that there is more than
317-7510 Radio Cable Assembly one ECM, select the engine ECM.
326-9606 Antenna (2)
7. If Cat ET and the communication adapter do not
Tool Operating Manual & Software CD ROM, NETG5057, “Com- communicate with the ECM, refer to
munication Adapter 3” Troubleshooting, “Electronic Service Tool Will Not
Communicate with ECM”.
Follow the instructions for the communication Refer to Troubleshooting, “Electronic Service Tool
adapter. Use the following procedure to connect Cat
ET and the communication adapter to a PC. Does Not Communicate” if any of the following
conditions exist:
1. Remove the electrical power from the ECM.
• Cat ET displays a message that refers to a
communication problem.
• Cat ET displays “Error #142 The interface

hardware is not responding” .
RENR5059-14 25
• Cat ET displays a message that indicates that

the firmware in the communications adapter is
old.
Dual Data Link Communications (If so

equipped)
When the connection of the communication adapter
is complete, observe the communication adapter and
Cat ET. Certain applications require that dual data
link communications be established to perform
various test procedures. These tests will be listed in
the “Diagnostic Tests” menu, some tests may not be
available (grayed out). If there are diagnostic tests
that are unavailable in Cat ET, ensure that your
service tool is communicating in dual data link mode.
Use the following indicators to confirm that Cat ET is
communicating on dual data links:
• “J1939” indicator is flashing

• “Cat Data Link” indicator is flashing Illustration 14 g02342942
(1) Personal computer (PC)
• Cat ET is not displaying “Service tool support is (5) 261-4867 Card (PCMCIA)
limited” (6) 239-9955 Communication Radio Gp
(7) 259-3183 Data Link Cable As
Refer to Troubleshooting, “Electronic Service Tool
Does Not Communicate” if the “J1939” indicator and Note: Items (5), (6), and (7) are part of the
the “Cat Data Link” indicator are not flashing. Both 261-3363 Wireless Communication Adapter Gp.
indicators will be flashing during dual data link
communications with the ECM. Note: The 261-3363 Wireless Communication
Adapter Gp was canceled and replaced by the
Communicating with the Wireless 349-1206 Radio Kit. However, the 261-3363
Wireless Communication Adapter Gp can still be
Communication Adapter (If so equipped) used.
Table 6 lists the optional hardware that is needed to Use the following procedure to connect the wireless
connect Cat ET by using a wireless connection. communication adapter for use with Cat ET.
Note: Some applications cannot use a wireless 1. Remove the electrical power from the ECM.
connection. Also, a dual data link cannot be used
2. Ensure that the computer has been correctly
with a wireless connection.
configured for the 261-4867 Card. Verify that the
Table 5 PC card is installed in the computer PCMCIA
Optional Hardware for the Use of Cat ET expansion slot.
Part Number Description 3. Connect cable (9) between communication radio
(8) and the service tool connector.
4. Restore the electrical power to the ECM. If Cat ET
and the communication radio do not communicate
with the ECM, refer to Troubleshooting, “Electronic
Service Tool Will Not Communicate with ECM”.
Communicating with the Wireless

Communication Adapter (If so equipped)
Table 6 lists the optional hardware that is needed to
connect Cat ET by using a wireless connection.
26 RENR5059-14
Note: Some applications cannot use a wireless 2. Ensure that the computer has been correctly
connection. Also, a dual data link cannot be used configured for the 802.11a or 802.11b/g enabled
with a wireless connection. wireless card. Verify that the PC wireless is
Although changes can be made to the internal installed and working correctly.
settings of the W-CA3 wirelessly. Caterpillar 3. Connect cable (9) between communication radio
recommends that the radio is connected to a PC via
317-7496 Computer Cable As (USB)Cable (8) and the service tool connector.
Assembly (8) and 317-7510 Radio Cable 4. Restore the electrical power to the ECM. If Cat ET
Assembly (9).
and the communication radio do not communicate
Table 6
with the ECM, refer to Troubleshooting, “Electronic
Optional Hardware for the Use of Cat ET Service Tool Will Not Communicate with ECM”.
(8) 317-7496 Computer Cable As (USB)
(9) 317-7510 Radio Cable AssemblyC
(9) 317-7510 Radio Cable Assembly
(10) W-CA3
Note: Items (8), (9), and (10) are part of the

349-1206 Radio Kit.
Use the following procedure to connect the wireless
communication adapter for use with Cat ET.
1. Remove the electrical power from the ECM.
RENR5059-14 27
PL1000E Communication ECM (If so

equipped)
The PL1000E is an ECM that provides the customer

with the ability to integrate Caterpillar engines into
specific applications. The PL1000E enables
communication from a J1939 data link to a device
that utilizes a MODBUS communication protocol. A
PC with the latest version of Cat ET installed can be
connected to the PL1000E through the RS232 serial
port of the PC. The PL1000E contains an embedded
communications adapter that will allow Cat ET to
communicate with the engine over the J1939 data
link.
Refer to System Operation/Troubleshooting/Test and
Adjust, RENR8091, “PL1000E Communication ECM”
for additional information.
28 RENR5059-14
Programming Parameters
Programming Parameters S/N: BRK287–Up

S/N: SBK1–Up
S/N: SEK1–Up
i02549044 S/N: YAL1–Up
S/N: YAM1–Up
S/N: FDN1515–Up
SMCS Code: 1901-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up
S/N: ZAH1–Up
S/N: BPJ472–Up
S/N: JDJ1–Up
S/N: SBJ1–Up
S/N: SFJ1–Up
S/N: ZAJ1–Up
RENR5059-14 29
Caterpillar Electronic Technician (ET) can be used to S/N: SFJ1–Up

view certain parameters that can affect the operation
of the engine. Cat ET can also be used to change S/N: ZAJ1–Up
certain parameters. Some of the parameters are
S/N: BRK287–Up
protected from unauthorized changes by passwords.
Parameters that can be changed have a tattletale S/N: SBK1–Up
number. The tattletale number shows if a parameter
has been changed. S/N: SEK1–Up
S/N: YAL1–Up
i02385531
S/N: YAM1–Up
Factory Passwords S/N: FDN1515–Up
SMCS Code: 1901-038 S/N: JCN1–Up
S/N: LYH1–Up
Passwords
S/N: YAH1–Up
Passwords are part of a security system that helps to
S/N: ZAH1–Up prevent unauthorized changing of certain
parameters. Passwords prevent unauthorized
S/N: BPJ472–Up erasing of logged events. Passwords allow the
factory to control access to engine calibration
S/N: JDJ1–Up parameters. Passwords allow the customer to control
S/N: SBJ1–Up access to certain engine parameters.
30 RENR5059-14
Factory Passwords If customer passwords have been entered, then the

customer passwords are required to change any
Factory passwords are required to clear any event parameter that is customer programmable. Refer to
code. Factory passwords are required to change the diagnostic procedure Troubleshooting, “System
certain parameters such as “Full Load Setting” . Configuration Parameters” for more detail on
Factory passwords restrict changes to authorized parameters that are customer programmable.
personnel. When the correct factory passwords have
been entered, the changes can then be made. Note: If the customer passwords are lost, the
parameters that are protected by customer
Note: Factory passwords are calculated on a passwords cannot be changed. You must use factory
computer system that is only available to Caterpillar passwords in order to read the customer passwords.
dealers. You may then use those customer passwords to
change parameters that have been protected by
In order to obtain the proper factory passwords,
certain information must be given to an authorized customer passwords.
Caterpillar dealer. Since the factory passwords
contain alphabetic characters, the Caterpillar i02419726
Electronic Technician (ET) can be used to perform
this function. In order to obtain the factory Flash Programming
passwords, proceed as if you already have the
factory passwords. At some point, if the factory SMCS Code: 1901-038
passwords are actually needed, Cat ET will request
the factory passwords and Cat ET will display the S/N: JM21–Up
information that is required to obtain the factory
passwords. S/N: GD31–Up
Note: The old interlock code and the new interlock S/N: JM31–Up
code are required to change the interlock code on a S/N: JM41–Up
used Electronic Control Module (ECM).
S/N: LD41–Up
The Cat ET screen for factory passwords will display
the following parameters: S/N: LY71–Up
• Serial number of the ECM S/N: LY81–Up
• Engine serial number S/N: LD91–Up

S/N: LY91–Up
• Serial number for Cat ET
S/N: CPA182–Up
• Reason code
S/N: BMB132–Up
• Interlock code
S/N: CNB1100–Up
• Total tattletale
S/N: YBB1–Up
Note: Factory passwords are only valid for the S/N: CMC1107–Up
current Cat ET screen. A different set of factory
passwords will be required if you exit the current Cat S/N: YBC1–Up
ET screen. A different set of passwords will be
required to change information on another Cat ET S/N: YBD1–Up
screen. S/N: ZAD1–Up
Customer Passwords S/N: JDE1–Up
Customer passwords allow the customer to restrict S/N: BLF166–Up

access to parameters that can be changed by the S/N: JCG1–Up
customer. The customer passwords cannot be longer
than eight characters. The customer passwords may S/N: SBG1–Up
consist of alphanumeric characters. The customer
has the option of entering one or two customer S/N: JCH1–Up
passwords.
S/N: JDH1–Up
S/N: LYH1–Up
S/N: YAH1–Up
RENR5059-14 31
S/N: ZAH1–Up Electronic Control Module (ECM).

S/N: BPJ472–Up
Caterpillar Electronic Technician (ET) is used to flash
S/N: JDJ1–Up program a file into the memory of the engine's ECM.
S/N: SBJ1–Up If you do not have the flash file, use the “Flash File
S/N: SFJ1–Up Search” tool on the Service Technician Workbench
(STW) to obtain the flash file for your engine.
S/N: ZAJ1–Up Alternatively, use the “Service Software Files” feature
on SIS Web to obtain the flash file for your engine.
S/N: BRK287–Up You must have the engine serial number in order to
search for the flash file. After locating the correct
S/N: SBK1–Up flash file, download the flash file to your PC. Write
down the name of the flash file for future reference.
S/N: SEK1–Up
S/N: YAL1–Up Programming a Flash File
S/N: YAM1–Up 1. Establish communication between Cat ET and the
engine's ECM.
S/N: FDN1515–Up
2. Select “WinFlash” from the “Utilities” menu on Cat
S/N: JCN1–Up ET.
S/N: YAN1–Up
Note: If “WinFlash” will not communicate with the
S/N: LYP1–Up ECM, refer to troubleshooting without a diagnostic
code Troubleshooting, “Electronic Service Tool Will
S/N: YAP1–Up Not Communicate with ECM”.
S/N: ZAP1–Up
3. Program the flash file into the ECM.
S/N: ZBP1–Up
a. Select the engine ECM under the “Detected
S/N: GAR1–Up ECMs” .
S/N: PBR1–Up b. Press the “Browse” button in order to select the
S/N: PDR1–Up name of the flash file that will be programmed
into the ECM.
S/N: YAR1–Up
c. When the correct flash file is selected, press the
S/N: YBR1–Up
“Open” button.
S/N: ZAR1–Up
d. Verify that the “File Values” match the
S/N: ZBR1–Up application. If the “File Values” do not match the
S/N: GZS1–Up application, obtain the correct flash file.
S/N: GZT1–Up e. When the correct flash file is selected, press the
“Begin Flash” button.
S/N: YAT1–Up
S/N: YBT1–Up f. Cat ET will indicate when flash programming
has been successfully completed.
S/N: YAW1–Up
4. Start the engine and check for proper operation.
S/N: YBW1–Up Repair any active diagnostic or event codes.
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up
Flash Programming – This is a method of
programming or updating the flash file in an engine's
32 RENR5059-14
“ WinFlash”” Error Messages S/N: SBJ1–Up
If you receive any error messages during flash S/N: SFJ1–Up

programming, click on the “Cancel” button in order to S/N: ZAJ1–Up
stop the process. Access the information about the
“ECM Summary” under the “Information” menu. S/N: BRK287–Up
Make sure that you are flashing the correct file for
your engine. S/N: SBK1–Up
S/N: SEK1–Up
i02760682
S/N: YAL1–Up
System Configuration S/N: YAM1–Up
Parameters S/N: FDN1515–Up
S/N: LYH1–Up
S/N: YAH1–Up
S/N: ZAH1–Up
S/N: BPJ472–Up
S/N: JDJ1–Up
RENR5059-14 33
System configuration parameters are parameters

that affect emissions and power of the engine.
Default values for the parameters are programmed at
the factory. Some parameters may be changed by
the customer in order to suit the needs of the specific
application. Values for these parameters can be
viewed on the electronic service tool. Certain
configuration parameters are also stamped on the
engine information plate.
No password is required for programming a new
Electronic Control Module (ECM) during the first 100
hours of service life. This 100 hour “free
configuration” feature enables the customer to tailor
the programmable setpoints to the requirements of
the installation. Exceptions are “Fuel Limit” and
“Personality Module Mismatch” .
Note: If the parameters that are protected with the
factory passwords are changed, the Caterpillar
warranty may be voided.
Parameter Table
Table 7
System Configuration Parameters
Parameter Default Range Password

Required
Personality Module Interlock Yes
ECM Yes
Serial Number
Engine Serial Number 00000000 8 alphanumeric numbers No
Equipment ID 00000000000000000 17 alphanumeric numbers No
Full Load Setting (FLS) 0 -128 to +127 Yes
Full Torque Setting (FTS) 0 -128 to +127 Yes
“Fuel Ratio Control Offset (FRC)” 0 −25 to 0 No
“Rated Fuel Positon (mm)” 14 The minimum rack is based on Yes

engine power.
Fuel Correction Factor (%) 0 -25 to +25 No
Low Idle (rpm) 1000 810 to 1000 No
Droop (%) 0.0 0.0 to 10.0 No
“Governor Gain Factor” Engine rating 0 to 39,999 Yes
“Governor Minimum Stability Engine rating 0 to 39,999 Yes

Factor”
“Governor Maximum Stability Engine rating 0 to 39,999 Yes
Factor”
Acceleration delay on start-up 0 0 to 60 No
(sec)
Acceleration Rate (rpm/sec) 250 5 to 2000 No
Programmable Torque Scaling The minimum rack is based on en- The minimum rack is based on Yes
gine power. engine power.
(continued)
34 RENR5059-14
(Table 7, contd)
“Engine Cooling System SCAC SCAC or JWAC Yes
Configuration”
Cold Cylinder Cutout Disabled Enabled No

Disabled
“Cooldown Engine Speed (rpm)” 900 810 to 1800 No
“Engine Cooldown Duration (min)” 0 0 to 30 No
“Engine Prelube Duration (sec)” 0 0 to 210 No
“Crank Duration (sec)” 0 0 to 60 No
“Maximum Number of Crank 0 0 to 10 No

Cycles”
“Crank Terminate Speed (rpm)” 400 100 to 500 No
“Total Tattletale” 0 0 to 255 N/A

Injector Code (1) 0000 4 numbers No
Parameter Descriptions “ Engine Serial Number””
“ Personality Module Interlock”” Program the “Engine Serial Number” to match the
engine serial number that is stamped on the engine
The “Personality Module Interlock” is automatically information plate.
programmed by the ECM after factory passwords are
Note: When you are requesting factory passwords,
entered.
always use the engine serial number that is resident
in the ECM.
“ ECM Serial Number””
The “ECM Serial Number” is stored in the memory of “ Equipment ID””
the ECM. The “ECM Serial Number” can be
accessed by the use of the service tool. “Equipment ID” allows the customer to enter a
description into the ECM in order to identify the
engine. A maximum of 17 characters may be entered
in the field. This parameter is only for reference by
the customer. This parameter is not required.
RENR5059-14 35
“ Full Load Setting (FLS)”” “ Governor Maximum Stability Factor””

“FLS” is a number that represents the adjustment to “Governor Maximum Stability Factor” functions in
the fuel system that was made at the factory in order order to eliminate steady state speed error. The
to fine tune the fuel system. The correct value for this parameter is used by the ECM when the steady state
parameter is stamped on the engine information speed error is greater than 20 rpm.
plate. Factory passwords are required.
“ Engine Acceleration Delay on Startup””
“ Full Torque Setting (FTS)””
“Engine Acceleration Delay on Start-up” is a time
“FTS” is similar to “FLS” . Factory passwords are period that limits engine speed to low idle. This time
required. period allows the engine oil pressure to build up to a
minimum pressure.
“ Fuel Ratio Control (FRC)””
“ Engine Acceleration Rate””
The “Fuel Ratio Control” limit controls the amount of
fuel to air ratio by limiting the rack as a function of “Engine Acceleration Rate” is the rate of acceleration
boost pressure, engine speed, and altitude. The and of deceleration.
“Fuel Ratio Control” function permits an offset to be
applied to the calculation for the altitude. The offset
changes the fuel to the air ratio to a richer mixture or “ Programmable Torque Scaling””
a leaner mixture.
“Programmable Torque Scaling” is a way to derate an
engine's maximum power output without exchanging
“ Rated Fuel Position”” torque maps.
This parameter is used to limit the engine power. A
factory password is required to change this setting. “ Engine Cooling System Configuration””
This parameter is used as a switch to toggle between
“ Fuel Correction Factor”” the SCAC cooling system or the JWAC cooling
system.
“Fuel Correction Factor” is a programmable offset
that is used to improve the accuracy of the calculated
fuel usage. “ Cold Cylinder Cutout””
The cold cylinder cutout automatically stops fuel
“ Low Idle Speed”” injection to cylinders that are not firing. The fuel
injection is stopped to the cylinders until the engine
“Low Idle Speed” is the minimum allowable operating reaches operating temperature.
speed for the engine.
“ Cooldown Engine Speed””
“ Droop Slope””
This parameter defines engine speed when the
“Droop” is the downward adjustment in engine speed engine is in the cooldown mode.
at full load and at high idle.
“ Engine Cooldown Duration””
“ Governor Gain Factor””
“Governor Gain Factor” is a programmable This parameter defines the duration of the cooldown
parameter that when multiplied by the engine speed mode. Programming this parameter to 0 will disable
error determines the rate of response to an engine this function.
load.
“ Engine Prelube Duration””
“ Governor Minimum Stability Factor””
This parameter sets the engine prelubrication timeout
“Governor Minimum Stability Factor” functions in period. Programming this parameter to 0 will disable
order to eliminate steady state speed error. The this function.
parameter is used by the ECM when the steady state
speed error is less than 20 rpm. “ Crank Duration””
This parameter determines the length of time that the
starting motors will engage the flywheel before
disengaging. Programming this parameter to 0 will
prevent the ECM from engaging the starting motors.
36 RENR5059-14
“ Maximum Number of Crank Cycles”” S/N: YBC1–Up
This parameter is the total number of crank cycles S/N: YBD1–Up

that can be performed. S/N: ZAD1–Up
“ Crank Terminate Speed”” S/N: JDE1–Up

S/N: BLF166–Up
This parameter determines when the starting motor
will disengage. S/N: JCG1–Up
S/N: SBG1–Up
“ Total Tattletale””
S/N: JCH1–Up
The parameter counts the number of changes to
system parameters. S/N: JDH1–Up
S/N: LYH1–Up
“ Injector Codes””
S/N: YAH1–Up
Note: The injector codes are not part of the
“Configuration” screen on the electronic service tool. S/N: ZAH1–Up
“Injector Codes Calibration” can be found under S/N: BPJ472–Up
“Calibrations” in the “Service” menu on the electronic
service tool. S/N: JDJ1–Up
The injector code is a number that is found on each S/N: SBJ1–Up
of the unit injectors. The ECM uses this number to
compensate for manufacturing variations between S/N: SFJ1–Up
individual injectors. If you replace any of the unit S/N: ZAJ1–Up
injectors, you must reprogram the code for the new
injectors. Also, if you replace the ECM, you must S/N: BRK287–Up
reprogram all of the injector codes.
S/N: SBK1–Up
i02304187 S/N: SEK1–Up
Customer Parameters S/N: YAL1–Up

Worksheet S/N: YAM1–Up
SMCS Code: 1901-038 S/N: FDN1515–Up

S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
RENR5059-14 37
S/N: YAT1–Up (Table 9, contd)
S/N: YBT1–Up “Inj #9 e-trim”
S/N: YAW1–Up “Inj #10 e-trim”
“Inj #11 e-trim”

S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up
Table 8
i02385539
System Configuration Parameters
Parameter Worksheet
Replacing the ECM
“Engine Serial Number” SMCS Code: 1901-038
“Equipment ID” S/N: JM21–Up
“Full Load Setting (FLS)”
S/N: GD31–Up
“Full Torque Setting (FTS)”
S/N: JM31–Up
“Personality Module interlock -
Rating”
S/N: JM41–Up
“Personality Module interlock - S/N: LD41–Up

ECM”
S/N: LY71–Up
Cold Cylinder Cutout
S/N: LY81–Up
“Ether Control Configuration”
S/N: LD91–Up
“Engine Cooling System
Configuration” S/N: LY91–Up
“Rated Fuel Positon (mm)” S/N: CPA182–Up

“Engine Rotation” S/N: BMB132–Up
“Fuel Ratio Control Offset” S/N: CNB1100–Up
“Fuel Correction Factor” S/N: YBB1–Up
Table 9
S/N: CMC1107–Up
Injector Codes S/N: YBC1–Up
“Inj #1 e-trim” S/N: YBD1–Up
“Inj #2 e-trim” S/N: ZAD1–Up
“Inj #3 e-trim” S/N: JDE1–Up
“Inj #4 e-trim” S/N: BLF166–Up
“Inj #5 e-trim” S/N: JCG1–Up
“Inj #6 e-trim” S/N: SBG1–Up
“Inj #7 e-trim” S/N: JCH1–Up
“Inj #8 e-trim” S/N: JDH1–Up
S/N: LYH1–Up
(continued) S/N: YAH1–Up
38 RENR5059-14
S/N: ZAH1–Up
NOTICE
S/N: BPJ472–Up
Keep all parts clean from contaminants.
S/N: JDJ1–Up
Contaminants may cause rapid wear and shortened
S/N: SBJ1–Up component life.
S/N: SFJ1–Up
The Electronic Control Module (ECM) contains no
S/N: ZAJ1–Up moving parts. Replacement of the ECM can be
S/N: BRK287–Up costly. Replacement can also be a time consuming
task. Follow the troubleshooting procedures in this
S/N: SBK1–Up manual in order to be sure that replacing the ECM
will correct the problem. Verify that the suspect ECM
S/N: SEK1–Up is the cause of the problem.
S/N: YAL1–Up Note: Ensure that the ECM is receiving power and
S/N: YAM1–Up that the ECM is properly wired to the negative battery
circuit before a replacement of the ECM is attempted.
S/N: FDN1515–Up Refer to Troubleshooting, “Electrical Power Supply”.
S/N: JCN1–Up Perform the following procedure in order to replace
the ECM.
S/N: YAN1–Up
1. Connect Caterpillar Electronic Technician (ET) to
S/N: LYP1–Up
the service tool connector for the engine.
S/N: YAP1–Up
2. Print the parameters from the “Configuration”
S/N: ZAP1–Up screen on Cat ET. If a printer is unavailable, record
all of the parameters. Record any logged
S/N: ZBP1–Up
diagnostic codes and logged event codes for your
S/N: GAR1–Up records. Record the injector codes from the
“Calibrations” screen in the “Service” menu on Cat
S/N: PBR1–Up
ET.
S/N: PDR1–Up
a. Copy the settings for the engine monitoring
S/N: YAR1–Up system. Refer to Troubleshooting, “Event
Codes”.
S/N: YBR1–Up
b. Copy the injector trim codes. The injector trim
S/N: ZAR1–Up
codes are not part of the “Configuration” screen
S/N: ZBR1–Up on Caterpillar Electronic Technician (ET).
“Injector Codes Calibration” can be found under
S/N: GZS1–Up
“Calibrations” in the “Service” menu on Cat ET.
S/N: GZT1–Up
Note: The injector trim code is a number that is
S/N: YAT1–Up found on each of the unit injectors. The ECM uses
this number to compensate for manufacturing
S/N: YBT1–Up
variations between individual injectors. If you
S/N: YAW1–Up replace any of the unit injectors, you must
reprogram the trim code for the new injectors. Also,
S/N: YBW1–Up if you replace the ECM, you must reprogram all of
S/N: BGX120–Up the trim codes.
S/N: GZY1–Up 3. Use the “Copy Configuration/ECM Replacement”

feature that is found under the “Service” menu on
S/N: JCY1–Up Cat ET. Select “Load from ECM” in order to copy
S/N: YAY1–Up the configuration from the suspect ECM.
S/N: YAZ1–Up
RENR5059-14 39
Note: If the “Copy Configuration” process fails and Note: If the “Copy Configuration” process fails and
the parameters were not obtained in Step 2.b, the the parameters were not obtained in Step 2.b, the
parameters must be obtained elsewhere. Some parameters must be obtained elsewhere. Some
parameters are stamped on the engine information parameters are stamped on the engine information
plate, but most parameters must be obtained from plate, but most parameters must be obtained from
the factory. the factory.
4. Remove the ECM. c. If necessary, program the engine monitoring

a. Turn the battery disconnect switch to the OFF system. Refer to Troubleshooting, “Event
position. Codes”.
8. Program the injector trim codes.
b. Disconnect the ECM connectors J1/P1 and J2/
P2. 9. Calibrate the injection timing. Refer to
Troubleshooting, “Engine Speed/Timing Sensor -
c. Remove the mounting bolts from the ECM.
Calibrate”.
d. Disconnect the ECM ground strap from the 10. Check for diagnostic codes and event codes.
engine.
5. Install the replacement ECM.
a. Use the old mounting hardware to install the

replacement ECM. Make sure that the mounting
hardware is free of damage. Ensure that the
ECM mounting hardware is installed correctly.
b. The ECM must be able to drift in the rubber

grommets.
c. Install the ECM ground strap on the engine.
d. Reconnect ECM connectors J1/P1 and J2/P2.

Torque the allen head screw for the 70 pin ECM
connector. Refer to Troubleshooting, “Inspecting
Electrical Connectors” for the correct torque
value for your application.
NOTICE
If the flash file and engine application are not
matched, engine damage may result.
6. Flash program the ECM. Refer to Troubleshooting,

“Flash Programming” for the correct procedure.
7. Configure the ECM.
a. If the “Copy Configuration” process from Step 3

was successful, return to the “Copy
Configuration/ECM Replacement” screen on
Cat ET and select “Program ECM” . Proceed to
Step 9.
b. If the “Copy Configuration” process was

unsuccessful, program the ECM parameters.
The parameters must match the parameters
from Step 2.b.
40 RENR5059-14
Troubleshooting without a Diagnostic Code
Troubleshooting without a S/N: ZAJ1–Up

S/N: BRK287–Up
Diagnostic Code
S/N: SBK1–Up
S/N: SEK1–Up
S/N: YAL1–Up
i02554797
S/N: YAM1–Up
Symptoms S/N: FDN1515–Up
SMCS Code: 1000-038; 1901-038 S/N: JCN1–Up
S/N: LYH1–Up Some engine symptoms can be unrelated to the
S/N: YAH1–Up electronic control system. Gather information about
the complaint that describes the symptoms. Verify
S/N: ZAH1–Up that the complaint is not due to normal engine
operation.
S/N: BPJ472–Up
Perform the following steps in order to determine the
S/N: JDJ1–Up problem.
S/N: SBJ1–Up 1. Repair all active diagnostic codes.
S/N: SFJ1–Up 2. Gather operator information.
RENR5059-14 41
3. Verify that the complaint is not due to normal S/N: JM41–Up

engine operation.
S/N: LD41–Up
4. Perform a visual inspection of the engine. Inspect
S/N: LY71–Up
the following items:
S/N: LY81–Up
• Wiring
S/N: LD91–Up
• Connectors
S/N: LY91–Up
• Fuel level S/N: CPA182–Up
• Fuel supply S/N: BMB132–Up
• Engine oil level S/N: CNB1100–Up

S/N: YBB1–Up
• Engine oil supply
S/N: CMC1107–Up
• Coolant level
S/N: YBC1–Up
• Intake air system
S/N: YBD1–Up
• Air exhaust system S/N: ZAD1–Up
5. Check the wiring and the connectors for the S/N: JDE1–Up
following problems:
S/N: BLF166–Up
• Damage S/N: JCG1–Up
• Abrasion S/N: SBG1–Up
• Corrosion S/N: JCH1–Up

S/N: JDH1–Up
• Incorrect attachment
S/N: LYH1–Up
6. Check for any logged diagnostic codes.
S/N: YAH1–Up
• Determine if the logged diagnostic codes
S/N: ZAH1–Up
correlate to probable causes.
S/N: BPJ472–Up
• Determine if the logged diagnostic codes occur
at the same time as the symptoms. S/N: JDJ1–Up
S/N: SBJ1–Up
• Determine if the logged diagnostic codes are
logged repeatedly. S/N: SFJ1–Up
If these inspections do not reveal any problems, use S/N: ZAJ1–Up
the procedure that best describes the symptoms.
S/N: BRK287–Up
i05848426 S/N: SBK1–Up
Alternator S/N: SEK1–Up
(Charging Problem and/or Noisy S/N: YAL1–Up
Operation) S/N: YAM1–Up

S/N: FDN1515–Up
SMCS Code: 1405-035
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
42 RENR5059-14
S/N: ZAP1–Up
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up
S/N: PDR1–Up
S/N: YAR1–Up
S/N: YBR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: GZS1–Up
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up
Probable Causes
• Alternator drive belts
• Alternator drive pulley
• Alternator bearings
• Charging circuit
• Regulator
• Alternator
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
RENR5059-14 43
Table 10
Troubleshooting Test Steps Values Results
1. Condition of the Alternator Drive Belts Drive belt Result: The alternator drive belts are in good condition and
the belt tension is correct.
A. Inspect the condition of the alternator drive belts.
Proceed to Test Step 2.
B. Check the belt tension. If the engine is equipped with an
automatic belt tensioner, check the automatic belt tensioner. Result: The alternator drive belts are not in good condition
or the belt tension is incorrect.
Excessive belt tension can result in damage to the alternator.
Repair: If the alternator drive belts are worn or damaged,
replace the belts. Refer to Disassembly and Assembly for
the correct procedure.
If necessary, replace the automatic belt tensioner. Refer to

Disassembly and Assembly for the correct procedure.
2. Condition of the Alternator Drive Pulley Alternator Drive Result: There is excessive wear on the alternator drive
Pulley pulley.
A. Check the condition of the alternator drive pulley. Look for
deep grooves that have been worn into the pulley by the belt. Repair: Replace the pulley.
Check that the nut for the pulley has not become loose.
Result: The alternator drive pulley nut was loose.
Repair: Tighten the nut.
Result: There is not excessive wear on the alternator drive

pulley.
3. Wear of the Alternator Bearings Alternator bearings Result: The alternator bearings are OK.
A. Check the alternator bearings for signs of wear. Proceed to Test Step 4.
Result: The alternator bearings are not OK.
Repair: Repair the alternator or replace the alternator, as

needed. Refer to Disassembly and Assembly for the correct
procedure.
4. Operation of the Alternator or Regulator Regulator and Result: The regulator and alternator are operating
alternator properly.
A. Verify that the alternator or the regulator is operating cor-
rectly. Refer to Special Instruction, REHS0354, “Charging Proceed to Test Step 5.
System Troubleshooting” for the proper testing procedures.
Result: The regulator and alternator are not operating
properly.
Repair: Repair the alternator and regulator or replace the

alternator and regulator, as needed. Refer to Disassembly
and Assembly for the correct procedure.
5. Inspection of the Charging Circuit Charging circuit Result: The charging circuit is not working properly.
A. Inspect the battery cables, wiring, and connections in the Repair: Clean all connections and tighten all connections.
charging circuit. Replace any faulty parts.
44 RENR5059-14
Complete the procedure in the order in which the S/N: BRK287–Up

steps are listed.
S/N: SBK1–Up
i02421020 S/N: SEK1–Up
Can Not Reach Top Engine S/N: YAL1–Up
RPM S/N: YAM1–Up

S/N: FDN1515–Up
SMCS Code: 1000-038; 1901-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
Note: If this problem occurs under load, refer to the
S/N: YAH1–Up diagnostic procedure Troubleshooting, “Low Power/
S/N: ZAH1–Up Poor Or No Response To Throttle”.
S/N: BPJ472–Up Probable Causes

S/N: JDJ1–Up
• Derated engine
S/N: SBJ1–Up
• Cold mode
S/N: SFJ1–Up
• Flash file
S/N: ZAJ1–Up
• Throttle signal
RENR5059-14 45
• Fuel supply 2. Cold weather adversely affects the characteristics

of the fuel. Refer to the Operation and
• Air inlet restriction Maintenance Manual for information on improving
• Exhaust restriction the characteristics of the fuel during cold weather
operation.
• Leaks in air system
3. Check the fuel pressure during engine cranking.
• Valve adjustment Check the fuel pressure after the fuel filter. Refer
to the Systems Operation/Testing and Adjusting
• Injectors manual for the correct pressure values. If the fuel
pressure is low, replace the fuel filters. If the fuel
• Faulty accessory equipment
pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling and
Recommended Actions fuel pressure regulating valve.
Derate Air Inlet Restriction
Connect Caterpillar Electronic Technician (ET) and
Replace plugged air filters and/or clean the filters.
check for an active derate event. A derate status flag
Leaks in the air inlet manifold system can lower Inlet
will appear on Cat ET if an active engine derate is
manifold pressure.
occurring. In order to view active events, go to the
“Events” menu under “Diagnostics” . Refer to
Troubleshooting, “Troubleshooting with an Event Exhaust Restriction
Code” for the specific events for this application.
Check the exhaust system for restrictions and/or for
leaks.
Cold Mode
Use Cat ET to verify that the engine has exited cold Valve Adjustment
mode. A status flag will appear if the engine is
operating in cold mode. This may limit engine speed. Check the valve lash setting.
Flash File Injectors

Verify that the correct flash file has been installed. Use Cat ET to determine if any active diagnostic
codes are present for the injector solenoids. Perform
Throttle Signal the “Injector Solenoid Test” . Observe that the injector
solenoids are being energized on Cat ET. Perform
Use Cat ET in order to monitor the status of the the “Cylinder Cutout Test” . Locate the misfiring
throttle. Observe the throttle position. Verify that the cylinder. Refer to the diagnostic functional test
throttle position is smooth from low idle to high idle. Troubleshooting, “Injector Solenoids”.
The throttle position should reach 100 percent at high
idle. Faulty Accessory Equipment
Fuel Supply Check attached accessory equipment. Ensure that
the accessory equipment is not lugging down the
Check fuel lines for the following problems: engine.
restrictions, collapse and pinched line. Repair the
lines and/or replace the lines. i02433524
1. Check the fuel tank for foreign objects which may

block the fuel supply. Check for air leaks in the
Coolant Temperature Is Too
suction line of the fuel pump. Prime the fuel High
system after you perform the following
procedures: SMCS Code: 1350-038; 1901-038
• Replacing the fuel filters S/N: JM21–Up

S/N: GD31–Up
• Working on the low pressure fuel supply circuit
S/N: JM31–Up
• Replacing fuel injectors
S/N: JM41–Up
46 RENR5059-14

S/N: LYH1–Up
Probable Causes
S/N: YAH1–Up
• Faulty temperature regulator
S/N: ZAH1–Up
• Radiator
S/N: BPJ472–Up
• Low coolant level
S/N: JDJ1–Up
S/N: SBJ1–Up • Faulty jacket water coolant pump
S/N: SFJ1–Up • Faulty engine cooling fan (if equipped)
S/N: ZAJ1–Up • Faulty pressure relief valve

S/N: BRK287–Up
Recommended Actions
S/N: SBK1–Up
S/N: SEK1–Up
Faulty Temperature Regulator
S/N: YAL1–Up Check the water temperature regulator. A water
temperature regulator that does not open, or a water
S/N: YAM1–Up temperature regulator that only opens part of the way
can cause overheating.
S/N: FDN1515–Up
S/N: JCN1–Up Radiator
S/N: YAN1–Up
1. Check the cooling fins on the radiator for dirt and/
S/N: LYP1–Up or for debris. Remove the dirt and/or debris.
S/N: YAP1–Up Inspect the cooling fins on the radiator for
damage. Refer to the Systems Operation/Testing
S/N: ZAP1–Up and Adjusting manual.
RENR5059-14 47
2. Check the radiator for internal blockage. Check the 2. Check the fan clutch, if equipped. A fan clutch or a
temperature difference between the top and the hydraulic driven fan that is not turning at the
bottom of the radiator. correct speed can cause improper air speed
across the radiator core. The lack of proper air
Low Coolant Level flow across the radiator core can cause the
coolant not to cool to the proper temperature
1. Verify that the cooling system is filled to the proper differential.
level. If the coolant level is too low, air will get into
the cooling system. Air in the cooling system will Faulty Pressure Relief Valve
cause a reduction in coolant flow and bubbles in
the coolant. Air bubbles will keep coolant away Check operation of the pressure relief valve and the
from the engine parts, which will prevent the radiator cap. If necessary, clean the pressure relief
transfer of heat to the coolant. Low coolant level is valve and/or the radiator cap. Check that the seating
surface of the valve is clean and undamaged. If
caused by leaks or incorrectly filling the radiator. necessary, install new parts.
2. Check the mixture of antifreeze and water. The
mixture should be approximately 50 percent water i06910188
and 50 percent antifreeze with 3 to 6 percent
coolant conditioner. Refer to Operation and ECM Will Not Accept Factory
Maintenance Manual. If the coolant mixture is Passwords
incorrect, drain the system. Put the correct mixture
of water, antifreeze and coolant conditioner in the SMCS Code: 1901-038
cooling system.
S/N: JM21–Up
3. Check for air in the cooling system. Air can enter
the cooling system in different ways. The most S/N: GD31–Up
common causes of air in the cooling system are S/N: JM31–Up
the incorrect filling of the cooling system and
combustion gas leakage into the cooling system. S/N: JM41–Up
Combustion gas can get into the system through S/N: LD41–Up
inside cracks, a damaged cylinder head, or a
damaged cylinder head gasket. S/N: LY71–Up
4. Check the cooling system hoses and clamps. S/N: LY81–Up

Damaged hoses with leaks can normally be seen. S/N: LD91–Up
Hoses that have no visual leaks can soften during
operation. The soft areas of the hose can become S/N: LY91–Up
kinked or crushed during operation. These areas S/N: CPA182–Up
of the hose can restrict the coolant flow. Hoses
become soft and/or get cracks after a period of S/N: BMB132–Up
time. The inside of a hose can deteriorate, and the S/N: CNB1100–Up
loose particles of the hose can restrict the coolant
flow. S/N: YBB1–Up
S/N: CMC1107–Up
Faulty Jacket Water Coolant Pump
S/N: YBC1–Up
Inspect the impeller vanes at the jacket water pump S/N: YBD1–Up
for damage and/or for erosion. Repair impeller vanes
and/or replace the impeller vanes. S/N: ZAD1–Up
S/N: JDE1–Up
Faulty Engine Cooling Fan (if equipped)
S/N: BLF166–Up
1. If the fan is belt driven, check for loose drive belts.
S/N: JCG1–Up
A loose fan drive belt will cause a reduction in the
air flow across the radiator. Check the fan drive S/N: SBG1–Up
belt for proper belt tension. Adjust the tension of
S/N: JCH1–Up
the fan drive belt, if necessary. Refer to Operation
and Maintenance Manual. S/N: JDH1–Up
48 RENR5059-14
S/N: LYH1–Up Probable Causes

S/N: YAH1–Up One of the following items may not be recorded
correctly on the Cat ® Electronic Technician (ET):
S/N: ZAH1–Up
• Passwords
S/N: BPJ472–Up
S/N: JDJ1–Up • Serial numbers
S/N: SBJ1–Up • Total tattletale

S/N: SFJ1–Up • Reason code
S/N: ZAJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
S/N: SEK1–Up
S/N: YAL1–Up
S/N: YAM1–Up
S/N: FDN1515–Up
S/N: JCN1–Up
S/N: YAN1–Up
S/N: LYP1–Up
S/N: YAP1–Up
S/N: ZAP1–Up
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up
S/N: PDR1–Up
S/N: YAR1–Up
S/N: YBR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: GZS1–Up
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up
RENR5059-14 49
Recommended Actions
Table 11
Troubleshooting Test Steps Values Steps
1. Check the Factory Passwords Factory Result: The factory passwords were not accepted in Cat ET.
Passwords
A. Verify that the correct passwords were entered. Repair: Check every character in each password and remove
the electrical power from the engine for 30 seconds and then
B. Verify that Cat ® Electronic Technician (ET) is displaying the retry.
“Enter Factory Passwords” dialog box.
Use Cat ET to verify that the following information has been en-
tered correctly: Engine Serial Number, Serial Number for the
Electrical Control Module, Serial Number for Cat ET, Total Tat-
tletale, and Reason Code.
For additional information, refer to Troubleshooting, S/N: JDE1–Up

“Factory Passwords”.
S/N: BLF166–Up
If the procedure did not correct the issues, contact
your Cat dealer Technical Communicator (TC). For S/N: JCG1–Up
further assistance, your TC can confer with the S/N: SBG1–Up
Dealer Solutions Network (DSN).
S/N: JCH1–Up
i02561478
S/N: JDH1–Up
ECM Will Not Communicate S/N: LYH1–Up
with Other Systems or Display S/N: YAH1–Up
Modules S/N: ZAH1–Up
SMCS Code: 1901-038 S/N: BPJ472–Up
S/N: JM21–Up S/N: JDJ1–Up
S/N: GD31–Up S/N: SBJ1–Up
S/N: JM31–Up S/N: SFJ1–Up
S/N: JM41–Up S/N: ZAJ1–Up
S/N: LD41–Up S/N: BRK287–Up
S/N: LY71–Up S/N: SBK1–Up
S/N: LY81–Up S/N: SEK1–Up
S/N: LD91–Up S/N: YAL1–Up
S/N: LY91–Up S/N: YAM1–Up
S/N: CPA182–Up S/N: FDN1515–Up
S/N: BMB132–Up S/N: JCN1–Up
S/N: CNB1100–Up S/N: YAN1–Up
S/N: YBB1–Up S/N: LYP1–Up
S/N: CMC1107–Up S/N: YAP1–Up
S/N: YBC1–Up S/N: ZAP1–Up
S/N: YBD1–Up S/N: ZBP1–Up
S/N: ZAD1–Up S/N: GAR1–Up

50 RENR5059-14
S/N: PBR1–Up CAN data link (if applicable)

S/N: PDR1–Up Verify that the CAN data link does not have an open
S/N: YAR1–Up or short circuit. Refer to the diagnostic functional test
Troubleshooting, “CAN Data Link”.
S/N: YBR1–Up
i02561494
S/N: ZAR1–Up
S/N: ZBR1–Up Electronic Service Tool Will
S/N: GZS1–Up Not Communicate with ECM
S/N: GZT1–Up SMCS Code: 1901-038
S/N: YAT1–Up S/N: JM21–Up
S/N: YBT1–Up S/N: GD31–Up
S/N: YAW1–Up S/N: JM31–Up
S/N: YBW1–Up S/N: JM41–Up
S/N: BGX120–Up S/N: LD41–Up
S/N: GZY1–Up S/N: LY71–Up
S/N: JCY1–Up S/N: LY81–Up
S/N: YAY1–Up S/N: LD91–Up
S/N: YAZ1–Up S/N: LY91–Up
Probable Causes S/N: CPA182–Up
• Electronic Control Module (ECM) S/N: BMB132–Up
• Connector or wiring problem S/N: CNB1100–Up

S/N: YBB1–Up
• Cat Data Link
S/N: CMC1107–Up
• CAN data link (if applicable)
S/N: YBC1–Up
Recommended Actions S/N: YBD1–Up
ECM S/N: ZAD1–Up

S/N: JDE1–Up
Connect Caterpillar Electronic Technician (ET). If the
ECM does not communicate with the Cat ET, perform S/N: BLF166–Up
the diagnostic functional test Troubleshooting,
“Electronic Service Tool Will Not Communicate With S/N: JCG1–Up
ECM”.
S/N: SBG1–Up
Connectors or Wiring S/N: JCH1–Up
Check for correct installation of the ECM connectors. S/N: JDH1–Up

Check any machine connector or the customer
connector in the circuit for correct installation. Refer S/N: LYH1–Up
to the diagnostic functional test Troubleshooting, S/N: YAH1–Up
“Inspecting Electrical Connectors”.
S/N: ZAH1–Up
Cat Data Link S/N: BPJ472–Up
Verify that the Cat Data Link does not have an open S/N: JDJ1–Up
or short circuit. Refer to the diagnostic functional test
Troubleshooting, “Cat Data Link”. S/N: SBJ1–Up
RENR5059-14 51
S/N: SFJ1–Up • Electrical power supply to the service tool

connector
S/N: ZAJ1–Up
• Caterpillar Electronic Technician (ET) and related
S/N: BRK287–Up
hardware
S/N: SBK1–Up
• Electrical power supply to the Electronic Control
S/N: SEK1–Up Module (ECM)
S/N: YAL1–Up • Flash file
S/N: YAM1–Up
• Cat Data Link
S/N: FDN1515–Up
S/N: JCN1–Up
Recommended Actions
Start the engine. If the engine starts, but the ECM will
S/N: YAN1–Up not communicate with Cat ET, continue with this
S/N: LYP1–Up procedure. If the engine will not start, refer to
Troubleshooting, “Engine Cranks but Will Not Start”.
S/N: YAP1–Up If the engine will not crank, refer to Troubleshooting,
“Engine Will Not Crank”.
S/N: ZAP1–Up
S/N: ZBP1–Up Configuration for the Communications
S/N: GAR1–Up Adapter
S/N: PBR1–Up 1. Access “Preferences” under the “Utilities” menu on
Cat ET.
S/N: PDR1–Up
2. Verify that the correct “Communications Interface
S/N: YAR1–Up
Device” is selected.
S/N: YBR1–Up
3. Verify that the correct port is selected for use by
S/N: ZAR1–Up the communication adapter.
S/N: ZBR1–Up Note: The most commonly used port is “COM 1” .
S/N: GZS1–Up
4. Check for any hardware that is utilizing the same
S/N: GZT1–Up port as the communications adapter. If any
devices are configured to use the same port, exit
S/N: YAT1–Up
or close the software programs for that device.
S/N: YBT1–Up
S/N: YAW1–Up
Electrical Connectors
S/N: YBW1–Up Check for correct installation of the J1/P1 and J2/P2
ECM connectors and of the service tool connector.
S/N: BGX120–Up Refer to Troubleshooting, “Inspecting Electrical
Connectors”.
S/N: GZY1–Up
S/N: JCY1–Up Communication Adapter and/or Cables
S/N: YAY1–Up 1. If you are using a “Communication Adapter II” ,
ensure that the firmware and software for the
S/N: YAZ1–Up
communication adapter are the most current files
Probable Causes that are available. If the firmware and software do
not match, the communication adapter will not
• Configuration for the communications adapter communicate with Cat ET.
• Electrical connectors 2. Disconnect the communication adapter and the

cables from the service tool connector. Reconnect
• Communication adapter and/or cables the communication adapter to the service tool
connector.
52 RENR5059-14
3. Verify that the correct cable is being used between S/N: LY71–Up
the communication adapter and the service tool
S/N: LY81–Up
connector. Refer to Troubleshooting, “Electronic
Service Tools”. S/N: LD91–Up
S/N: LY91–Up
Electrical Power Supply to the Service
S/N: CPA182–Up
Tool Connector
S/N: BMB132–Up
Verify that battery voltage is present between
terminals A and B of the service tool connector. If the S/N: CNB1100–Up
communication adapter is not receiving power, the
display on the communication adapter will be blank. S/N: YBB1–Up
S/N: CMC1107–Up
Cat ET and Related Hardware
S/N: YBC1–Up
In order to eliminate Cat ET and the related hardware
as the problem, connect Cat ET to a different engine. S/N: YBD1–Up
If the same problem occurs on a different engine,
check Cat ET and the related hardware in order to S/N: ZAD1–Up
determine the cause of the problem.
S/N: JDE1–Up
Electrical Power Supply to the Electronic S/N: BLF166–Up
Control Module (ECM) S/N: JCG1–Up
Check power to the ECM. Refer to Troubleshooting, S/N: SBG1–Up

“Electrical Power Supply”. S/N: JCH1–Up
Note: If the ECM is not receiving battery voltage, the S/N: JDH1–Up
ECM will not communicate.
S/N: LYH1–Up
Flash File S/N: YAH1–Up
Ensure that the correct flash file is properly installed S/N: ZAH1–Up
in the ECM.
S/N: BPJ472–Up
Note: The new ECM does not have a flash file. The
engine will not start and the engine will not S/N: JDJ1–Up
communicate with Cat ET until the flash file has been S/N: SBJ1–Up
installed. Refer to Troubleshooting, “Flash
Programming”. S/N: SFJ1–Up
S/N: ZAJ1–Up
Cat Data Link
S/N: BRK287–Up
Troubleshoot the Cat Data Link for possible
problems. Refer to Troubleshooting, “Cat Data Link”. S/N: SBK1–Up
S/N: SEK1–Up
i02526060
S/N: YAL1–Up
Engine Cranks but Will Not S/N: YAM1–Up
Start S/N: FDN1515–Up
RENR5059-14 53
S/N: GAR1–Up Note: If Cat ET will not communicate with the ECM,
the problem is most likely with the electrical power
S/N: PBR1–Up supply to the ECM. Refer to Troubleshooting,
S/N: PDR1–Up “Electrical Power Supply”.
S/N: YAR1–Up Fuel Supply

S/N: YBR1–Up
1. Visually check the fuel level. Do not rely on the fuel
S/N: ZAR1–Up gauge only. If necessary, add fuel. If the engine
S/N: ZBR1–Up has been run out of fuel, it will be necessary to
prime the fuel system. Refer to Operation and
S/N: GZS1–Up Maintenance Manual for the correct procedure.
S/N: GZT1–Up 2. Check the fuel lines for the following problems:
S/N: YAT1–Up restrictions, collapsed lines and pinched lines. If
problems are found with the fuel lines, repair the
S/N: YBT1–Up lines and/or replace the lines.
S/N: YAW1–Up 3. Check the fuel tank for foreign objects which may
S/N: YBW1–Up block the fuel supply.
S/N: BGX120–Up NOTICE

S/N: GZY1–Up Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
S/N: JCY1–Up minutes before cranking the engine again.
S/N: YAY1–Up
S/N: YAZ1–Up 4. Prime the fuel supply system if any of the following
procedures have been performed:
Probable Causes
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Event codes
• Replacement of unit injectors
• Fuel supply
Note: A sight glass in the supply line is helpful in
• Electrical power supply to the Electronic Control diagnosing air in the fuel. Refer to the Systems
Module (ECM) Operation/Testing and Adjusting manual for more
information.
• Starting aids (if applicable)
5. Cold weather adversely affects the characteristics
• Engine shutdown switches (if applicable) of the fuel. Refer to the Operation and
• Engine speed/timing Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
• Unit injectors operation.
• Combustion 6. Check fuel flow after the fuel filters. If the fuel flow
is low, replace the fuel filters. If the fuel flow is still
Recommended Actions low, check the following items: fuel transfer pump,
fuel transfer pump coupling and fuel pressure
Diagnostic Codes, Event Codes, and regulating valve.
Electrical Power Supply to the ECM Starting Aids (if applicable)
Certain diagnostic codes and/or event codes may
prevent the engine from starting. Connect the 1. If cold ambient conditions exist, check operation of
Caterpillar Electronic Technician (ET) and check for starting aids. Verify that the ether system is
active codes and/or for logged codes. Troubleshoot operating correctly. Refer to Troubleshooting,
any codes that are present before continuing with this “Ether Injection System”.
procedure.
54 RENR5059-14
2. Ensure the proper operation of the jacket water S/N: LY71–Up

heater. Repair the jacket water heater and/or
S/N: LY81–Up
replace the jacket water heater, if necessary.
S/N: LD91–Up
3. Check for presence of solidified fuel (wax).
S/N: LY91–Up
Engine Shutdown Switches (if S/N: JDE1–Up
applicable)
S/N: JCG1–Up
The engine shutdown switches should be in the OFF S/N: LYH1–Up
position. Use Cat ET to verify the status of the
shutdown switches. When a shutdown occurs, the S/N: YAL1–Up
keyswitch must be turned to the OFF position for at
least 15 seconds before restarting the engine. S/N: LYP1–Up
Engine Speed/Timing Probable Causes

• Maintenance intervals and/or incorrect oil
1. Crank the engine and observe the engine speed
on the Cat ET status screen. If Cat ET indicates • Engine oil
zero rpm, refer to Troubleshooting, “Engine
Speed/Timing Sensor”. • Oil pressure
Note: Upon initial cranking, the status for engine • Air system
speed may indicate that the engine speed signal is
abnormal. This message will be replaced with an • Fuel filters
engine speed once the ECM is able to calculate a
speed from the signal. Recommended Actions
2. Ensure that the timing reference gear is installed Note: The procedures have been listed in order of
correctly. The engine will not start if the gear was probability. Complete the procedures in the order of
installed backward. Check for proper orientation the listed test steps.
between the crankshaft and camshaft drive gears.
Correct the orientation and/or replace the drive
gear, if necessary. Refer to the Disassembly and
Assembly manual.
Unit Injectors
Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids are
being energized by the ECM. Refer to
Troubleshooting, “Injector Solenoids” for additional
information.
Combustion
Check for mechanical problems in the combustion
system.
i05326518
Engine Has Early Wear

SMCS Code: 1000-038; 1901-038
S/N: JM21–Up
S/N: GD31–Up
S/N: LD41–Up
RENR5059-14 55
Table 12
1. Incorrect Maintenance Intervals and/or Incorrect Oil Maintenance Result: The engine oil was changed at the interval that is
intervals recommended by the engines Operation and Mainte-
A. Use engine oil that is recommended and change the engine oil nance Manual and S-O-S oil analysis.
at the interval that is recommended by the engines Operation and
Maintenance Manual and by the interval suggested from S-O-S oil Proceed to Test Step 2.
analysis.
Result: The engine oil was not changed at the interval
that is recommended by the engines Operation and Main-
tenance Manual.
Repair: Use at least the minimum grade of Cat oil.
Change the engine oil at the interval that is recom-

mended. Repair or replace any damaged parts.
Verify that the repair eliminated the problem.
2. Contaminated Engine Oil Contamination Result: The oil is contaminated.
A. Obtain an S-O-S oil analysis. The analysis will contribute to a Repair: Determine the reason for any contamination of
better understanding of oil contamination. the engine oil and make the necessary repairs. Drain the
crankcase and refill the crankcase with clean engine oil.
B. Check the oil filter bypass valve. Install new engine oil filters. Refer to the engines Opera-
tion and Maintenance Manual.
If the oil filter bypass valve is open, the oil will not be filtered. Verify that the repair eliminated the problem.
Check the oil filter bypass valve for a weak spring or for a broken
spring. If the spring is broken, replace the spring. Verify that the oil Result: The oil is not contaminated.
bypass valve is operating correctly. Refer to the Disassembly and
Assembly manual. Proceed to Test Step 3.
Refer to the Caterpillar guidelines for “Reusability and Salvage/

Repair” for determining if the replacement of parts is necessary in
order to perform a quality repair.
3. Low Oil Pressure Restriction Result: The inlet tube has a restriction.
A. Engine oil that is contaminated with another liquid can cause Repair: Clear the obstruction.
low engine oil pressure. High engine oil level can be an indication Verify that the repair eliminated the problem.
of contamination. Obtain an analysis of the engine oil.
Result: The inlet tube does not have a restriction.
B. The inlet screen of the suction tube for the engine oil pump can
have a restriction. This restriction will cause cavitation and a loss Proceed to Test Step 4.
of engine oil pressure. Check the inlet screen on the suction tube
and remove any material that may be restricting engine oil flow.
When some components of the engine show wear in a short time,

the cause can be a restriction in a passage for engine oil. An indi-
cator for the engine oil pressure may indicate sufficient pressure,
but a component is worn due to a lack of lubrication. In such a
case, look at the passage for the engine oil supply to the compo-
nent. Refer to Systems Operation/Testing and Adjusting, “Lubrica-
tion System” for additional information.
(continued)
56 RENR5059-14
(Table 12, contd)

4. Leaks in Air System Air leak Result: There are no air leaks.
A. A leak in the air intake system may allow unfiltered air into the Proceed to Test Step 5.
engine. Inspect the air intake system for streaks which may indi-
cate a leakage of unfiltered air. Inspect all of the gaskets and the Result: There are air leaks.
connections.
Repair: Repair any leaks.
5. Inspect the Fuel Filters for Contamination Fuel filters Result: The fuel has contamination.
A. Remove the fuel filters. Inspect the fuel filters for contamina- Repair: Determine the cause of any contamination and
tion. Contaminants in the fuel such as hydrogen sulfide and sulfur make the necessary repairs.
can lead to the formation of acids in the crankcase. Obtain a fuel
analysis. Install new fuel filters. Refer to the Operation and Mainte-
nance Manual.
If the procedure did not correct the issue, contact S/N: JDE1–Up
your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the S/N: BLF166–Up
Dealer Solutions Network (DSN). S/N: JCG1–Up
i05451574 S/N: SBG1–Up
S/N: JCH1–Up
Engine Has Early Wear
S/N: JDH1–Up
SMCS Code: 1000-038; 1901-038
S/N: LYH1–Up
S/N: JM21–Up
S/N: YAH1–Up
S/N: GD31–Up
S/N: ZAH1–Up
S/N: JM31–Up
S/N: BPJ472–Up
S/N: JM41–Up
S/N: JDJ1–Up
S/N: LD41–Up
S/N: SBJ1–Up
S/N: LY71–Up
S/N: SFJ1–Up
S/N: LY81–Up
S/N: ZAJ1–Up
S/N: LD91–Up
S/N: BRK287–Up
S/N: LY91–Up
S/N: SBK1–Up
S/N: CPA182–Up
S/N: SEK1–Up
S/N: BMB132–Up
S/N: YAL1–Up
S/N: CNB1100–Up
S/N: YAM1–Up
S/N: YBB1–Up
S/N: FDN1515–Up
S/N: CMC1107–Up
S/N: JCN1–Up
S/N: YBC1–Up
S/N: YAN1–Up
S/N: YBD1–Up
S/N: LYP1–Up
S/N: ZAD1–Up
S/N: YAP1–Up
RENR5059-14 57
S/N: ZAP1–Up
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up
S/N: PDR1–Up
S/N: YAR1–Up
S/N: YBR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: GZS1–Up
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up
Probable Causes
• Incorrect maintenance intervals and/or incorrect
oil
• Contaminated engine oil
• Low oil pressure

• Leaks in the air system
• Inspect the fuel filters for contamination.
Recommended Actions
probability. Complete the procedures in order.
58 RENR5059-14
Table 13
1. Incorrect Maintenance Intervals and/or Incorrect Oil Maintenance Result: The engine oil was changed at the interval that is
intervals recommended by the engines Operation and Mainte-
A. Use engine oil that is recommended and change the engine oil nance Manual.
at the interval that is recommended by the engines Operation and
Maintenance Manual. Proceed to Test Step 2.
Result: The engine oil was not changed at the interval

that is recommended by the engines Operation and Main-
tenance Manual.
Use at least the minimum grade of Cat oil.
Change the engine oil at the interval that is recom-

mended. Repair or replace any damaged parts.
2. Contaminated Engine Oil Contamination Result: The oil is contaminated.
A. Obtain an S-O-S oil analysis. The analysis will contribute to a Determine the reason for any contamination of the engine
better understanding of oil contamination. oil and make the necessary repairs. Drain the crankcase
and refill the crankcase with clean engine oil. Install new
B. Check the oil filter bypass valve. engine oil filters. Refer to the engines Operation and
Maintenance Manual.
If the oil filter bypass valve is open, the oil will not be filtered.
Check the oil filter bypass valve for a weak spring or for a broken Result: The oil is not contaminated.
spring. If the spring is broken, replace the spring. Verify that the oil
bypass valve is operating correctly. Refer to the Disassembly and Proceed to Test Step 3.
Assembly manual.
Refer to the Caterpillar guidelines for “Reusability and Salvage/

Repair” for determining if the replacement of parts is necessary in
order to perform a quality repair.
3. Low Oil Pressure Restriction Result: The inlet tube has a restriction.
A. Engine oil that is contaminated with another liquid can cause Clear the obstruction. Verify the repair.
low engine oil pressure. High engine oil level can be an indication
of contamination. Obtain an analysis of the engine oil. Result: The inlet tube does not have a restriction.
B. The inlet screen of the suction tube for the engine oil pump can Proceed to Test Step 4.
have a restriction. This restriction will cause cavitation and a loss
of engine oil pressure. Check the inlet screen on the suction tube
and remove any material that may be restricting engine oil flow.
When some components of the engine show wear in a short time,

the cause can be a restriction in a passage for engine oil. An indi-
cator for the engine oil pressure may indicate sufficient pressure,
but a component is worn due to a lack of lubrication. In such a
case, look at the passage for the engine oil supply to the compo-
nent. Refer to Systems Operation/Testing and Adjusting, “Lubrica-
tion System” for additional information.
(continued)
RENR5059-14 59
(Table 13, contd)

4. Leaks in Air System Air leak Result: There are no air leaks.
A. A leak in the air intake system may allow unfiltered air into the Proceed to Test Step 5.
engine. Inspect the air intake system for streaks which may indi-
cate a leakage of unfiltered air. Inspect all of the gaskets and the Result: There are air leaks.
connections.
Repair any leaks.
5. Inspect the Fuel Filters for Contamination Fuel filters Result: The fuel has contamination.
A. Remove the fuel filters. Inspect the fuel filters for contamination. Determine the cause of any contamination and make the
Contaminants in the fuel such as hydrogen sulfide and sulfur can necessary repairs.
lead to the formation of acids in the crankcase. Obtain a fuel
analysis. Install new fuel filters. Refer to the Operation and Mainte-
nance Manual.
Complete the procedure in the order in which the S/N: CMC1107–Up

steps are listed.
S/N: YBC1–Up
The procedure corrected the issue. Return the
engine to service. S/N: YBD1–Up
The procedure did not correct the issue. S/N: ZAD1–Up

S/N: JDE1–Up
Contact your Cat dealer Technical Communicator
(TC). For further assistance, your TC can confer with S/N: BLF166–Up
the Dealer Solutions Network (DSN).
S/N: JCG1–Up
i06569719 S/N: SBG1–Up
Engine Misfires, Runs Rough S/N: JCH1–Up
or Is Unstable S/N: JDH1–Up
SMCS Code: 1000-038; 1901-038 S/N: LYH1–Up

S/N: YAH1–Up
S/N: JM21–Up
S/N: ZAH1–Up
S/N: GD31–Up
S/N: BPJ472–Up
S/N: JM31–Up
S/N: JDJ1–Up
S/N: JM41–Up
S/N: SBJ1–Up
S/N: LD41–Up
S/N: SFJ1–Up
S/N: LY71–Up
S/N: ZAJ1–Up
S/N: LY81–Up
S/N: BRK287–Up
S/N: LD91–Up
S/N: SBK1–Up
S/N: LY91–Up
S/N: SEK1–Up
S/N: CPA182–Up
S/N: YAL1–Up
S/N: BMB132–Up
S/N: YAM1–Up
S/N: CNB1100–Up
S/N: FDN1515–Up
S/N: YBB1–Up
S/N: JCN1–Up
60 RENR5059-14
S/N: YAN1–Up Recommended Actions

S/N: LYP1–Up Note: If the symptom only occurs under certain
operating conditions (high idle, full load, engine
S/N: YAP1–Up
operating temperature, etc), test the engine under
S/N: ZAP1–Up those conditions. Troubleshooting the symptom
under other conditions can give misleading results.
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up
S/N: PDR1–Up
S/N: YAR1–Up
S/N: YBR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: GZS1–Up
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up
Note: If the symptom is intermittent and the symptom
cannot be repeated, refer to Troubleshooting,
“Intermittent Low Power or Power Cutout”. If the
symptom is consistent and the symptom can be
repeated, continue with this procedure.
Probable Causes
• Electrical connectors
• Fuel supply
• Cold mode operation and cold cylinder cutout

• Throttle signal
• Unit injectors
• Air inlet and exhaust system
RENR5059-14 61
Table 14
1. Check for Diagnostic Codes Diagnostic Codes Results: There are no diagnostic codes.
A. Check for codes on Cat ® Electronic Tech- Proceed to Test Step 2.

nician (ET).
Results: There are active or logged diagnos-
tic codes.
Repair: Troubleshoot the diagnostic codes

before continuing with this procedure.
2. Inspect the Electrical Connectors Electrical Connectors Result: The electrical connectors are OK.
A. Check for correct installation of the J1/P1 Proceed to Test Step 3.

and J2/P2 Electronic Control Module (ECM)
connectors and the unit injector connectors. Result: Repair or replace any worn or dam-
Refer to Troubleshooting, “Inspecting Electri- aged electrical connectors.
cal Connectors”.
3. Check the Fuel Supply Fuel Supply Result: The fuel supply is OK.
A. Check the fuel level in the fuel tank. En- Proceed to Test Step 4.
sure that adequate fuel is available for the
application. Result: The fuel supply is NOT OK.
B. Check fuel lines for the following prob- Repair: Repair or replace any worn or dam-
lems: restrictions, collapse and pinched line. aged components pertaining to the fuel
supply.
C. Check the fuel tank for foreign objects
which may block the fuel supply. Check for
air leaks in the suction line of the fuel pump.
Note: Cold weather adversely affects the

characteristics of the fuel. Refer to the Oper-
ation and Maintenance Manual for informa-
tion on improving the characteristics of the
fuel during cold weather operation.
D. Check the fuel pressure during engine op-

eration. Check the fuel pressure after the fuel
filter. Refer to the Systems Operation/Testing
and Adjusting manual for the correct pres-
sure values. If the fuel pressure is low, re-
place the fuel filters. If the fuel pressure is
still low, check the following items: fuel trans-
fer pump, fuel transfer pump coupling and
fuel pressure regulating valve.
(continued)
62 RENR5059-14
(Table 14, contd)
4. Check for Cold Mode Operation and Cold Mode Operation and Cold Cylinder Result: Cold Mode Operation and Cold Cyl-
Cold Cylinder Cutout Cutout inder Cutout are OK.
A. Use Cat ET in order to verify that the en- Proceed to Test Step 5.
gine has exited cold mode. During cold
mode, fuel injection timing is modified. When Result: Cold Mode Operation and Cold Cyl-
the engine is in cold mode, the cold cylinder inder Cutout are NOT OK.
cutout strategy may be active. Cold mode
cylinder cutouts may cause variations in vi- Repair: Troubleshoot the reason the engine
bration and available power. This is normal is in Cold Mode Operation or Cold Cylinder
operation. Cutout.
5. Check the Throttle Signal Throttle Signal Result: The throttle signal is OK.
A. Monitor the throttle signal on Cat ET. Veri- Proceed to Test Step 6.
fy that the throttle signal is smooth from the
low idle position to the high idle position. Result: The throttle signal is NOT OK.
Repair: Troubleshoot and make necessary

repairs to the throttle signal.
6. Check the Unit Injectors Unit Injectors Result: The unit injectors are OK.
A. Use Cat ET to determine if there are any Proceed to Test Step 7.

active diagnostic codes for the unit injectors.
Result: The unit injectors are NOT OK.
B. Perform the “Injector Solenoid Test” on
Cat ET in order to determine if all of the injec- Repair: Replace the unit injectors.
tor solenoids are being energized by the
ECM.
C. Perform the “Cylinder Cutout Test” on Cat

ET in order to identify any misfiring cylinder
(s). Refer to Troubleshooting, “Injector Sole-
noids” for more information.
7. Check the Air Inlet and Exhaust System Air Inlet and Exhaust System Result: The air inlet and exhaust system is
OK.
A. Check for an air filter restriction.
B Return the engine to service.
. If air shutoff valves are installed, verify that
the air shutoff valves are fully opened. Result: The air inlet and exhaust system is
NOT OK.
C. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to the Sys- Repair: Repair or replace any damaged or
tems Operation/Testing and Adjusting for in- worn components in the air inlet and exhaust
formation on the air inlet and exhaust system.
system.
i05870429 S/N: JM31–Up

S/N: JM41–Up
Engine Oil in Cooling System
S/N: LD41–Up
SMCS Code: 1350-038; 1901-038
S/N: LY71–Up
S/N: JM21–Up
S/N: LY81–Up
S/N: GD31–Up
RENR5059-14 63

S/N: LYH1–Up
Probable Causes
S/N: YAH1–Up
• Engine oil cooler core
S/N: ZAH1–Up
• Cylinder head gasket
S/N: BPJ472–Up
• Water pump
S/N: JDJ1–Up
S/N: SBJ1–Up
S/N: SFJ1–Up
S/N: ZAJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
S/N: SEK1–Up
S/N: YAL1–Up
S/N: YAM1–Up
S/N: FDN1515–Up
S/N: JCN1–Up
S/N: YAN1–Up
S/N: LYP1–Up
S/N: YAP1–Up
S/N: ZAP1–Up
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up
64 RENR5059-14
Recommended Actions
Table 15
Result: The oil cooler core is leaking.

1. Engine Oil Cooler Core
Repair: Replace the oil cooler core. Drain the
Oil Cooler Core crankcase and refill the crankcase with clean
A. Inspect the engine oil cooler core for any
engine oil. Install new engine oil filters.
leaks.
Refer to Disassembly and Assembly and Op-
eration and Maintenance Manual.
2. Cylinder Head Gasket
A. Remove the cylinder head. Refer to the Dis-

assembly and Assembly
Result: New cylinder head gasket and water
seals were installed.
B. Check the cylinder liner projection. Refer to Cylinder Head Gasket
the Systems Operation and Testing and Ad-
justing manual.
C. Install a new cylinder head gasket and new

water seals in the spacer plate. Refer to the
Disassembly and Assembly manual.
Result: The water pump is leaking.

3. Water Pump
Repair: Replace the water pump. Refer to the
A. Check the weep hole in the water pump for Water Pump Disassembly and Assembly manual for more
blockage. information.
B. Check the water pump seals. Result: The water pump is not leaking.
i02385598 S/N: YBB1–Up
Engine Stalls at Low RPM S/N: CMC1107–Up

S/N: YBC1–Up
SMCS Code: 1000-038; 1901-038
S/N: YBD1–Up
S/N: JM21–Up
S/N: ZAD1–Up
S/N: GD31–Up
S/N: JDE1–Up
S/N: JM31–Up
S/N: BLF166–Up
S/N: JM41–Up
S/N: JCG1–Up
S/N: LD41–Up
S/N: SBG1–Up
S/N: LY71–Up
S/N: JCH1–Up
S/N: LY81–Up
S/N: JDH1–Up
S/N: LD91–Up
S/N: LYH1–Up
S/N: LY91–Up
S/N: YAH1–Up
S/N: CPA182–Up
S/N: ZAH1–Up
S/N: BMB132–Up
S/N: BPJ472–Up
S/N: CNB1100–Up
S/N: JDJ1–Up
RENR5059-14 65
S/N: SBJ1–Up • Air shutoff valves (if applicable) or blocked air

supply
S/N: SFJ1–Up
• Low engine idle
S/N: ZAJ1–Up
S/N: BRK287–Up • Accessory equipment
S/N: SBK1–Up Recommended Actions

S/N: SEK1–Up
Unit Injectors
S/N: YAL1–Up
S/N: YAM1–Up 1. Check for correct installation of the J1/P1 and J2/
P2 connectors for the Electronic Control Module
S/N: FDN1515–Up (ECM). Check for correct installation of the
S/N: JCN1–Up connectors for the unit injectors. Refer to
Troubleshooting, “Inspecting Electrical
S/N: YAN1–Up Connectors”.
S/N: LYP1–Up 2. Perform the “Injector Solenoid Test” with the
S/N: YAP1–Up Caterpillar Electronic Technician (ET) in order to
determine if all of the injector solenoids are being
S/N: ZAP1–Up energized by the ECM.
S/N: ZBP1–Up 3. Perform the “Cylinder Cutout Test” with Cat ET in
S/N: GAR1–Up order to identify any injectors that might be
misfiring. Refer to Troubleshooting, “Injector
S/N: PBR1–Up Solenoids” for the proper procedure.
S/N: PDR1–Up
Fuel Supply
S/N: YAR1–Up
S/N: YBR1–Up 1. Check the fuel pressure. Refer to the Systems
Operation/Testing and Adjusting manual for the
S/N: ZAR1–Up correct procedure.
S/N: ZBR1–Up 2. Check the fuel lines for the following problems:
S/N: GZS1–Up restrictions, collapsed lines and pinched lines. If
problems are found with the fuel lines, repair the
S/N: GZT1–Up lines and/or replace the lines.
S/N: YAT1–Up 3. Check the fuel tank for foreign objects which may
S/N: YBT1–Up block the fuel supply.
S/N: YAW1–Up NOTICE
S/N: YBW1–Up Do not crank the engine continuously for more than
S/N: BGX120–Up 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
S/N: GZY1–Up
S/N: JCY1–Up 4. Prime the fuel system if any of the following
procedures have been performed:
S/N: YAY1–Up
S/N: YAZ1–Up • Replacement of the fuel filters

Probable Causes
• Unit injectors
Note: A sight glass in the fuel supply line is helpful in
• Fuel supply
diagnosing air in the fuel.
66 RENR5059-14
5. Cold weather adversely affects the characteristics S/N: YAT1–Up

of the fuel. Refer to the applicable Operation and
Maintenance Manual for information on improving Probable Causes
operation. • Active codes and logged codes
6. Check the fuel pressure after the fuel filter while • Incorrect parameters
the engine is being cranked. Refer to the Systems • Air shut-off system (if applicable)
Operation/Testing and Adjusting manual for the
correct pressure values. If the fuel pressure is low, • Fuel system
replace the fuel filters. If the fuel pressure is still
low, check the following items: fuel transfer pump, • Fuel injectors
fuel transfer pump coupling and fuel pressure
• Engine accessories
regulating valve.
• Parasitic loads
Air Shutoff Valves (if applicable)
Recommended Actions
1. Verify that the air shutoff valves are open.
2. Check for restrictions in the air inlet system. Refer probability. Complete the procedures in the order of
to the Systems Operation/Testing and Adjusting the listed test steps.
manual for information on the air inlet system.
Low Idle
Check the low idle setting.
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.
i05848619
Engine Stalls at Low RPM

SMCS Code: 1000-038; 1901-038
S/N: JM21–Up
S/N: GD31–Up
S/N: LD41–Up
S/N: LY71–Up
S/N: LY81–Up
S/N: LD91–Up
S/N: LY91–Up
S/N: JDE1–Up
S/N: JCG1–Up
S/N: LYH1–Up
S/N: YAL1–Up
S/N: LYP1–Up
S/N: ZAP1–Up
RENR5059-14 67
Table 16
1. Check for Active Codes and Logged Codes Codes Result: A code is active or logged.
A. Establish communication between Caterpillar Electronic Techni- Repair: Troubleshoot any codes before continuing with
cian (ET) and the Electronic Control Module (ECM) . this procedure.
B. Monitor the diagnostic codes on Cat ET. Certain diagnostic codes Verify that the repair eliminated the problem.
and/or event codes may cause poor performance.
Result: A code is not active or logged.
Note: Wait at least 30 seconds in order for diagnostic codes to be-
come active. Proceed to Test Step 2.
2. Check for Incorrect Parameters Parameters Result: The correct parameters are being used.
A. Use Cat ET to verify that the correct parameters are being used. Proceed to Test Step 3.
Refer to Troubleshooting, “Configuration Parameters” for additional
information. Result: The correct parameters are not being used.
Repair: Configure the correct parameters.
3. Inspect the Air Shutoff System (if applicable)) Air Shutoff Result: The air shutoff is operating correctly.
A. Check for proper operation of the air shutoff system. Refer to Proceed to Test Step 4.
Troubleshooting, “Air Shutoff - Test”.
Result: The air shutoff is not operating correctly.
Repair: Make the necessary repairs.
4. Check the Fuel System Fuel System Result: The fuel system is operating properly.
A. Visually check the fuel level in the fuel tank. Do not rely on the Proceed to Test Step 5.
fuel gauge only.
Result: The fuel system is not operating properly.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position. Repair: Make the necessary repairs.
C.. Inspect the fuel system. Refer to Systems Operation/Testing Verify that the repair eliminates the problem.
and Adjusting, “Fuel System - Inspect” for additional information.
Cold weather adversely affects the characteristics of the fuel. Refer

to the engines Operation and Maintenance Manual for information
on improving the characteristics of the fuel during cold-weather
operation.
D. Check fuel quality. Refer to Systems Operation/Testing and Ad-

justing, “Fuel Quality - Test” for the proper procedure. Check the fuel
tank for debris or foreign objects which may block the fuel supply.
E. Check the filtered fuel pressure while the engine is being

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low” for the
proper testing procedure.
(continued)
68 RENR5059-14
(Table 16, contd)

5. Test the Fuel Injectors Fuel Injector Result: The test was successful.
If service has been performed on the engine fuel system recently, Proceed to Test Step 6.
verify that the injector trim files are correct. Use Cat ET to check that
the injector trim files are correct for the injectors that are installed on Result: The test was not successful.
the engine.
Repair: Diagnose the problem and then repair the
A. Perform the “Injector Solenoid Test” on Cat ET in order to deter- problem.
mine if all of the injector solenoids are being energized by the ECM.
Reset all active codes and clear all logged codes.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests” under
the “Diagnostics” menu. Verify that the repair eliminated the problem.
C. Perform the “Automatic Cylinder Cutout Test” on Cat ET.
6. Check the Engine Accessories Engine Result: An engine accessory is creating an excessive
Accessories load.
A. Inspect any engine accessories and the transmission (if
applicable). Repair: Repair the engine accessory.
If the procedure did not correct the issue, contact S/N: YBD1–Up
further assistance, your TC can confer with the S/N: ZAD1–Up
Dealer Solutions Network (DSN).
S/N: JDE1–Up
i02460746 S/N: BLF166–Up
S/N: JCG1–Up
Engine Will Not Crank
S/N: SBG1–Up
SMCS Code: 1000-038; 1901-038
S/N: JCH1–Up
S/N: JM21–Up
S/N: JDH1–Up
S/N: GD31–Up
S/N: LYH1–Up
S/N: JM31–Up
S/N: YAH1–Up
S/N: JM41–Up
S/N: ZAH1–Up
S/N: LD41–Up
S/N: BPJ472–Up
S/N: LY71–Up
S/N: JDJ1–Up
S/N: LY81–Up
S/N: SBJ1–Up
S/N: LD91–Up
S/N: SFJ1–Up
S/N: LY91–Up
S/N: ZAJ1–Up
S/N: CPA182–Up
S/N: BRK287–Up
S/N: BMB132–Up
S/N: SBK1–Up
S/N: CNB1100–Up
S/N: SEK1–Up
S/N: YBB1–Up
S/N: YAL1–Up
S/N: CMC1107–Up
S/N: YAM1–Up
S/N: YBC1–Up
RENR5059-14 69
S/N: FDN1515–Up • Engine accessories

S/N: JCN1–Up • Hydraulic cylinder lock
S/N: YAN1–Up • Internal engine problem
S/N: LYP1–Up
S/N: YAP1–Up
Recommended Actions
S/N: ZAP1–Up Batteries and/or Battery Cables
S/N: ZBP1–Up
1. Inspect the main power switch, battery posts, and
S/N: GAR1–Up battery cables for loose connections and for
corrosion. If the battery cables are corroded,
S/N: PBR1–Up
remove the battery cables and clean the battery
S/N: PDR1–Up cables. Tighten any loose connections.
S/N: YAR1–Up 2. Inspect the batteries.
S/N: YBR1–Up a. Charge the batteries. Refer to Special
S/N: ZAR1–Up Instruction, SEHS7633, “Battery Test
Procedure”.
S/N: ZBR1–Up
b. Load test the batteries. Refer to Special
S/N: GZS1–Up Instruction, SEHS9249, “Use of 4C-4911
S/N: GZT1–Up Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries”.
S/N: YAT1–Up
S/N: YBT1–Up Starting Motor Solenoid or Starting
S/N: YAW1–Up Circuit
S/N: YBW1–Up 1. Check the operation of the engine start switch.
S/N: BGX120–Up Monitor the engine start switch on Caterpillar
Electronic Technician (ET).
S/N: GZY1–Up
Refer to the appropriate troubleshooting test that
S/N: JCY1–Up is applicable to your engine if repairs are required.
S/N: YAY1–Up 2. Test the operation of the starting motor solenoid.
S/N: YAZ1–Up 3. Check the wiring to the starting motor solenoid.
Probable Causes Starting Motor or Flywheel Ring Gear

• Batteries
1. Test the operation of the starting motor.
• Battery cables 2. Inspect the solenoid on the starter and the flywheel
• Starting circuit ring gear for damage.
• Starting motor solenoid Prelubrication System (if applicable)

• Starting motor If equipped, inspect the prelubrication system for
proper operation.
• Shutdown switch
• Prelubrication system (if applicable) Shutdown Switch

• Faulty crank enable switch (if applicable) Use Cat ET to monitor the status of the engine.
Check the status of engine shutdowns that are
• Flywheel ring gear “ACTIVE” due to shutdown switches. Determine the
cause for the engine shutdown and take the
• Transmission (if applicable) necessary action in order to resolve the shutdown.
70 RENR5059-14
Crank Enable Switch (if applicable) • Bent components
Ensure that the crank enable switch is not faulty. i02549516
Transmission or Engine Accessories (if Excessive Engine Oil

applicable) Consumption
1. If the engine's application has a transmission SMCS Code: 1300-038; 1901-038
neutral switch, test the operation of the
transmission neutral switch. Ensure that the S/N: JM21–Up
machine is in neutral gear before attempting to S/N: GD31–Up
start the engine.
S/N: JM31–Up
2. Ensure free movement of the driveline.
S/N: JM41–Up
3. Ensure that the timing pin was not left in the
flywheel housing. S/N: LD41–Up
4. Remove any engine accessories that may lock up S/N: LY71–Up

the engine and inspect any engine accessories S/N: LY81–Up
that may lock up the engine.
S/N: LD91–Up
The following list illustrates examples of engine
accessories that may lock up the engine: S/N: LY91–Up
S/N: CPA182–Up
• Hydraulic pump that is driven from the rear
gear group S/N: BMB132–Up
• Air compressor S/N: CNB1100–Up

S/N: YBB1–Up
• Engine oil pump
S/N: CMC1107–Up
• Other components that are driven by the
engine S/N: YBC1–Up
S/N: YBD1–Up
Hydraulic Cylinder Lock
S/N: ZAD1–Up
Check for fluid in the cylinders (hydraulic cylinder S/N: JDE1–Up
lock) by removing the individual unit injectors.
S/N: BLF166–Up
Note: Drain the fuel from the cylinder head. Fuel will
flow from the cylinder head into the cylinders when S/N: JCG1–Up
the unit injector is removed.
S/N: SBG1–Up
Internal Engine Problem S/N: JCH1–Up
S/N: JDH1–Up
Disassemble the engine. Refer to the Disassembly
and Assembly manual. Inspect the internal S/N: LYH1–Up
components for the following conditions:
S/N: YAH1–Up
• Seizure
S/N: ZAH1–Up
• Broken components
S/N: BPJ472–Up
S/N: JDJ1–Up
S/N: SBJ1–Up
S/N: SFJ1–Up
S/N: ZAJ1–Up
S/N: BRK287–Up
RENR5059-14 71
S/N: SBK1–Up • Incorrect installation of the compression ring and/

or the intermediate ring
S/N: SEK1–Up
S/N: YAL1–Up Recommended Actions
S/N: YAM1–Up
Oil Leaks
S/N: FDN1515–Up
Locate all oil leaks. Repair the oil leaks. Check for
S/N: JCN1–Up dirty crankcase breathers.
S/N: YAN1–Up
Oil Level
S/N: LYP1–Up
Inspect the engine oil level. Remove any extra oil
S/N: YAP1–Up from the engine. Recheck all fluid levels.
S/N: ZAP1–Up
Engine Oil Cooler
S/N: ZBP1–Up
S/N: GAR1–Up Check for leaks in the engine oil cooler. Check for oil
in the engine coolant. If necessary, repair the engine
S/N: PBR1–Up oil cooler.
S/N: PDR1–Up
Turbocharger
S/N: YAR1–Up
Check the air inlet manifold for oil. Check for oil
S/N: YBR1–Up leakage past the seal rings in the impeller end of the
turbocharger shaft. If necessary, repair the
S/N: ZAR1–Up turbocharger.
S/N: ZBR1–Up
Valve Guides
S/N: GZS1–Up
If the valve guides are worn, reconditioning of the
S/N: GZT1–Up cylinder head is required.
S/N: YAT1–Up
Piston Rings
S/N: YBT1–Up
S/N: YAW1–Up Inspect the internal engine components. Replace any
worn components.
S/N: YBW1–Up
i02304643
S/N: BGX120–Up
S/N: GZY1–Up Excessive Black Smoke
S/N: JCY1–Up SMCS Code: 1000-038; 1901-038
S/N: YAY1–Up
S/N: JM21–Up
S/N: YAZ1–Up
S/N: GD31–Up
Probable Causes S/N: JM31–Up
• Oil leaks S/N: JM41–Up
• Oil level S/N: LD41–Up

S/N: LY71–Up
• Engine oil cooler
S/N: LY81–Up
• Turbocharger
S/N: LD91–Up
• Valve guides
S/N: LY91–Up
• Piston rings
S/N: CPA182–Up
72 RENR5059-14

S/N: LYH1–Up
Probable Causes
S/N: YAH1–Up
• Air shutoff (if applicable)
S/N: ZAH1–Up
S/N: BPJ472–Up
• Fuel injector
S/N: JDJ1–Up
• Turbocharger
S/N: SBJ1–Up
S/N: SFJ1–Up • Atmospheric pressure sensor
S/N: ZAJ1–Up • “Fuel Position” and/or “FRC Fuel Limit”

S/N: BRK287–Up • Flash file
S/N: SBK1–Up • Fuel quality
S/N: SEK1–Up
• Valve adjustment
S/N: YAL1–Up
S/N: YAM1–Up
Recommended Actions
S/N: FDN1515–Up Air Shutoff (if applicable)
S/N: JCN1–Up Check that both the air shutoffs are open.
S/N: YAN1–Up
Air Inlet and Exhaust System
S/N: LYP1–Up
S/N: YAP1–Up 1. Check the air inlet system for restrictions and/or for
leaks.
S/N: ZAP1–Up
a. Check for an air filter restriction.
S/N: ZBP1–Up
S/N: GAR1–Up b. Check for derates and for alarms.
S/N: PBR1–Up c. Perform a visual inspection of the system for

restrictions and/or for leaks.
S/N: PDR1–Up
2. Check the exhaust system for restrictions.
S/N: YAR1–Up
S/N: YBR1–Up
RENR5059-14 73
3. Repair any leaks that were found. Remove any Note: A problem with the FRC will only cause black
restrictions that were found. Replace any smoke during acceleration. A problem with the FRC
damaged components that were found. will not cause black smoke during steady state
operation.
Fuel Injector
Flash File
Check that the injector trim codes have been
entered. Perform the “Cylinder Cutout Test” . Use Verify that the correct flash file is installed. Refer to
similar conditions for the test that were experienced Troubleshooting, “Flash Programming” for more
during operation. Refer to the diagnostic functional information.
test Troubleshooting, “Injector Solenoids”.
Fuel Quality
Turbocharger
Cold weather adversely affects the characteristics of
Verify that the turbocharger has not failed. Periodic the fuel. Refer to Operation and Maintenance Manual
inspection and cleaning is recommended for the for information on improving the characteristics of the
turbocharger compressor housing (inlet side). fuel during cold weather operation.
Atmospheric Pressure Sensor Valve Adjustment
1. Check the atmospheric pressure sensor for dirt Check the valve adjustment. Refer to the Systems
Operation/Testing and Adjusting manual for more
and/or for debris. Remove the dirt and/or the information.
debris. The atmospheric pressure should be
between 50 kPa (7.2 psi) and 100 kPa (14.5 psi). i06850180
The atmospheric pressure will vary depending on
your altitude. If there is an active diagnostic code, Excessive White Smoke
perform the diagnostic functional test
Troubleshooting, “Engine Sensor Open/Short SMCS Code: 1000-038; 1901-038
Test”.
S/N: JM21–Up
2. Verify that the crankshaft and the camshaft drive
gears are set with the proper orientation. Refer to S/N: GD31–Up
the Disassembly and Assembly manual. S/N: JM31–Up
Turbocharger Compressor Outlet S/N: JM41–Up
Pressure Sensor, “ Fuel Position”” , and/or S/N: LD41–Up

“ FRC Fuel Limit”” S/N: LY71–Up
S/N: LY81–Up
1. Monitor the status of “Fuel Position” and “Rated
Fuel Limit” while the engine is operating under full S/N: LD91–Up
load. If “Fuel Position” equals “Rated Fuel Limit”
S/N: LY91–Up
and “Fuel Position” is less than “FRC Fuel Limit” ,
the electronics are operating correctly. Otherwise, S/N: CPA182–Up
proceed to the next Step.
S/N: BMB132–Up
2. Verify that there are no active diagnostic codes for
S/N: CNB1100–Up
the turbocharger compressor outlet pressure
sensor. S/N: YBB1–Up
3. Monitor the status of “Turbocharger compressor S/N: CMC1107–Up
outlet pressure” and “Atmospheric Pressure” for
S/N: YBC1–Up
normal operation on the Caterpillar Electronic
Technician (ET). When the engine is not running, S/N: YBD1–Up
“Turbocharger compressor outlet pressure” should
S/N: ZAD1–Up
be 0 kPa (0 psi).
S/N: JDE1–Up
S/N: BLF166–Up
74 RENR5059-14

S/N: LYH1–Up Note: Some white smoke may be present during cold
S/N: YAH1–Up start-up conditions when the engine is operating
normally. If the white smoke persists, there may be a
S/N: ZAH1–Up problem.
S/N: BPJ472–Up
Probable Causes
S/N: JDJ1–Up
• Starting aids (if applicable)
S/N: SBJ1–Up
• Coolant temperature sensor
S/N: SFJ1–Up
• Water temperature regulators
S/N: ZAJ1–Up
S/N: BRK287–Up • Engine speed/timing sensor
S/N: SBK1–Up • Unit injectors

S/N: SEK1–Up • Flash file
S/N: YAL1–Up • Fuel supply
S/N: YAM1–Up • Component wear
S/N: FDN1515–Up
• Cooling system
S/N: JCN1–Up
• Turbocharger
S/N: YAN1–Up
S/N: LYP1–Up Recommended Actions
S/N: YAP1–Up Starting Aids (if applicable)
S/N: ZAP1–Up
1. If equipped, check for proper operation of installed
S/N: ZBP1–Up starting aids.
S/N: GAR1–Up
a. Ensure that the ether canister is not empty and/
S/N: PBR1–Up or low. Replace the ether canister if the ether
canister is empty and/or low.
S/N: PDR1–Up
S/N: YAR1–Up b. Actuate the system manually after start-up and
observe results. The ether system will not
S/N: YBR1–Up operate if the coolant temperature is too high.
S/N: ZAR1–Up Refer to the diagnostic functional test
Troubleshooting, “Ether Injection System”.
S/N: ZBR1–Up
S/N: GZS1–Up Coolant Temperature Sensor
S/N: GZT1–Up 1. Use the Caterpillar Electronic Technician (ET) to
S/N: YAT1–Up verify that the engine has exited cold mode.
S/N: YBT1–Up 2. Compare the coolant temperature from Cat ET to

the coolant temperature that is obtained from the
S/N: YAW1–Up 6V-9130 Temperature Adapter (MULTIMETER).
S/N: YBW1–Up
S/N: BGX120–Up
RENR5059-14 75
Water Temperature Regulators Turbocharger Oil Leak

Check the water temperature regulators for correct Inspect the turbocharger for failure of turbocharger oil
operation. Verify that the engine reaches full seal. Remove the exhaust outlet piping from the
operating temperature. If the engine does not reach turbocharger. Visually inspect the piping for the
full operating temperature, a water temperature presence of oil. Refer to Operation and Maintenance
regulator may be stuck open. Remove the water Manual, “Turbocharger-Inspect”.
temperature regulator and inspect the water
temperature regulator. If necessary, repair the water i06570310
temperature regulator and/or replace the coolant
temperature regulator. Refer to the Systems
Operation/Testing and Adjusting manual for the Exhaust Temperature Is Too
proper procedure. High
Engine Speed/Timing SMCS Code: 1050-038; 1901-038
Check the calibration of the engine speed/timing S/N: JM21–Up

sensor. Refer to Troubleshooting, “Engine Speed/ S/N: GD31–Up
Timing Sensor - Calibrate”.
S/N: JM31–Up
Unit Injectors S/N: JM41–Up
Perform the “Cylinder Cutout Test” on Cat ET in order S/N: LD41–Up
to try to isolate any injectors that might be misfiring.
Refer to Troubleshooting, “Injector Solenoids”. S/N: LY71–Up
S/N: LY81–Up
Flash File
S/N: LD91–Up
Verify that the correct flash file is installed.
S/N: LY91–Up
Fuel Supply S/N: CPA182–Up
Check the fuel quality. Low cetane fuel can create S/N: BMB132–Up
white smoke. If necessary, replace the fuel with a S/N: CNB1100–Up
higher cetane fuel. Cold weather adversely affects
the characteristics of the fuel. Refer to the Operation S/N: YBB1–Up
and Maintenance Manual for information on
improving the characteristics of the fuel during cold- S/N: CMC1107–Up
weather operation.
S/N: YBC1–Up
Check the fuel level in the fuel tank. Ensure that
adequate fuel is available for the application. S/N: YBD1–Up
S/N: ZAD1–Up
Component Wear
S/N: JDE1–Up
Check the engine for the following problems:
Excessive valve wear, piston wear, ring wear, liner S/N: BLF166–Up
wear and reduced compression pressure. S/N: JCG1–Up
Cooling System S/N: SBG1–Up

S/N: JCH1–Up
Check for proper operation of the jacket water heater.
Repair the jacket water heater or replace the jacket S/N: JDH1–Up
water heater. Check for an internal coolant leak into
the cylinder and/or the exhaust. Refer to the Systems S/N: LYH1–Up
Operation/Testing and Adjusting manual for more
information. S/N: YAH1–Up
S/N: ZAH1–Up
S/N: BPJ472–Up
S/N: JDJ1–Up
76 RENR5059-14
S/N: SBJ1–Up
S/N: SFJ1–Up
S/N: ZAJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
S/N: SEK1–Up
S/N: YAL1–Up
S/N: YAM1–Up
S/N: FDN1515–Up
S/N: JCN1–Up
S/N: YAN1–Up
S/N: LYP1–Up
S/N: YAP1–Up
S/N: ZAP1–Up
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up
S/N: PDR1–Up
S/N: YAR1–Up
S/N: YBR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: GZS1–Up
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up
Probable Causes
• Air leak
RENR5059-14 77
Recommended Actions
Table 17
1. Check for Diagnostic Codes Diagnostic Codes Result: There are no diagnostic codes.
A. Connect Cat ® Electronic Technician (ET) Proceed to Test Step 2.

to determine if any diagnostic codes for the
injector solenoids are present. Check that Result: There are diagnostic codes.
the injector trim codes have been entered.
Perform the “Injector Solenoid Test” . Ob- Repair: Troubleshoot the diagnostic codes
serve that the injector solenoids are being before continuing with this procedure.
energized on Cat ET. Perform the “Cylinder
Cutout Test” . Locate the misfiring cylinder.
Refer to the diagnostic functional test Trou-
bleshooting, “Injector Solenoids”.
2. Check the Air Inlet and Exhaust System Air Inlet and Exhaust System Result: The air inlet and exhaust system is
OK.
A. Check the air inlet manifold pressure.
Check for air inlet restrictions and/or leaks. Return the engine to service.
Refer to the Systems Operation/Testing and
Adjusting manual for more information. Result: The air inlet and exhaust system is
NOT OK.
B. Check for leaks between the exhaust
manifold and the turbocharger. Check for ex- Repair: Repair or replace any damaged or
haust restrictions. Refer to the Systems Op- worn components.
eration/Testing and Adjusting manual for
more information.
i05915474 S/N: YBC1–Up

S/N: YBD1–Up
Fuel Dilution of Engine Oil
S/N: ZAD1–Up
SMCS Code: 1300-038; 1901-038
S/N: JDE1–Up
S/N: JM21–Up
S/N: BLF166–Up
S/N: GD31–Up
S/N: JCG1–Up
S/N: JM31–Up
S/N: SBG1–Up
S/N: JM41–Up
S/N: JCH1–Up
S/N: LD41–Up
S/N: JDH1–Up
S/N: LY71–Up
S/N: LYH1–Up
S/N: LY81–Up
S/N: YAH1–Up
S/N: LD91–Up
S/N: ZAH1–Up
S/N: LY91–Up
S/N: BPJ472–Up
S/N: CPA182–Up
S/N: JDJ1–Up
S/N: BMB132–Up
S/N: SBJ1–Up
S/N: CNB1100–Up
S/N: SFJ1–Up
S/N: YBB1–Up
S/N: ZAJ1–Up
S/N: CMC1107–Up
S/N: BRK287–Up
78 RENR5059-14
S/N: SBK1–Up
S/N: SEK1–Up
S/N: YAL1–Up
S/N: YAM1–Up
S/N: FDN1515–Up
S/N: JCN1–Up
S/N: YAN1–Up
S/N: LYP1–Up
S/N: YAP1–Up
S/N: ZAP1–Up
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up
S/N: PDR1–Up
S/N: YAR1–Up
S/N: YBR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: GZS1–Up
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up
Probable Causes
• Leaking seals on the case of the unit injector or on
the barrel of the unit injector
• Leaking seals on the fuel line adapter for the
cylinder head
• Excessive leakage from the unit injector tip or

breakage of the unit injector tip
• Cracked fuel supply manifold

• Leaking seal on the fuel transfer pump
RENR5059-14 79
Recommended Actions
Table 18
Fuel Injector
1. Unit Injector Case/Barrel Seal Leak Result: The unit injector seals have no damage.
A. Check for signs of damage to the seals for the unit Proceed to Test Step 2.
injectors.
Result: The unit injectors seals are damaged.
Repair: Replace any seals that are damaged.
Fuel Line Adapter

2. Cylinder Head Fuel Line Adapter Seal Leak Result: The fuel line adapter seals have no damage.
A. Check for signs of damage to the seals on the fuel line Proceed to Test Step 3.
adapter for the cylinder head.
Result: The fuel line adapter seals are damaged.
Repair: Replace any seals that are damaged.
Fuel Injector
3. Unit Injector Excessive Leakage Result: The unit injector is not leaking and there is no damage.
A. Check for signs of damage to the unit injector. Proceed to Test Step 4.
Result: The unit injector is leaking and there is damage.
Repair: Repair or replace the unit injectors.
Fuel Supply
4. Cracked Fuel Supply Manifold Manifold Result: There is no damage to the fuel supply manifold.
A. Check for signs of damage to the fuel supply manifold. Proceed to Test Step 5.
Result: There is damage to the fuel supply manifold.
Repair: Repair or replace the fuel supply manifold.
Fuel Transfer
5. Leaking Fuel Transfer Pump Seal Pump Result: The weep hole is not plugged and the fuel transfer
pump seal is not leaking.
A. Check to ensure that the weep hole is not plugged.
STOP
Result: The weep hole is plugged and the fuel transfer pump
seal is leaking.
Repair: Repair or replace the fuel transfer pump and the seal.
i05915860 S/N: JM41–Up

S/N: LD41–Up
Fuel in Cooling System
S/N: LY71–Up
SMCS Code: 1350-038; 1901-038
S/N: LY81–Up
S/N: JM21–Up
S/N: LD91–Up
S/N: GD31–Up
S/N: LY91–Up
S/N: JM31–Up
80 RENR5059-14

S/N: LYH1–Up
Probable Causes
S/N: YAH1–Up
S/N: ZAH1–Up
Injector Sleeve or Injector Sleeve Seal
S/N: BPJ472–Up • Leaking injector sleeve and/or damaged seal
S/N: JDJ1–Up
S/N: SBJ1–Up
S/N: SFJ1–Up Personal injury can result from hot coolant,
steam and alkali.
S/N: ZAJ1–Up
At operating temperature, engine coolant is hot
S/N: BRK287–Up and under pressure. The radiator and all lines to
S/N: SBK1–Up heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
S/N: SEK1–Up
Remove filler cap slowly to relieve pressure only
S/N: YAL1–Up when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
S/N: YAM1–Up
Cooling System Conditioner contains alkali.
S/N: FDN1515–Up Avoid contact with skin and eyes.
S/N: JCN1–Up
S/N: YAN1–Up
S/N: LYP1–Up
S/N: YAP1–Up
S/N: ZAP1–Up
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up
S/N: PDR1–Up
S/N: YAR1–Up
RENR5059-14 81
Recommended Actions
Table 19
1. Check for a Leaking Injector Sleeve and/or Damaged Damaged Sleeve Result: The injector sleeve and/or seal is leaking.
Seal or Seal
Repair: Remove the injector sleeve that is leaking. Care-
A. Remove the valve mechanism covers. fully inspect the sleeve for damage. If there are visible
signs of damage to the injector sleeve, replace the sleeve.
B. Remove the fuel injectors from the cylinder head. Replace the O-ring seals for the injector sleeve and rein-
stall the sleeve. Replace any damaged components.
Note: Do not allow the pressure on the cooling system to ex-
ceed 103 kPa (15 psi) during the test. Damage to the cooling Verify that the repair eliminated the problem.
system may result from applying excessive pressure.
Note: Coolant may also be contaminating the fuel system.
C. Pressurize the cooling system in order to identify the leaking Pressure in the cooling system after the engine is shut
injector sleeve. Closely inspect the sealing joint around the top down may cause the transfer of coolant into the fuel sys-
of each injector sleeve. tem. Inspect the fuel tank for coolant. If necessary, obtain
a fuel analysis in order to determine if the fuel is contami-
Small amounts of coolant will be dripping from the injector nated. The contamination of coolant in the fuel system
sleeve that is leaking. may damage injectors and other fuel system components.
Ensure that all of the fuel system components are in good
Note: Coolant may also be contaminating the fuel system. Pres- repair prior to returning the engine to service.
sure in the cooling system after the engine is shut down may
cause the transfer of coolant into the fuel system. Inspect the Note: Do not crank the engine if a cylinder is full of flu-
fuel tank for coolant. If necessary, obtain a fuel analysis in order id. Damage can occur to the engine.
to determine if the fuel is contaminated. The contamination of
coolant in the fuel system may damage injectors and other fuel Evacuate all cylinders of fluid before attempting to start the
system components. Ensure that all of the fuel system compo- engine.
nents are in good repair prior to returning the engine to service.
If the procedure did not correct the issue, contact S/N: YBB1–Up
further assistance, your TC can confer with the S/N: CMC1107–Up
Dealer Solutions Network (DSN). S/N: YBC1–Up
i02526655 S/N: YBD1–Up
S/N: ZAD1–Up
Intermittent Engine Shutdown
S/N: JDE1–Up
SMCS Code: 1000-038; 1901-038
S/N: BLF166–Up
S/N: JM21–Up
S/N: JCG1–Up
S/N: GD31–Up
S/N: SBG1–Up
S/N: JM31–Up
S/N: JCH1–Up
S/N: JM41–Up
S/N: JDH1–Up
S/N: LD41–Up
S/N: LYH1–Up
S/N: LY71–Up
S/N: YAH1–Up
S/N: LY81–Up
S/N: ZAH1–Up
S/N: LD91–Up
S/N: BPJ472–Up
S/N: LY91–Up
S/N: JDJ1–Up
S/N: CPA182–Up
S/N: SBJ1–Up
S/N: BMB132–Up
S/N: SFJ1–Up
S/N: CNB1100–Up
82 RENR5059-14
S/N: ZAJ1–Up • Fuel supply

S/N: BRK287–Up • Engine shutdown switch (if applicable)
S/N: SBK1–Up • Crank without injection input (if applicable)
S/N: SEK1–Up
S/N: YAL1–Up
Recommended Actions
S/N: YAM1–Up Engine Start Switch
S/N: FDN1515–Up Check the engine start switch on Cat ET. Look for an
S/N: JCN1–Up intermittent problem in the wiring for the engine start
switch.
S/N: YAN1–Up
S/N: LYP1–Up Engine Speed/Timing Sensor
S/N: YAP1–Up If the following diagnostic codes are applicable,
check Cat ET for any logged diagnostic codes for the
S/N: ZAP1–Up primary engine speed/timing sensor: 190-02, 190-03
and 190-08. If the engine is equipped with a
S/N: ZBP1–Up secondary engine speed/timing sensor, check for any
S/N: GAR1–Up of the following logged diagnostic codes: 342-02,
342-03 and 342-08. Refer to the diagnostic functional
S/N: PBR1–Up test Troubleshooting, “Engine Speed/Timing Sensor”.
S/N: PDR1–Up
S/N: YAR1–Up
1. Check Cat ET for the following logged diagnostic
S/N: YBR1–Up
codes: 168-01 and 168-02. Follow the battery
S/N: ZAR1–Up wires from the ECM back to the battery
compartment. Refer to the electrical system
S/N: ZBR1–Up
schematic. Inspect the wires and the power relay.
S/N: GZS1–Up Check the power to the ECM and to the ground
connections. Refer to the diagnostic functional test
S/N: GZT1–Up
Troubleshooting, “Electrical Power Supply”.
S/N: YAT1–Up
2. Check for correct installation of the J1/P1 and J2/
S/N: YBT1–Up P2 Electronic Control Module (ECM) connectors.
Refer to Troubleshooting, “Inspecting Electrical
S/N: YAW1–Up
Connectors”.
S/N: YBW1–Up
3. Inspect the battery wires from the ECM back to the
S/N: BGX120–Up battery compartment. Refer to the Electrical
System Schematic. Inspect the wires and the
S/N: GZY1–Up
power relay. Check the power and ground
S/N: JCY1–Up connections to the ECM. Refer to Troubleshooting,
“Electrical Power Supply” for more information.
S/N: YAY1–Up
S/N: YAZ1–Up Fuel Supply
Note: Use this procedure only if the engine shuts Check the fuel level in the fuel tank. Ensure that
down completely and the engine must be restarted. adequate fuel is available for the application.
Probable Causes Check fuel lines for the following problems:

• Engine start switch lines and/or replace the lines.
• Engine speed/timing sensor(s)
• Electrical connections
RENR5059-14 83
1. Check the fuel tank for foreign objects which may S/N: LY81–Up
S/N: LD91–Up
suction line of the fuel pump. Prime the fuel
system after you perform the following S/N: LY91–Up
procedures:
S/N: CPA182–Up
• Replacing the fuel filters S/N: BMB132–Up
• Working on the low pressure fuel supply circuit S/N: CNB1100–Up
• Replacing fuel injectors S/N: YBB1–Up

S/N: CMC1107–Up
2. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and S/N: YBC1–Up
Maintenance Manual for information on improving
S/N: YBD1–Up
operation. S/N: ZAD1–Up
3. Check the fuel pressure during engine operation. S/N: JDE1–Up
Check the fuel pressure after the fuel filter. Refer
S/N: BLF166–Up
manual for the correct pressure values. If the fuel S/N: JCG1–Up
S/N: SBG1–Up
pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling and S/N: JCH1–Up
S/N: JDH1–Up
Engine Shutdown Switch (if applicable) S/N: LYH1–Up
Use Cat ET to monitor the status of the engine. S/N: YAH1–Up

Check for active shutdowns due to the engine S/N: ZAH1–Up
shutdown switch. Determine the cause for the active
shutdown and make any repairs necessary. S/N: BPJ472–Up
S/N: JDJ1–Up
Crank Without Injection Input (if
applicable) S/N: SBJ1–Up
S/N: SFJ1–Up
If equipped, verify that the plug is installed for the
crank without injection input. Ensure that the plug for S/N: ZAJ1–Up
the crank without injection input is installed securely.
Refer to the diagnostic functional test S/N: BRK287–Up
Troubleshooting, “Crank without Injection Input”.
S/N: SBK1–Up
i02526753 S/N: SEK1–Up
S/N: YAL1–Up
Intermittent Low Power or
Power Cutout S/N: YAM1–Up
S/N: FDN1515–Up
SMCS Code: 1000-038; 1901-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
84 RENR5059-14
S/N: PBR1–Up Fuel Supply

S/N: PDR1–Up Check the fuel level in the fuel tank. Ensure that
adequate fuel is available for the application.
S/N: YAR1–Up
S/N: YBR1–Up Check fuel lines for the following problems:
S/N: ZAR1–Up lines and/or replace the lines.
S/N: ZBR1–Up 1. Check the fuel tank for foreign objects which may
S/N: GZS1–Up suction line of the fuel pump. Prime the fuel
S/N: GZT1–Up system after you perform the following
procedures:
S/N: YAT1–Up
S/N: YBT1–Up • Replacing the fuel filters
S/N: YAW1–Up • Working on the low pressure fuel supply circuit

S/N: YBW1–Up • Replacing fuel injectors
S/N: BGX120–Up 2. Cold weather adversely affects the characteristics
S/N: GZY1–Up of the fuel. Refer to the Operation and
S/N: JCY1–Up the characteristics of the fuel during cold weather
S/N: YAY1–Up operation.
S/N: YAZ1–Up 3. Check the fuel pressure during engine operation.
Note: Use this procedure only if the engine does not to the Systems Operation/Testing and Adjusting
shut down completely. manual for the correct pressure values. If the fuel
Probable Causes pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling and
• Fuel supply
• Derates
Derate
• Throttle signal
Connect Caterpillar Electronic Technician (ET) and
• Engine speed/timing sensor(s) check for an active derate event. A derate status flag
will appear on Cat ET if an active engine derate is
• Turbocharger occurring. In order to view active events, go to the
“Events” menu under “Diagnostics” .
• Rated fuel position
• Air inlet and exhaust restrictions Throttle Signal
• Power supply for the Electronic Control Module Use Cat ET in order to monitor the status of the
(ECM) throttle. Observe the throttle position. Verify that the
throttle position is smooth from low idle to high idle.
• Fuel position multiplier (if applicable) The throttle position should reach 100 percent at high
idle.
Recommended Actions
Engine Speed/Timing Sensor(s)
Note: If the problem only occurs under certain
conditions, test the engine under those conditions. If the following diagnostic codes are applicable,
Examples of certain conditions are high engine check Cat ET for any logged diagnostic codes for the
speed, full load and engine operating temperature. primary engine speed/timing sensor: 190-02, 190-03
Troubleshooting the symptoms under other and 190-08. If the engine is equipped with a
conditions can give misleading results. secondary engine speed/timing sensor, check for any
of the following logged diagnostic codes: 342-02,
342-03 and 342-08. Refer to the diagnostic functional
test Troubleshooting, “Engine Speed/Timing Sensor”.
RENR5059-14 85
Turbocharger S/N: GD31–Up
Ensure that the turbocharger is operating correctly. S/N: JM31–Up

Periodic inspection and cleaning is recommended for S/N: JM41–Up
the turbocharger compressor housing (inlet side).
S/N: LD41–Up
Rated Fuel Position S/N: LY71–Up
Operate the engine under full load. Use Cat ET in S/N: LY81–Up
order to monitor the following values: turbocharger
compressor outlet pressure, fuel position, rated fuel S/N: LD91–Up
position and Fuel Ratio Control (FRC). The fuel
position should equal the rated fuel position. The S/N: LY91–Up
FRC fuel position should be greater than the rated S/N: CPA182–Up
fuel position.
S/N: BMB132–Up
If any of the above values are changing rapidly for no
apparent reason, there may be an intermittent S/N: CNB1100–Up
problem with the wiring. Refer to the diagnostic
functional test Troubleshooting, “Inspecting Electrical S/N: YBB1–Up
Connectors”.
S/N: CMC1107–Up
Air Inlet and Exhaust Restrictions S/N: YBC1–Up
Check the air inlet system for the following problems: S/N: YBD1–Up
restrictions, collapse and pinched line. Repair the S/N: ZAD1–Up
lines and/or replace the lines.
S/N: JDE1–Up
Check for an air filter restriction indicator. Replace
plugged air filters and/or clean filters. Repair any S/N: BLF166–Up
leaks.
S/N: JCG1–Up
ECM Power Supply S/N: SBG1–Up
1. Inspect the circuit between the ECM and the S/N: JCH1–Up
batteries. Refer to the Electrical System S/N: JDH1–Up
Schematic. Inspect the wires, the connectors, and
the components in the circuit. Refer to S/N: LYH1–Up
Troubleshooting, “Electrical Power Supply” for S/N: YAH1–Up
more information.
S/N: ZAH1–Up
2. Inspect the circuit between the ECM and the
keyswitch. Refer to the Electrical System S/N: BPJ472–Up
Schematic. Inspect the wires, the connectors, and S/N: JDJ1–Up
the components in the circuit. Refer to
Troubleshooting, “Electrical Power Supply” for S/N: SBJ1–Up
more information. S/N: SFJ1–Up
Fuel Position Multiplier (if applicable) S/N: ZAJ1–Up

S/N: BRK287–Up
If equipped, use Cat ET to verify that the fuel position
multiplier is not affecting the available fuel rack. Refer S/N: SBK1–Up
to the diagnostic procedure Troubleshooting, “Fuel
Position Multiplier”. S/N: SEK1–Up
S/N: YAL1–Up
i02304699
S/N: YAM1–Up
Low Engine Oil Pressure S/N: FDN1515–Up

86 RENR5059-14
S/N: LYP1–Up Recommended Actions

S/N: YAP1–Up
Engine Oil Level
S/N: ZAP1–Up
Inspect the engine oil level. If engine oil is low add
S/N: ZBP1–Up engine oil.
S/N: GAR1–Up
Oil Filter
S/N: PBR1–Up
Inspect the engine oil filter. If the engine oil filter is
S/N: PDR1–Up dirty, install a new engine oil filter. Check the
S/N: YAR1–Up operation of bypass valve for the filter. Clean the
bypass valve and the housing. If necessary, install
S/N: YBR1–Up new parts.
S/N: ZAR1–Up
Engine Oil Pump
S/N: ZBR1–Up
Check for blockage of the inlet screen in the engine
S/N: GZS1–Up oil pump. Examine the engine oil pump for excessive
wear.
S/N: GZT1–Up
S/N: YAT1–Up Oil Cooler
S/N: YBT1–Up Inspect the engine's oil cooler. Clean the engine oil
cooler core(s) and/or install new engine oil cooler
S/N: YAW1–Up
core(s).
S/N: YBW1–Up
S/N: BGX120–Up
Fuel Dilution of Engine Oil
S/N: GZY1–Up Check for presence of fuel in lubricating oil. Refer to
the diagnostic procedure Troubleshooting, “Fuel
S/N: JCY1–Up Dilution of Engine Oil”.
S/N: YAY1–Up
Camshaft and/or Crankshaft
S/N: YAZ1–Up
Inspect the camshaft and/or camshaft bearings.
NOTICE Check the components for excessive wear.
Excessive wear is an indication of a blocked oil
Do not operate engine with low oil pressure. Engine passage. Inspect the crankshaft and/or crankshaft
damage will result. If measured engine oil pressure is bearings. Check the components for excessive wear.
low, discontinue engine operation until the problem is
corrected. i02526779
Low Power/Poor or No
Probable Causes
Response to Throttle
• Low engine oil level
SMCS Code: 1000-038; 1901-038
• Dirty engine oil filters
S/N: JM21–Up
• Restriction at engine oil pump
S/N: GD31–Up
• Restriction in engine oil cooler(s)
S/N: JM31–Up
• Fuel dilution of engine oil S/N: JM41–Up
• Camshaft and/or camshaft bearings S/N: LD41–Up
• Crankshaft bearings S/N: LY71–Up
S/N: LY81–Up
S/N: LD91–Up
RENR5059-14 87

S/N: LYH1–Up Probable Causes
S/N: YAH1–Up
• Fuel supply
S/N: ZAH1–Up
• Derate mode
S/N: BPJ472–Up
• Cold mode operation and cold cylinder cutout
S/N: JDJ1–Up
• Throttle signal
S/N: SBJ1–Up
S/N: SFJ1–Up • Electrical connectors
S/N: ZAJ1–Up • Injector

S/N: BRK287–Up • Fuel Ratio Control Limit (FRC)
S/N: SBK1–Up • Air inlet restriction
S/N: SEK1–Up
• Exhaust restrictions
S/N: YAL1–Up
• Electronic Control Module (ECM)
S/N: YAM1–Up
• Fuel position multiplier (if applicable)
S/N: FDN1515–Up
• Air shutoff valve (if applicable)
S/N: JCN1–Up
S/N: LYP1–Up
Fuel Supply
S/N: YAP1–Up
Check the fuel level in the fuel tank. Ensure that
S/N: ZAP1–Up adequate fuel is available for the application.
S/N: ZBP1–Up Check fuel lines for the following problems:
S/N: GAR1–Up restrictions, collapse and pinched line. Repair the
lines and/or replace the lines.
S/N: PBR1–Up
S/N: PDR1–Up
88 RENR5059-14
1. Check the fuel tank for foreign objects which may Electrical Connector
suction line of the fuel pump. Prime the fuel Check for the correct installation of the ECM
connector(s) J1/P1 and/or J2/P2. Check for correct
system after you perform the following installation of the applicable fuel Injector connectors.
procedures: Refer to the diagnostic functional test
Troubleshooting, “Inspecting Electrical Connectors”.
• Replacing the fuel filters
• Working on the low pressure fuel supply circuit Injector
• Replacing fuel injectors Use Cat ET to determine if any active diagnostic

codes are present. Check that the injector trim codes
2. Cold weather adversely affects the characteristics have been entered. Use Cat ET to determine if any
logged diagnostic codes are present. Perform the
of the fuel. Refer to the Operation and “Injector Solenoid Test” . Observe that the solenoids
Maintenance Manual for information on improving for the injectors are being energized on Cat ET.
the characteristics of the fuel during cold weather Perform the “Cylinder Cutout Test” . Locate the
operation. misfiring cylinder. Refer to the diagnostic functional
test Troubleshooting, “Injector Solenoids”.
3. Check the fuel pressure during engine operation.
Fuel Ratio Control Limit (FRC)
manual for the correct pressure values. If the fuel Operate the engine under full load. Use Cat ET in
pressure is low, replace the fuel filters. If the fuel order to monitor the following values: turbocharger
pressure is still low, check the following items: fuel compressor outlet pressure, fuel position, rated fuel
transfer pump, fuel transfer pump coupling and position and Fuel Ratio Control (FRC). The fuel
fuel pressure regulating valve. position should equal the rated fuel position. The
FRC fuel position should be greater than the rated
fuel position.
Derate Mode
If any of the above values are changing rapidly for no
Connect Cat ET and check for logged derate events. apparent reason, there may be an intermittent
A derate status flag will appear on Cat ET if an active problem with the wiring. Refer to the diagnostic
engine derate is occurring. The engine speed might functional test Troubleshooting, “Inspecting Electrical
be limited due to one of the following possible Connectors”.
causes: altitude, high exhaust temperatures, air filter
restriction, high coolant temperature, aftercooler
water temperature and crankcase pressure. Air Inlet Restriction
Check for an air filter restriction indicator. Replace
Cold Mode Operation and Cold Cylinder plugged air filters and/or clean the filters. Repair any
Cutout leaks.
Check the air inlet system for the following problems:
Use the Caterpillar Electronic Technician (ET) in restrictions, collapse, pinched line and loose fittings.
order to verify that the engine has exited cold mode. Repair the lines and/or replace the lines.
During cold mode, fuel injection timing is modified.
When the engine is in cold mode, the cold cylinder
cutout strategy may be active. Cold mode cylinder Exhaust Restrictions
cutouts may cause variations in vibration and
available power. This is normal operation. Check the exhaust system for the following problems:
restrictions, collapse, pinched line and loose fittings.
Repair the lines and/or replace the lines.
Throttle Signal
Use Cat ET in order to monitor the status of the Electronic Control Module (ECM)
throttle. Observe the throttle position. Verify that the
throttle position is smooth from low idle to high idle. If you have replaced the ECM, check the read/
The throttle position should reach 100 percent at high change system configuration parameters. Verify that
idle. the parameters match the information on the engine
information plate. Verify that the correct flash file has
been installed.
RENR5059-14 89
Fuel Position Multiplier (if applicable) S/N: BPJ472–Up
If equipped, use Cat ET to verify that the fuel position S/N: JDJ1–Up
multiplier is not affecting the available fuel rack. Refer S/N: SBJ1–Up
to Troubleshooting, “Fuel Position Multiplier” if a
problem is suspected with the input for the fuel S/N: SFJ1–Up
position multiplier.
S/N: ZAJ1–Up
Air Shutoff Valve (if applicable) S/N: BRK287–Up
Check that both of the air shutoffs are open. S/N: SBK1–Up
S/N: SEK1–Up
i02549632
S/N: YAL1–Up
Mechanical Noise (Knock) in S/N: YAM1–Up
Engine S/N: FDN1515–Up
S/N: LYH1–Up
Probable Causes
S/N: YAH1–Up
• Faulty accessory
S/N: ZAH1–Up
90 RENR5059-14
• Damage to valve train components S/N: BMB132–Up

• Failure of connecting rod bearing S/N: CNB1100–Up
• Crankshaft bearings S/N: YBB1–Up

S/N: CMC1107–Up
Recommended Actions
S/N: YBC1–Up
Faulty Accessory S/N: YBD1–Up
Isolate the source of the noise. Remove the suspect S/N: ZAD1–Up
engine accessories. Inspect the suspect engine S/N: JDE1–Up
accessories. Repair the engine accessories and/or
replace the engine accessories. S/N: BLF166–Up
S/N: JCG1–Up
Damage to Valve Train Components
S/N: SBG1–Up
Remove the valve cover from the suspect cylinder(s).
Check the following items for damage: camshaft, S/N: JCH1–Up
valve rotocoil, valve springs, lifters, pushrods,
bridges and injectors. Check for valves that do not S/N: JDH1–Up
move freely. Remove the cylinder head and inspect S/N: LYH1–Up
the valves. Replace any damaged parts. If damage
has occurred, clean the following components: S/N: YAH1–Up
cylinder liner, piston and exhaust system. Replace
any damaged parts. S/N: ZAH1–Up
S/N: BPJ472–Up
Failure of Connecting Rod Bearing
S/N: JDJ1–Up
Inspect the connecting rod bearings and the bearing
S/N: SBJ1–Up
surfaces (journals) on the crankshaft. Check the
piston pin for excessive wear. Replace any damaged S/N: SFJ1–Up
parts.
S/N: ZAJ1–Up
Crankshaft Bearings S/N: BRK287–Up
Check the crankshaft and/or crankshaft bearings. S/N: SBK1–Up
Check the components for excessive wear.
S/N: SEK1–Up
i06714410 S/N: YAL1–Up
Noise Coming from Cylinder S/N: YAM1–Up

S/N: FDN1515–Up
SMCS Code: 1000-038; 1290-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
RENR5059-14 91
S/N: ZAR1–Up Electrical Connectors

S/N: ZBR1–Up Check for the correct installation of the connector(s)
for the Electronic Control Module (ECM) J1/P1 and/or
S/N: GZS1–Up J2/P2. Check for correct installation of the applicable
S/N: GZT1–Up fuel injector connectors. Repair the connector and/or
replace the connector. Refer to the diagnostic
S/N: YAT1–Up functional test Troubleshooting, “Inspecting Electrical
Connectors”.
S/N: YBT1–Up
S/N: YAW1–Up Injector
S/N: YBW1–Up Use Caterpillar Electronic Technician (ET) to
S/N: BGX120–Up determine if any diagnostic codes for the injector
solenoids are present. Perform the “Injector Solenoid
S/N: GZY1–Up Test” . Observe that the injector solenoids are being
energized on Cat ET. Check injector height setting.
S/N: JCY1–Up Perform the “Cylinder Cutout Test” . Locate the
misfiring cylinder. Refer to the diagnostic functional
S/N: YAY1–Up test Troubleshooting, “Injector Solenoids”.
S/N: YAZ1–Up
Not Enough Lubrication
Probable Causes
Check the lubrication in the valve compartment.
• Low quality fuel Check for sufficient lubrication between the injector
tappet and the rocker arm buttons. Check for blocked
• Engine speed/timing sensor oil passages. Oil passages must be clean. Ensure
that the oil passages that send oil to the cylinder
• Electrical connectors heads are clean.
• Injector
Valve Lash
• Not enough lubrication
Check the valve lash. Refer to the diagnostic
• Too much valve lash procedure Troubleshooting, “Too Much Valve Lash”.
• Damage to valve train components Damage to Valve Train Components

• Failure of connecting rod bearing Remove the valve cover from the suspect cylinder(s).
Check the following items for damage: camshaft,
Recommended Actions valve rotocoil, valve springs, lifters, pushrods, and
bridges. Check for valves that do not move freely.
Remove the cylinder head. Inspect the valves.
Low Quality Fuel Replace any damaged parts.
Refer to Operation and Maintenance Manual for
information on the proper characteristics of the fuel. Failure of Connecting Rod Bearing
Obtain a fuel analysis.
Inspect the connecting rod bearings and the bearing
surfaces (journals) on the crankshaft. Check the
Engine Speed/Timing Sensor piston pin for excessive wear. Replace any damaged
parts.
Calibrate the engine speed/timing sensor if a CID-
FMI 261-13 Engine Timing calibration required
diagnostic code is active. Refer to the calibration i05711915
procedure Troubleshooting, “Engine Speed/Timing
Sensor - Calibrate”. Oil Contains Coolant
SMCS Code: 1348-035; 1395-035
S/N: JM21–Up
S/N: GD31–Up
S/N: JM31–Up
92 RENR5059-14

S/N: LYH1–Up Evidence of the following substances in the results of
engine oil analysis are indications of coolant in the
S/N: YAH1–Up oil:
S/N: ZAH1–Up
• Glycol
S/N: BPJ472–Up
• Water
S/N: JDJ1–Up
• Sodium (Na) when a conventional coolant is used
S/N: SBJ1–Up
• Potassium (K) when Extended Life Coolant (ELC)
S/N: SFJ1–Up is used
S/N: ZAJ1–Up
• Silicon (Si) is used in coolant as an anti-foaming
S/N: BRK287–Up agent. Si is also used as an anti-corrosion agent
for aluminum components.
S/N: SBK1–Up
Elevated levels of Na or K and Si can occur in an oil
S/N: SEK1–Up analysis without glycol or water. The glycol or water is
S/N: YAL1–Up boiled off if the coolant is burned during engine
operation.
S/N: YAM1–Up
In some cases, water or glycol can seep into the oil
S/N: FDN1515–Up when the engine is not operating.
S/N: JCN1–Up The presence of Si and glycol or water in the oil
indicates direct entry of coolant.
S/N: YAN1–Up
Review the results of the oil analysis before
S/N: LYP1–Up troubleshooting.
S/N: YAP1–Up
RENR5059-14 93
Review the service records in order to determine the

components that may be more likely to have caused
the coolant contamination.
Oil Analysis Results and Probable
Causes
Table 20
Oil Analysis Result Probable Cause Additional Notes
High Na or K Failure of the seal in the jacket water pump or Troubleshoot the more likely jacket water
Elevated Si auxiliary water pump pump first
Presence of glycol or water
High Na or K Leaking oil cooler The oil pressure is greater than the coolant
Presence of glycol or water pressure during engine operation. The coolant
level will rise as oil enters the cooling system.
Glycol and water can enter the oil if the engine

is unused for days or if the leak is severe.
High Na or K Cracked turbocharger cartridge With a crack between the coolant passage
No glycol or water and the turbine housing, the coolant is burned
or in the exhaust.
High Na or K
Elevated Si Backpressure of the exhaust gas on the oil
Presence of glycol or water system seal enables contamination.
White smoke is in the exhaust.
A crack between the coolant passage and oil

passage can allow coolant into the oil drain.
High Na or K Cracked cylinder head Glycol and water can appear in the oil sample
No glycol or water after months of burning coolant.
Glycol and water can also appear if the engine

is unused for days.
Small cracks can be hard to find.
Small cracks only open when the cylinder

head is hot.
A severe crack can enable hydraulic lock, but

the condition is unlikely.
High Na or K Cracked aftercooler core Typically rapid progression

No glycol or water if the engine is operated
Presence of glycol or water if the engine is not White smoke for an extended period at start-
run for an extended period up
For a severe leak, white smoke continues dur-

ing operation.
High Na or K Cracked cylinder liner A cracked cylinder liner is unlikely.

No glycol or water
or A cracked cylinder liner allows coolant into the
High Na or K combustion chamber or into the crankcase.
Usually, a cracked cylinder liner is associated
with piston seizure.
The crack develops quickly with little warning

or with no warning.
(continued)
94 RENR5059-14
(Table 20, contd)

High Na or K Damaged lower cylinder liner seal Failure of the lower liner seal is not common.
A failed lower seal could be due to an installa-
tion issue or to cavitation erosion.
High Na or K Failed cylinder head gasket Sometimes a small amount of burned coolant
No glycol or water is detected in the oil because of a failed cylin-
der head gasket.
A more common symptom of a failed cylinder

head gasket is exhaust gas in the coolant.
High Na or K Cracked water-cooled air compressor head (If A leak from a coolant passage in the air com-
Presence of glycol or water equipped) pressor can allow coolant to flow into the air
system or the lubrication system.
If the leak occurs in an area where air pres-

sure can enter the cooling system, the cooling
system can be pressurized.
Air dryers and air filters may plug quickly if

coolant leaks into the air system.
RENR5059-14 95
Recommended Actions
Typical water pump
(1) Weep hole (2) Felt dust filter
Table 21
Troubleshooting Test Steps Value Result
1. Check the water pumps for leaks Failed water pump seal Result: There is a stream of coolant from the
weep hole.
Perform this procedure for the jacket water
pump and for the auxiliary water pump. Start Repair: Replace the water pump seal or re-
with the jacket water pump, which is more place the water pump.
likely to have a leak.
Result: No coolant flows from the weep hole.
A. Locate weep hole (1) in the water pump
housing. Remove felt dust filter (2) (if Repair: Install a new felt dust filter into the
equipped) from the weep hole. water pump.
· If coolant flows from the weep hole, a failed Proceed to Test Step 2.
water pump seal is probably the cause of cool-
ant in the oil.
· A slightly damp dust filter is acceptable, but a

stream of coolant indicates excessive leaking
of the water pump seal.
· A visual inspection of the dust filter is not suf-

ficient. A dust filter may appear to be dry, but
the pump may have internally leaked coolant
that appears when the filter is removed.
96 RENR5059-14
Typical oil cooler
(3) End sheet (4) Baffle
Table 22
Troubleshooting Test Step Value Result
2. Visually check for engine oil in the Leaking oil cooler Result: There is an oil slick on top of the
coolant coolant.
A. Remove the radiator cap. Use a bright flash- Repair:

light to help look for an oil slick on top of the 1. Drain the engine oil and change the oil
coolant. filters.
2. Disassemble the oil cooler. Look for fretting

or wear between the baffles and the tubes.
Look for a break of the seal at the end sheet.
3.Repair the oil cooler or replace the oil cooler.

Refill the engine with oil.
Result: There is no oil slick on top of the

coolant.
Table 23
3. Check the turbocharger for a leak. Cracked turbocharger cartridge Result: There is a loss of air pressure.
A. Drain the coolant to a level that is below the Repair: Replace the turbocharger cartridge or
turbocharger. replace the turbocharger.
B. Plug the coolant return line. Result: The air pressure is maintained at
100 kPa (15 psi) with no loss of pressure.
C. Pressurize the coolant supply side of the
turbocharger with 100 kPa (15 psi) of air Proceed to Test Step 4.
pressure.
D. Monitor the pressure.

RENR5059-14 97
(5) Plug in the exhaust side (6) Hole for the valve cover bolt in the intake (7) Inner spring on the exhaust side
side
98 RENR5059-14
Table 24
4. Check the intake side of the cylinder Cracked cylinder head Result: The end of the bolt is wet or there is
head for evidence of coolant leaks. residue from coolant on the bolt.
A. Remove the valve cover bolt from hole (6). Repair: The cylinder head is probably
cracked. Replace the cylinder head.
Note: The bolt should be relatively dry. There
may be a slight buildup of carbon on the bolt, Note: After the cylinder head is removed, in-
which is normal. spect the inside of the air inlet elbow for the
cylinder. Look for coolant residue that is white
B. Inspect the bolt for moisture and for residue in color or purple to red. Some residue may
from coolant. have swirled from the intake valve partly up in-
to the elbow. If the residue coats the entire in-
side of the elbow, a leaking aftercooler is the
problem.
Result: The bolt is relatively dry. There is no

evidence of coolant residue on the bolt.
5. Check the exhaust side of the cylinder Cracked cylinder head Result: One or more of the following condi-
head for evidence of coolant leaks.. tions are found:
A. Remove plug (5). · NA or K was found on plug (5).

· Wet, slimy residue was found in the exhaust
B. Examine the plug with a spectrometer to port.
detect the presence of NA or K. · Black, gelatinous residue was found on the
inner springs.
C. Insert a borescope into the hole for plug (5)
in order to inspect the exhaust port. Look for Repair: The cylinder head is probably
residue that is wet and slimy. cracked. Replace the cylinder head.
D. Remove the valve cover. Use a bright flash- Result: No evidence of coolant was found.
light to inspect the two inner springs (7) on the
exhaust side. Look for black, gelatinous Proceed to Test Step 6.
material.
The material is the result of burned coolant

mixed with oil that was pushed up the valve
guide during operation.
RENR5059-14 99
(8) Air inlet elbow
Table 25
6. Inspect the insides of the air inlet Leaking aftercooler core Result: One or both of the elbows have resi-
elbows. due that is white in color or that is a color from
purple to red.
A. Remove the two air inlet elbows that are ap-
propriate for the engine model: Repair: To locate the leak, pressurize the
cooling system to 103 kPa (15 psi). Use a
- For 16 cylinder engines, the remove elbows bright flashlight and look through the air inlet
for cylinder heads 1 and 16 manifold. Repair the aftercooler core or re-
place the aftercooler core.
- For 12 cylinder engines, the remove elbows
for cylinder heads 1 and 12 Result: The elbows do not have residue that
is white in color or that is a color from purple to
- For eight cylinder engines, the remove el- red.
bows for cylinder heads 1 and 8 Proceed to Test Step 7.
inspect the inside of the elbows. Look for resi-

due that is white in color or that is a color from
purple to red.
Note:If the intake side of the cylinder head is

cracked, some residue may have swirled from
the intake valve partly up into the elbow. If the
residue coats the entire inside of the elbow, a
leaking aftercooler is the problem.
100 RENR5059-14
(9) Lower edge of the cylinder liner (10) Main bearing cap
RENR5059-14 101
Table 26
7. Pressurize the cylinders. Cracked cylinder liner Result: The cooling system becomes pressur-
ized and/or the cylinder loses compression
A. Pressurize each cylinder according to Spe- rapidly.
cial Instruction, REHS7138, “New Cylinder
Leak Test Procedure Available for 3500 Repair: Replace the damaged parts.
Engines”.
Result: The cooling system does not become
B. Check for pressurization of the cooling sys- pressurized. The cylinder does not lose com-
tem. Also check for a loss of cylinder pression rapidly.
compression.
Repair: Proceed to Test Step 8.
Note: Usually, a cracked cylinder liner is asso-
ciated with damage to the liner and to the pis-
ton rings. A loss of cylinder compression
begins almost immediately.
8. Look for internal coolant leaks. Damaged lower cylinder liner seal Result: Coolant is dripping from the lowest
edges of the cylinder liner and from the main
A. Remove the crankcase side covers, as bearing caps.
necessary.
Repair: Remove the cylinder liner and replace
B. Pressurize the cooling system to 103 kPa the seals.
(15 psi).
Result: Coolant is not dripping from the lowest
C. Look for coolant dripping from the lowest edges of the cylinder liner and from the main
edges of the cylinder liners (9) and from the bearing caps.
main bearing caps (10). Proceed to Test Step 9.
9. Check for a leaking cylinder head gasket. Leaking cylinder head gasket Result: A stream of bubbles emerges from
the hose, indicating that exhaust gas is forced
A. Check for combustion gas in the coolant. into the coolant..
a. Attach one end of a hose to the radiator and Repair: Use the cylinder cutout test to cut
submerge the other end of the hose into a con- groups of cylinders out in order to isolate the
tainer of water. problem cylinder head. Replace the head
gasket.
b. Run the engine and observe the end of the
hose in the water. Result:
A few isolated bubbles may emerge from the When the cylinder head is pressurized, the
hose, but if a stream of bubbles emerges. ex- level of the jacket water rises and/or bubbles
haust gas is being forced into the coolant. emerge from the jacket water..
B. Pressurize the cylinder heads. Repair: Replace the head gasket.
a. Install a dummy injector into the cylinder Result: A stream of bubbles does not emerge
head. from the hose. When the cylinder head is pres-
surized, the level of the jacket water does not
b. Apply a maximum of 690 kPa (100 psi) of rise. Bubbles do not emerge from the jacket
nitrogen pressure into the cylinder. water.
c. Observe the jacket water for an increase of Proceed to Test Step 10.
the level and for the presence of bubbles..
102 RENR5059-14
(11) Coolant supply to the compressor (13) Oil drain from the compressor to the oil
(12) Coolant drain pan
Table 27
10. Check the air compressor head for Cracked water-cooled air compressor head Result: One or more of the following condi-
cracks. tions are found:
A. Check for additional pressurization of the · The pressure of the cooling system rises
cooling system. when the air compressor operates.
·Coolant is found in the oil drain from the air
a. Operate the engine without the air compres- compressor.
sor operating. Monitor the cooling system · There is a pressure drop in the compressor
pressure. head.
b. Activate the air compressor and look for ad- Repair: Replace the air compressor.
ditional pressurization of the cooling system.
B. Check for coolant in the oil drain from the air

compressor to the oil pan.
C. Pressurize the air compressor head.
a. Disconnect the coolant hoses from the air

compressor.
b. Plug the coolant inlet or outlet to the air com-

pressor. Pressurize the other opening with
100 kPa (15 psi) of air pressure.
c. Monitor the pressure.

RENR5059-14 103
i02386640 S/N: YAL1–Up

S/N: YAM1–Up
Poor Fuel Consumption
S/N: FDN1515–Up
SMCS Code: 1000-038; 1901-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up
Probable Causes
S/N: ZAH1–Up • Engine speed/timing sensor(s)
S/N: BPJ472–Up • Electrical connectors
S/N: JDJ1–Up • Injector

S/N: SBJ1–Up • Fuel supply
S/N: SFJ1–Up • Air inlet restrictions
S/N: ZAJ1–Up
• Exhaust restrictions
S/N: BRK287–Up
• Accessory equipment
S/N: SBK1–Up
S/N: SEK1–Up
104 RENR5059-14
Recommended Actions 5. Check the fuel pressure after the fuel filter while
the engine is being cranked. Refer to the Systems
Engine Speed/Timing Sensor(s) Operation/Testing and Adjusting manual for the
correct pressure values. If the fuel pressure is low,
Check the calibration of the engine speed/timing replace the fuel filters. If the fuel pressure is still
sensor if a CID-FMI 261-13 Engine Timing calibration low, check the following items: fuel transfer pump,
required diagnostic code is active. Refer to the fuel transfer pump coupling and fuel pressure
calibration procedure Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”. regulating valve. Refer to Systems Operation/
Testing and Adjusting for more information.
Air inlet Restrictions
Check for the correct installation of the connectors for
the Electronic Control Module (ECM) J1/P1 and/or Inspect the engine air cleaner. Replace plugged air
J2/P2. Check for the correct installation of the filters and/or clean the filters. Check the air inlet
applicable fuel injector connectors. Repair the systems for restrictions and for leaks.
connector and/or replace the connector. Refer to the
diagnostic functional test Troubleshooting, Exhaust Restrictions
Check the exhaust systems for restrictions and for
Injector leaks.
Check for active diagnostic codes that are associated Accessory Equipment
with the circuits for the fuel injector. Check that the
injector trim codes have been entered. Perform the Check attached accessory equipment. Ensure that
“Injector Solenoid Test” . Verify that the ECM is the accessory equipment is not lugging down the
energizing all the injector solenoids. Refer to the engine.
diagnostic functional test Troubleshooting, “Injector
Solenoids”.
i02549667
Fuel Supply Too Much Valve Lash

1. Check the fuel lines for the following problems: SMCS Code: 1000-038; 1901-038
restrictions, collapsed lines and pinched lines. If
problems are found with the fuel lines, repair the S/N: JM21–Up
lines and/or replace the lines. S/N: GD31–Up
2. Check the fuel tank for foreign objects which may S/N: JM31–Up
block the fuel supply.
S/N: JM41–Up
3. Prime the fuel supply if any of the following
procedures have been performed: S/N: LD41–Up
• Replacement of the fuel filters S/N: LY71–Up

S/N: LY81–Up
S/N: LD91–Up
S/N: LY91–Up
Refer to the Operation and Maintenance Manual
for the correct procedure. S/N: CPA182–Up
S/N: BMB132–Up
Note: A sight glass in the fuel supply line is helpful in
diagnosing air in the fuel. S/N: CNB1100–Up
4. Cold weather adversely affects the characteristics S/N: YBB1–Up

of the fuel. Refer to the Operation and S/N: CMC1107–Up
the characteristics of the fuel during cold weather S/N: YBC1–Up
operation. S/N: YBD1–Up
S/N: ZAD1–Up
RENR5059-14 105

S/N: LYH1–Up
Probable Causes
S/N: YAH1–Up
• Rocker arm
S/N: ZAH1–Up
• Not enough lubrication
S/N: BPJ472–Up
• Worn rocker arm
S/N: JDJ1–Up
• Worn bridges for valves
S/N: SBJ1–Up
S/N: SFJ1–Up • Worn pushrods
S/N: ZAJ1–Up • Worn valve lifters

S/N: BRK287–Up • Worn camshaft
S/N: SBK1–Up • Worn valve stem
S/N: SEK1–Up
• Incorrect valve lash
S/N: YAL1–Up
• Loose retaining bolt(s) for rocker shaft
S/N: YAM1–Up
• Worn valve springs
S/N: FDN1515–Up
• Valve seats
S/N: JCN1–Up
S/N: LYP1–Up
Rocker Arm
S/N: YAP1–Up
Check for proper installation of the rocker arm
S/N: ZAP1–Up adjustment screw locknut. If the rocker arm
adjustment screw locknut is loose, adjust the valve
S/N: ZBP1–Up lash.
S/N: GAR1–Up Check the rocker arms for signs of wear. If there is
S/N: PBR1–Up too much wear, install new parts or rocker arms.
Adjust the valve lash.
S/N: PDR1–Up
S/N: YAR1–Up Not Enough Lubrication
S/N: YBR1–Up Check the lubrication in the valve compartment.
Check for sufficient lubrication between the injector
S/N: ZAR1–Up tappet and the rocker arm buttons.
S/N: ZBR1–Up
Worn Bridges for Valves
S/N: GZS1–Up
Check the bridges for signs of wear. Adjust the
S/N: GZT1–Up bridges and/or replace the bridges. If there is too
S/N: YAT1–Up much wear, install new parts. Adjust the valve lash.
S/N: YBT1–Up
S/N: YAW1–Up
106 RENR5059-14
Worn Pushrods S/N: CNB1100–Up

Inspect the pushrods for signs of wear. If there is too S/N: YBB1–Up
much wear, install new pushrods. Adjust the valve
lash. S/N: CMC1107–Up
S/N: YBC1–Up
Worn Valve Lifters
S/N: YBD1–Up
Clean the valve train. Install new valve lifters. S/N: ZAD1–Up
Worn Camshaft S/N: JDE1–Up
Check the camshaft for wear. S/N: BLF166–Up

S/N: JCG1–Up
Worn Valve Stem
S/N: SBG1–Up
Check the valve stem for signs of wear. Check for S/N: JCH1–Up
free movement of valves. Check for a bent valve
stem. Adjust the valve lash. S/N: JDH1–Up
Loose Retaining Bolt(s) for Rocker Shaft S/N: LYH1–Up

S/N: YAH1–Up
Repair the retaining bolt for the rocker shaft and/or
replace the retaining bolt. S/N: ZAH1–Up
S/N: BPJ472–Up
Worn Valve Springs
S/N: JDJ1–Up
Check the valve springs for damage or for signs of
wear. If there is too much wear, install new springs. S/N: SBJ1–Up
Adjust the valve lash. S/N: SFJ1–Up
Valve Seats S/N: ZAJ1–Up
Check the valve seats for signs of wear. If there is too S/N: BRK287–Up
much wear, install new valve seats. Adjust the valve S/N: SBK1–Up
lash.
S/N: SEK1–Up
i02304874
S/N: YAL1–Up
Too Much Vibration S/N: YAM1–Up
SMCS Code: 1000-038; 1901-038 S/N: FDN1515–Up
S/N: JM21–Up S/N: JCN1–Up
S/N: GD31–Up S/N: YAN1–Up
S/N: JM31–Up S/N: LYP1–Up
S/N: LD41–Up S/N: ZAP1–Up
S/N: LY71–Up S/N: ZBP1–Up
S/N: LD91–Up S/N: PBR1–Up
S/N: LY91–Up S/N: PDR1–Up
S/N: CPA182–Up S/N: YAR1–Up
S/N: BMB132–Up S/N: YBR1–Up

S/N: ZAR1–Up
RENR5059-14 107
S/N: ZBR1–Up Alignment and balance

S/N: GZS1–Up Check alignment and the balance. If the symptom
S/N: GZT1–Up remains refer to the diagnostic procedure
Troubleshooting, “Engine Misfires, Runs Rough or Is
S/N: YAT1–Up Unstable”.
S/N: YBT1–Up i02549674
S/N: YAW1–Up
Valve Rotocoil or Spring Lock
S/N: YBW1–Up
Is Free
S/N: BGX120–Up
SMCS Code: 1109-038
S/N: GZY1–Up
S/N: JCY1–Up S/N: JM21–Up
S/N: YAY1–Up S/N: GD31–Up
S/N: YAZ1–Up S/N: JM31–Up

S/N: JM41–Up
Probable Causes
S/N: LD41–Up
• Vibration damper
S/N: LY71–Up
• Loose engine supports S/N: LY81–Up
• Fan blade S/N: LD91–Up
• Misfiring cylinder S/N: LY91–Up
• Alignment and balance S/N: CPA182–Up
S/N: BMB132–Up
Recommended Actions
S/N: CNB1100–Up
Vibration damper S/N: YBB1–Up
Check the vibration damper for damage. Tighten the S/N: CMC1107–Up
bolts. Check the vibration damper bolt holes for
damage and/or wear. S/N: YBC1–Up
S/N: YBD1–Up
Loose engine supports
S/N: ZAD1–Up
Run the engine. Check the engine for the following S/N: JDE1–Up
problems: loose mounts, broken mounts, loose
brackets and broken brackets. Tighten all mounting S/N: BLF166–Up
bolts.
S/N: JCG1–Up
Fan blade S/N: SBG1–Up
Check the fan blade for damage. Ensure that the fan S/N: JCH1–Up
blade is balanced.
S/N: JDH1–Up
Misfiring cylinder S/N: LYH1–Up
Check for a misfiring cylinder. Perform the Cylinder S/N: YAH1–Up

Cutout Test. Refer to the diagnostic functional test S/N: ZAH1–Up
Troubleshooting, “Injector Solenoids”.
S/N: BPJ472–Up
S/N: JDJ1–Up
S/N: SBJ1–Up
108 RENR5059-14
S/N: SFJ1–Up Recommended Actions

S/N: ZAJ1–Up
Valve Rotocoil
S/N: BRK287–Up
Determine the cause of the cracked rotocoil. Install
S/N: SBK1–Up new parts.
S/N: SEK1–Up
Spring Locks
S/N: YAL1–Up
Check the locks. A broken lock can cause the valve
S/N: YAM1–Up to fall into the cylinder.
S/N: FDN1515–Up
Valve Spring(s)
S/N: JCN1–Up
Install the new valve spring(s). Replace the valve
S/N: YAN1–Up
and/or other damaged parts.
S/N: LYP1–Up
S/N: YAP1–Up
S/N: ZAP1–Up
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up
S/N: PDR1–Up
S/N: YAR1–Up
S/N: YBR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: GZS1–Up
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up
Probable Causes
• Cracked inlet valve rotocoil
• Broken spring locks

• Broken valve spring(s)
RENR5059-14 109
Troubleshooting with a Diagnostic Code
Troubleshooting with a S/N: ZAJ1–Up

S/N: BRK287–Up
Diagnostic Code
S/N: SBK1–Up
S/N: SEK1–Up
S/N: YAL1–Up
i02385771
S/N: YAM1–Up
Diagnostic Codes S/N: FDN1515–Up
S/N: LYH1–Up
Diagnostic Codes
S/N: YAH1–Up
Diagnostic codes alert the operator that a problem in
S/N: ZAH1–Up the electronic system has been detected. Diagnostic
codes also indicate the nature of the problem to the
S/N: BPJ472–Up service technician. The Caterpillar Electronic
S/N: JDJ1–Up Technician (ET) is a software program that is
designed to run on a personal computer. Diagnostic
S/N: SBJ1–Up codes may be viewed on a personal computer that
has Cat ET software.
S/N: SFJ1–Up
110 RENR5059-14
Module Identifier (MID) – The MID is a three digit Active Diagnostic Codes
code that indicates the electronic module that
generated the diagnostic code. The MID for the An active diagnostic code represents a problem with
engine's Electronic Control Module (ECM) is 36. the electronic control system. Correct the problem
as soon as possible.
Component Identifier (CID) – The CID is a number
with three or four digits. The CID indicates the When an active diagnostic code is generated, the
component that generated the code. For example, “Active Alarm” indicator ( “Engine Control Alarm
the CID number 0001 identifies the fuel injector for Status” on Cat ET) is activated in order to alert the
the number one cylinder. operator. If the condition that generated the code is
Failure Mode Identifier (FMI) – The FMI is a two momentary, the message disappears from the list of
digit code that indicates the type of failure. active diagnostic codes. The diagnostic code
becomes logged.
Note: Do not confuse diagnostic codes with event When an active diagnostic code is generated, a
codes. For information on event codes, see display module such as the Vital Information
Troubleshooting, “Event Codes”. Management System (VIMS) may produce a
warning.
Logged Diagnostic Codes

When the Electronic Control Module (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.
Output voltage from a typical analog temperature Note: Always clear logged diagnostic codes after
sensor investigating and correcting the problem which
generated the code.
Illustration 24 indicates the signal range for a typical
analog sensor. Diagnostic codes will be generated if
the sensor's output signal is below 0.2 VDC or above
4.8 VDC.
RENR5059-14 111
Diagnostic Codes Table

Table 28
3500B System Diagnostic Codes
CID FMI Description
0001 05 Injector Cylinder 1 open circuit
0001 06 Injector Cylinder 1 short
(continued)
112 RENR5059-14
(Table 28, contd)

CID FMI Description
0091 08 Throttle Position signal abnormal
0094 03 Filtered Fuel Pressure

0094 04 Filtered Fuel Pressure
0100 03 Filtered Oil Pressure
0100 04 Filtered Oil Pressure
0101 03 Crankcase Pressure open/short to +batt
0101 04 Crankcase Pressure short to ground
0105 043 Inlet Manifold Air Temp
0105 04 Inlet Manifold Air Temp
0110 03 Engine Coolant Temperature open/short to +batt
0110 04 Engine Coolant Temperature short to ground
0168 00 System Voltage Low
0168 01 System Voltage Low
0168 02 System Voltage intermittent
0168 0168 System Voltage intermittent
0175 03 Engine Oil Temperature
0175 04 Engine Oil Temperature
0190 03 Engine Speed
0190 04 Engine Speed
0190 08 Engine Speed signal abnormal
0248 09 Abnormal Update
0253 02 Data Intermittent
0254 12 ECM High Voltage Supply
0261 13 Engine Timing calibration required
0262 03 5 Volt Sensor DC Power Supply short to +batt
0262 04 5 Volt Sensor DC Power Supply short to ground
0263 03 Digital Sensor supply short to +batt
0263 04 Digital Sensor supply short to ground
0268 02 Check Programmable Parameters
0273 00 Data High
0273 03 Turbo Outlet Pressure open/short to +batt
0273 04 Turbo Outlet Pressure short to ground
0274 03 Atmospheric Pressure open/short to +batt
0274 04 Atmospheric Pressure short to ground
(continued)
RENR5059-14 113
(Table 28, contd)

CID FMI Description
0275 03 Right Turbo Inlet Pressure open/short to +batt
0275 04 Right Turbo Inlet Pressure short to ground
0276 03 Left Turbo Inlet Pressure open/short to +batt
0276 04 Left Turbo Inlet Pressure short to ground
0279 03 Aftercollar Temperature
0279 04 Aftercollar Temperature
0289 02 Unfiltered Fuel Pressure

0336 02 Engine Control Switch
0337 02 E-Stop SWitch Inputs
0338 05 Pre-Lube Relay open circuit
0338 06 Pre-Lube Relay short to ground
0446 05 Air Shutoff Relay Driver
0446 06 Air Shutoff Relay Driver
0542 02 Unfiltered Engine Oil Pressure
0542 03 Unfiltered Engine Oil Pressure open/short to +batt
0542 04 Unfiltered Engine Oil Pressure short to ground
0546 05 Ether Hold Relay open/short to ground
0546 06 Ether Hold Relay short to +batt
0799 12 Poor Device or Component
0827 08 Left Exhaust Temperature signal abnormal
0828 08 Right Exhaust Temperature signal abnormal
1495 02 Injector Trim Codes Not Programmed
i01954438 S/N: LD91–Up

S/N: LY91–Up
MID 036 - CID 0001 - FMI 05
Injector Cylinder 1 open circuit S/N: CPA182–Up
SMCS Code: 1290-038 S/N: BMB132–Up

S/N: CNB1100–Up
S/N: JM21–Up
S/N: YBB1–Up
S/N: GD31–Up
S/N: CMC1107–Up
S/N: JM31–Up
S/N: YBC1–Up
S/N: JM41–Up
S/N: YBD1–Up
S/N: LD41–Up
S/N: ZAD1–Up
S/N: LY71–Up
S/N: JDE1–Up
S/N: LY81–Up
114 RENR5059-14

S/N: LYH1–Up Conditions Which Generate This Code:
S/N: YAH1–Up The Electronic Control Module (ECM) detects an
S/N: ZAH1–Up open circuit or short to battery voltage in the No. 1
cylinder injector solenoid.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
The CID-FMI is logged in memory. The ECM will
S/N: SBJ1–Up continue to operate all injectors.
S/N: SFJ1–Up
Perform the following diagnostic procedure: “Injector
S/N: ZAJ1–Up Solenoids”
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
S/N: YAL1–Up • REPAIRED, OK – STOP. REPAIRED, OK
i01954439
S/N: YAM1–Up
S/N: FDN1515–Up MID 036 - CID 0001 - FMI 06
S/N: JCN1–Up Injector Cylinder 1 short
S/N: YAN1–Up SMCS Code: 1290-038
S/N: LYP1–Up S/N: JM21–Up
S/N: YAP1–Up S/N: GD31–Up
S/N: ZAP1–Up S/N: JM31–Up
S/N: ZBP1–Up S/N: JM41–Up
S/N: GAR1–Up S/N: LD41–Up
S/N: PBR1–Up S/N: LY71–Up
S/N: PDR1–Up S/N: LY81–Up
S/N: YAR1–Up S/N: LD91–Up
S/N: YBR1–Up S/N: LY91–Up
S/N: ZAR1–Up S/N: CPA182–Up
S/N: ZBR1–Up S/N: BMB132–Up
S/N: GZS1–Up S/N: CNB1100–Up
S/N: GZT1–Up S/N: YBB1–Up
S/N: YAT1–Up S/N: CMC1107–Up
S/N: YBT1–Up S/N: YBC1–Up
S/N: YAW1–Up S/N: YBD1–Up
S/N: YBW1–Up S/N: ZAD1–Up
RENR5059-14 115

S/N: YAH1–Up The Electronic Control Module (ECM) detects a short
S/N: ZAH1–Up circuit or short to ground in the No. 1 cylinder injector
solenoid.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954440
S/N: YAM1–Up
S/N: JCN1–Up Injector Cylinder 2 open circuit
116 RENR5059-14

S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954441
S/N: YAM1–Up
RENR5059-14 117

solenoid.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954483
S/N: YAM1–Up
118 RENR5059-14

S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954484
S/N: YAM1–Up
RENR5059-14 119

solenoid.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954486
S/N: YAM1–Up
120 RENR5059-14

S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954487
S/N: YAM1–Up
RENR5059-14 121

solenoid.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954489
S/N: YAM1–Up
122 RENR5059-14

S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954491
S/N: YAM1–Up
RENR5059-14 123

solenoid.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954493
S/N: YAM1–Up
124 RENR5059-14

S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954496
S/N: YAM1–Up
RENR5059-14 125

solenoid.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954498
S/N: YAM1–Up
126 RENR5059-14

S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954500
S/N: YAM1–Up
RENR5059-14 127

solenoid.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954501
S/N: YAM1–Up
128 RENR5059-14

S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954503
S/N: YAM1–Up
RENR5059-14 129

solenoid.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954504
S/N: YAM1–Up
130 RENR5059-14

S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
i01954506
S/N: YAM1–Up
RENR5059-14 131

solenoid.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
S/N: YAM1–Up
S/N: FDN1515–Up
S/N: JCN1–Up
S/N: YAN1–Up
132 RENR5059-14
i01954507 S/N: SBK1–Up

S/N: SEK1–Up
MID 036 - CID 0010 - FMI 05
Injector Cylinder 10 open S/N: YAL1–Up
circuit S/N: YAM1–Up

S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: CMC1107–Up S/N: GZS1–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: ZAD1–Up S/N: YBT1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up Conditions Which Generate This Code:
S/N: ZAH1–Up The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 10
S/N: BPJ472–Up cylinder injector solenoid.
S/N: JDJ1–Up System Response:
S/N: SBJ1–Up The CID-FMI is logged in memory. The ECM will
S/N: SFJ1–Up continue to operate all injectors.
S/N: ZAJ1–Up Perform the following diagnostic procedure: “Injector

S/N: BRK287–Up Solenoids”
RENR5059-14 133
Results: S/N: ZAJ1–Up
• OK – STOP. OK S/N: BRK287–Up

S/N: SBK1–Up
• REPAIRED, OK – STOP. REPAIRED, OK
S/N: SEK1–Up
i01954508
S/N: YAL1–Up
MID 036 - CID 0010 - FMI 06 S/N: YAM1–Up
Injector Cylinder 10 short S/N: FDN1515–Up
SMCS Code: 1290-038
S/N: JCN1–Up
S/N: LYH1–Up
Conditions Which Generate This Code:
S/N: YAH1–Up
The Electronic Control Module (ECM) detects a short
S/N: ZAH1–Up circuit or a short to ground in the No. 10 cylinder
injector solenoid.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SBJ1–Up The CID-FMI is logged in memory. The ECM will
continue to operate all injectors.
S/N: SFJ1–Up
134 RENR5059-14
Perform the following diagnostic procedure: “Injector S/N: JDJ1–Up

Solenoids”
S/N: SBJ1–Up
Results: S/N: SFJ1–Up
• OK – STOP. OK S/N: ZAJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
i01954509
S/N: SEK1–Up
MID 036 - CID 0011 - FMI 05 S/N: YAL1–Up
Injector Cylinder 11 open S/N: YAM1–Up
circuit
S/N: FDN1515–Up
SMCS Code: 1290-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up
The Electronic Control Module (ECM) detects an
S/N: BPJ472–Up
RENR5059-14 135
System Response: S/N: ZAH1–Up

The CID-FMI is logged in memory. The ECM will S/N: BPJ472–Up
continue to operate all injectors.
S/N: JDJ1–Up
Perform the following diagnostic procedure: “Injector S/N: SBJ1–Up
Solenoids”
S/N: SFJ1–Up
S/N: SBK1–Up
S/N: SEK1–Up
i01954510
S/N: YAL1–Up
Injector Cylinder 11 short
S/N: FDN1515–Up
SMCS Code: 1290-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up
136 RENR5059-14
Conditions Which Generate This Code: S/N: JCH1–Up

The Electronic Control Module (ECM) detects a short S/N: JDH1–Up
circuit or short to ground in the No. 11 cylinder
injector solenoid. S/N: LYH1–Up
S/N: YAH1–Up
System Response:
S/N: ZAH1–Up
continue to operate all injectors. S/N: BPJ472–Up
S/N: JDJ1–Up
Solenoids” S/N: SBJ1–Up

S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
S/N: SBK1–Up
i01954511
S/N: SEK1–Up
circuit S/N: FDN1515–Up
RENR5059-14 137
S/N: YAY1–Up S/N: SBG1–Up

S/N: YAZ1–Up S/N: JCH1–Up
Conditions Which Generate This Code: S/N: JDH1–Up
The Electronic Control Module (ECM) detects an S/N: LYH1–Up

open circuit or short to battery voltage in the No. 12 S/N: YAH1–Up
S/N: ZAH1–Up
System Response:
S/N: BPJ472–Up
continue to operate all injectors. S/N: JDJ1–Up
S/N: SBJ1–Up
Solenoids” S/N: SFJ1–Up
S/N: ZAJ1–Up
Results:
S/N: BRK287–Up
• OK – STOP. OK
S/N: SBK1–Up
• REPAIRED, OK – STOP. REPAIRED, OK S/N: SEK1–Up
i01954513
S/N: YAL1–Up

138 RENR5059-14
S/N: JCY1–Up S/N: BLF166–Up

S/N: YAY1–Up S/N: JCG1–Up
S/N: YAZ1–Up S/N: SBG1–Up

circuit or short to ground in the No. 12 cylinder S/N: LYH1–Up
injector solenoid.
S/N: YAH1–Up
System Response:
S/N: ZAH1–Up
S/N: JDJ1–Up
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
• REPAIRED, OK – STOP. REPAIRED, OK S/N: SBK1–Up
i01954514
S/N: SEK1–Up
RENR5059-14 139
S/N: BGX120–Up S/N: JDE1–Up

S/N: GZY1–Up S/N: BLF166–Up
S/N: JCY1–Up S/N: JCG1–Up

S/N: ZAH1–Up
System Response:
S/N: BPJ472–Up
S/N: SBJ1–Up
S/N: ZAJ1–Up
Results:
S/N: BRK287–Up
• OK – STOP. OK
S/N: SBK1–Up
i01954515
S/N: YAL1–Up

140 RENR5059-14
S/N: YBW1–Up S/N: YBD1–Up

S/N: BGX120–Up S/N: ZAD1–Up
S/N: GZY1–Up S/N: JDE1–Up

injector solenoid.
S/N: YAH1–Up
System Response:
S/N: ZAH1–Up
S/N: JDJ1–Up
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i01954517
S/N: SEK1–Up
RENR5059-14 141


S/N: ZAH1–Up
System Response:
S/N: BPJ472–Up
S/N: SBJ1–Up
S/N: ZAJ1–Up
Results:
S/N: BRK287–Up
• OK – STOP. OK
S/N: SBK1–Up
i01954518
S/N: YAL1–Up

142 RENR5059-14
S/N: YAT1–Up S/N: YBB1–Up

S/N: YBT1–Up S/N: CMC1107–Up
S/N: YAW1–Up S/N: YBC1–Up

injector solenoid.
S/N: YAH1–Up
System Response:
S/N: ZAH1–Up
S/N: JDJ1–Up
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i01954519
S/N: SEK1–Up
RENR5059-14 143


S/N: ZAH1–Up
System Response:
S/N: BPJ472–Up
S/N: SBJ1–Up
S/N: ZAJ1–Up
Results:
S/N: BRK287–Up
• OK – STOP. OK
S/N: SBK1–Up
i01954522
S/N: YAL1–Up

144 RENR5059-14
S/N: ZBR1–Up S/N: CPA182–Up

S/N: GZS1–Up S/N: BMB132–Up
S/N: GZT1–Up S/N: CNB1100–Up

injector solenoid.
S/N: YAH1–Up
System Response:
S/N: ZAH1–Up
S/N: JDJ1–Up
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i01954523
S/N: SEK1–Up
RENR5059-14 145


S/N: ZAH1–Up
System Response:
S/N: BPJ472–Up
S/N: SBJ1–Up
S/N: ZAJ1–Up
Results:
S/N: BRK287–Up
• OK – STOP. OK
S/N: SBK1–Up
i01954525
S/N: YAL1–Up

146 RENR5059-14
S/N: YAR1–Up S/N: LY81–Up

S/N: YBR1–Up S/N: LD91–Up
S/N: ZAR1–Up S/N: LY91–Up

injector solenoid.
S/N: YAH1–Up
System Response:
S/N: ZAH1–Up
S/N: JDJ1–Up
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i02415704
S/N: SEK1–Up
Throttle Position signal S/N: YAM1–Up
abnormal S/N: FDN1515–Up
RENR5059-14 147
S/N: PBR1–Up i01936028
S/N: PDR1–Up
MID 036 - CID 0094 - FMI 03
S/N: YAR1–Up Fuel Pressure open/short to
S/N: YBR1–Up +batt
S/N: ZAR1–Up SMCS Code: 1901-038
S/N: ZBR1–Up
S/N: JM21–Up
S/N: GZS1–Up
S/N: GD31–Up
S/N: GZT1–Up
S/N: JM31–Up
S/N: YAT1–Up
S/N: JM41–Up
S/N: YBT1–Up
S/N: LD41–Up
S/N: YAW1–Up
S/N: LY71–Up
S/N: YBW1–Up
S/N: LY81–Up
S/N: BGX120–Up
S/N: LD91–Up
S/N: GZY1–Up
S/N: LY91–Up
S/N: JCY1–Up
S/N: CPA182–Up
S/N: YAY1–Up S/N: BMB132–Up
S/N: YAZ1–Up
S/N: CNB1100–Up
Conditions Which Generate This Code: S/N: YBB1–Up
The engine's Electronic Control Module (ECM) S/N: CMC1107–Up
detected an abnormal throttle signal.
S/N: YBC1–Up
System Response:
S/N: YBD1–Up
The throttle position is set to a default value of 0
percent (low idle) by the ECM. The code is logged. S/N: ZAD1–Up
S/N: JDE1–Up
A. Determine if the “Direct Fuel Control Mode” is ON S/N: BLF166–Up
or OFF. View the configuration screen in order to
find the status of the “Direct Fuel Control Mode” . S/N: JCG1–Up
S/N: SBG1–Up
Expected Result:
S/N: JCH1–Up
The “Direct Fuel Control Mode” is ON.
S/N: JDH1–Up
Results: S/N: LYH1–Up
• OK – The “Direct Fuel Control Mode” is ON. S/N: YAH1–Up
Repair: Perform the diagnostic functional test S/N: ZAH1–Up

Troubleshooting, “Direct Fuel Control Mode”. S/N: BPJ472–Up
STOP. S/N: JDJ1–Up
S/N: SBJ1–Up
• Not OK – The “Direct Fuel Control Mode” is OFF.
S/N: SFJ1–Up
Repair: Perform the diagnostic functional test
Troubleshooting, “Speed Control”. S/N: ZAJ1–Up
S/N: BRK287–Up
STOP.
148 RENR5059-14
S/N: SBK1–Up Perform the following diagnostic procedure: “Engine

Sensor Open/Short Test”
S/N: SEK1–Up
S/N: YAL1–Up Results:
S/N: YAM1–Up • OK – STOP. OK

S/N: FDN1515–Up
S/N: JCN1–Up
i01936029
S/N: YAN1–Up
S/N: LYP1–Up
MID 036 - CID 0094 - FMI 04
S/N: YAP1–Up
Fuel Pressure short to ground
SMCS Code: 1901-038
S/N: ZAP1–Up
S/N: JM21–Up
S/N: ZBP1–Up
S/N: GD31–Up
S/N: GAR1–Up
S/N: JM31–Up
S/N: PBR1–Up
S/N: JM41–Up
S/N: PDR1–Up
S/N: LD41–Up
S/N: YAR1–Up
S/N: LY71–Up
S/N: YBR1–Up
S/N: LY81–Up
S/N: ZAR1–Up
S/N: LD91–Up
S/N: ZBR1–Up
S/N: LY91–Up
S/N: GZS1–Up
S/N: CPA182–Up
S/N: GZT1–Up
S/N: BMB132–Up
S/N: YAT1–Up
S/N: CNB1100–Up
S/N: YBT1–Up
S/N: YBB1–Up
S/N: YAW1–Up
S/N: CMC1107–Up
S/N: YBW1–Up
S/N: YBC1–Up
S/N: BGX120–Up
S/N: YBD1–Up
S/N: GZY1–Up
S/N: ZAD1–Up
S/N: JCY1–Up
S/N: JDE1–Up
S/N: YAY1–Up
S/N: BLF166–Up
S/N: YAZ1–Up
S/N: JCG1–Up
S/N: SBG1–Up
The Electronic Control Module (ECM) reads signal
voltage that is greater than 4.8 VDC for one second. S/N: JCH1–Up
The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. S/N: JDH1–Up
S/N: LYH1–Up
System Response:
S/N: YAH1–Up
The code is logged. The ECM flags filtered fuel
pressure as invalid data and a default value of S/N: ZAH1–Up
500 kPa (73 psi) is used.
S/N: BPJ472–Up
S/N: JDJ1–Up
RENR5059-14 149
S/N: SBJ1–Up System Response:

S/N: SFJ1–Up The code is logged. The ECM flags filtered fuel
pressure as invalid data and a default value of
S/N: ZAJ1–Up 500 kPa (73 psi) is used.
S/N: BRK287–Up
Perform the following diagnostic procedure: “Engine
S/N: SBK1–Up Sensor Open/Short Test”
S/N: SEK1–Up
Results:
S/N: YAL1–Up
• OK – STOP. OK
S/N: YAM1–Up
S/N: FDN1515–Up • REPAIRED, OK – STOP. REPAIRED, OK
S/N: JCN1–Up i01954600
S/N: YAN1–Up MID 036 - CID 0100 - FMI 03

S/N: LYP1–Up Engine Oil Pressure open/
S/N: YAP1–Up short to +batt
S/N: ZAP1–Up SMCS Code: 1924-038
S/N: GAR1–Up S/N: GD31–Up
S/N: PBR1–Up S/N: JM31–Up
S/N: PDR1–Up S/N: JM41–Up
S/N: ZBR1–Up S/N: LD91–Up
S/N: GZS1–Up S/N: LY91–Up
S/N: GZT1–Up S/N: CPA182–Up
S/N: YAT1–Up S/N: BMB132–Up
S/N: YBT1–Up S/N: CNB1100–Up
S/N: YAW1–Up S/N: YBB1–Up
S/N: YBW1–Up S/N: CMC1107–Up
S/N: BGX120–Up S/N: YBC1–Up
S/N: GZY1–Up S/N: YBD1–Up
S/N: JCY1–Up S/N: ZAD1–Up
S/N: YAY1–Up S/N: JDE1–Up
S/N: YAZ1–Up S/N: BLF166–Up
Conditions Which Generate This Code: S/N: JCG1–Up
The Electronic Control Module (ECM) reads signal S/N: SBG1–Up
voltage that is below 0.2 VDC for one second. The
ECM has been powered for three seconds. The S/N: JCH1–Up
diagnostic codes 262-03 and 262-04 are not active.
S/N: JDH1–Up
S/N: LYH1–Up
150 RENR5059-14

S/N: ZAH1–Up The Electronic Control Module (ECM) reads signal
voltage that is greater than 4.8 VDC for one second.
S/N: BPJ472–Up The ECM has been powered for three seconds. The
S/N: JDJ1–Up
S/N: SFJ1–Up The CID-FMI is logged in memory. The ECM flags

engine oil pressure as invalid data and a default
S/N: ZAJ1–Up value of 500 kPa (73 psi) is used.
S/N: BRK287–Up
S/N: SEK1–Up
Results:
S/N: YAL1–Up
• OK – STOP. OK
S/N: YAM1–Up
i01954601
S/N: JCN1–Up
S/N: LYP1–Up Engine Oil Pressure short to
S/N: YAP1–Up ground
S/N: JCG1–Up
RENR5059-14 151

S/N: YAH1–Up The Electronic Control Module (ECM) reads signal
S/N: ZAH1–Up voltage that is below 0.2 VDC for one second. The
ECM has been powered for three seconds. The
S/N: BPJ472–Up diagnostic codes 262-03 and 262-04 are not active.

S/N: SBJ1–Up The CID-FMI is logged in memory. The ECM flags
engine oil pressure as invalid data and a default
S/N: SFJ1–Up
value of 500 kPa (73 psi) is used.
S/N: ZAJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
Results:
S/N: SEK1–Up
S/N: YAL1–Up • OK – STOP. OK
S/N: YAM1–Up • REPAIRED, OK – STOP. REPAIRED, OK

S/N: FDN1515–Up i01954609
S/N: JCN1–Up MID 036 - CID 0101 - FMI 03

S/N: YAN1–Up Crankcase Pressure open/
S/N: LYP1–Up short to +batt
S/N: YAP1–Up SMCS Code: 1916-038
S/N: ZBP1–Up S/N: GD31–Up
S/N: GAR1–Up S/N: JM31–Up
S/N: PDR1–Up S/N: LD41–Up
S/N: ZAR1–Up S/N: LD91–Up
S/N: ZBR1–Up S/N: LY91–Up
S/N: GZS1–Up S/N: CPA182–Up
S/N: GZT1–Up S/N: BMB132–Up
S/N: YAT1–Up S/N: CNB1100–Up
S/N: YBT1–Up S/N: YBB1–Up
S/N: YAW1–Up S/N: CMC1107–Up
S/N: YBW1–Up S/N: YBC1–Up
S/N: BGX120–Up S/N: YBD1–Up
S/N: GZY1–Up
152 RENR5059-14

S/N: ZAH1–Up voltage that is greater than 4.8 VDC for one second.

crankcase pressure as invalid data. The engine
S/N: SFJ1–Up monitoring system is disabled for crankcase
S/N: ZAJ1–Up pressure.
S/N: BRK287–Up Perform the following diagnostic procedure: “Engine

S/N: SEK1–Up Results:

S/N: YAM1–Up
S/N: FDN1515–Up
i01954610
S/N: JCN1–Up
S/N: YAN1–Up
MID 036 - CID 0101 - FMI 04
S/N: LYP1–Up
Crankcase Pressure short to
S/N: YAP1–Up
ground
SMCS Code: 1916-038
S/N: ZAP1–Up
S/N: JM21–Up
S/N: ZBP1–Up
S/N: GD31–Up
S/N: GAR1–Up
S/N: JM31–Up
S/N: PBR1–Up
S/N: JM41–Up
S/N: PDR1–Up
S/N: LD41–Up
S/N: YAR1–Up
S/N: LY71–Up
S/N: YBR1–Up
S/N: LY81–Up
S/N: ZAR1–Up
S/N: LD91–Up
S/N: ZBR1–Up
S/N: LY91–Up
S/N: GZS1–Up
S/N: CPA182–Up
S/N: GZT1–Up
S/N: BMB132–Up
S/N: YAT1–Up
S/N: CNB1100–Up
S/N: YBT1–Up
RENR5059-14 153

S/N: ZAH1–Up voltage that is less than 0.2 VDC for one second. The

crankcase pressure as invalid data. The engine
S/N: SFJ1–Up
monitoring system is disabled for crankcase
S/N: ZAJ1–Up pressure.
S/N: BRK287–Up Perform the following diagnostic procedure: “Engine

S/N: SEK1–Up Results:

S/N: YAM1–Up
S/N: FDN1515–Up
i02319045
S/N: JCN1–Up
S/N: YAN1–Up
MID 036 - CID 0105 - FMI 03
S/N: LYP1–Up
Inlet Manifold Temp Sensor
S/N: YAP1–Up
open/short to +batt
SMCS Code: 1921-038
S/N: ZAP1–Up
S/N: JM21–Up
S/N: ZBP1–Up
S/N: GD31–Up
S/N: GAR1–Up
S/N: JM31–Up
S/N: PBR1–Up
S/N: JM41–Up
S/N: PDR1–Up
S/N: LD41–Up
S/N: YAR1–Up
S/N: LY71–Up
S/N: YBR1–Up
S/N: LY81–Up
S/N: ZAR1–Up
S/N: LD91–Up
S/N: ZBR1–Up
154 RENR5059-14

S/N: YAH1–Up The Electronic Control Module (ECM) detects all of
S/N: ZAH1–Up the following conditions:
S/N: BPJ472–Up • The ECM reads signal voltage that is above 4.8
VDC for one second.
S/N: JDJ1–Up
• The ECM has been powered for at least three
S/N: SBJ1–Up seconds.
S/N: SFJ1–Up
• Diagnostic codes 262-03 and 262-04 are not
S/N: ZAJ1–Up active.
S/N: BRK287–Up System Response:
S/N: SBK1–Up The ECM will log the diagnostic code. The ECM flags
S/N: SEK1–Up the inlet air temperature as invalid data and a default
value of 85 °C (185 °F) is used.
S/N: YAL1–Up
Possible Performance Effect:
S/N: YAM1–Up
• Low power
S/N: FDN1515–Up
• The engine may emit white smoke at start-up.
S/N: JCN1–Up
S/N: YAN1–Up Troubleshooting:
S/N: LYP1–Up Perform the following diagnostic procedure: “Engine

S/N: YAP1–Up Sensor Open/Short Circuit - Test”
S/N: ZAP1–Up Results:

S/N: ZBP1–Up
• OK – STOP.
S/N: GAR1–Up
S/N: PBR1–Up
S/N: PDR1–Up
RENR5059-14 155
i02319076 S/N: SBK1–Up

S/N: SEK1–Up
MID 036 - CID 0105 - FMI 04
Inlet Manifold Temp Sensor S/N: YAL1–Up
short to ground S/N: YAM1–Up

S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: ZAH1–Up The Electronic Control Module (ECM) detects all of
the following conditions:
S/N: BPJ472–Up
• The ECM reads signal voltage that is below 0.2
S/N: JDJ1–Up VDC for one second.
S/N: SBJ1–Up
• The ECM has been powered for at least three
S/N: SFJ1–Up seconds.
S/N: ZAJ1–Up • Diagnostic codes 262-03 and 262-04 are not
active.
S/N: BRK287–Up
156 RENR5059-14
System Response: S/N: JCG1–Up

The ECM will log the diagnostic code. The diagnostic S/N: SBG1–Up
code may be viewed on a display module or on the
Caterpillar Electronic Technician (ET). The ECM flags S/N: JCH1–Up
the inlet air temperature as invalid data and a default S/N: JDH1–Up
value of 85 °C (185 °F) is used.
S/N: LYH1–Up
S/N: YAH1–Up
• Low power
S/N: ZAH1–Up
• The engine may emit white smoke at start-up. S/N: BPJ472–Up
Troubleshooting: S/N: JDJ1–Up
Perform the following diagnostic procedure: “Engine S/N: SBJ1–Up

Sensor Open/Short Circuit - Test” S/N: SFJ1–Up

S/N: BRK287–Up
• OK – STOP.
S/N: SBK1–Up
i01954615
S/N: SEK1–Up
Engine Coolant Temperature S/N: YAM1–Up
open/short to +batt
S/N: FDN1515–Up
SMCS Code: 1906-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
RENR5059-14 157


System Response: S/N: LYH1–Up
The CID-FMI is logged in memory. The ECM flags S/N: YAH1–Up

coolant temperature as invalid data and a default
S/N: ZAH1–Up
value of −40 °C (−40 °F) is used.
S/N: BPJ472–Up
Sensor Open/Short Test” S/N: JDJ1–Up
S/N: SBJ1–Up
Results:
S/N: SFJ1–Up
• OK – STOP. OK
S/N: ZAJ1–Up
• REPAIRED, OK – STOP. REPAIRED, OK S/N: BRK287–Up
i01954616 S/N: SBK1–Up
MID 036 - CID 0110 - FMI 04 S/N: SEK1–Up
Engine Coolant Temperature S/N: YAL1–Up

short to ground S/N: YAM1–Up
S/N: LY91–Up S/N: PDR1–Up
S/N: CNB1100–Up S/N: ZAR1–Up
S/N: YBB1–Up S/N: ZBR1–Up
S/N: YBC1–Up S/N: GZT1–Up

S/N: YAT1–Up
158 RENR5059-14

S/N: GZY1–Up S/N: ZAD1–Up
S/N: JCY1–Up S/N: JDE1–Up
S/N: YAY1–Up S/N: BLF166–Up
S/N: YAZ1–Up S/N: JCG1–Up
Conditions Which Generate This Code: S/N: SBG1–Up
The Electronic Control Module (ECM) reads signal S/N: JCH1–Up

voltage that is less than 0.2 VDC for one second. The S/N: JDH1–Up
diagnostic codes 262-03 and 262-04 are not active. S/N: LYH1–Up
System Response: S/N: YAH1–Up
The CID-FMI is logged in memory. The ECM flags S/N: ZAH1–Up

coolant temperature as invalid data and a default
S/N: BPJ472–Up
value of −40 °C (−40 °F) is used.
S/N: JDJ1–Up
Sensor Open/Short Test” S/N: SBJ1–Up
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i01954667 S/N: SEK1–Up
System Voltage High S/N: YAM1–Up


S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up

S/N: PDR1–Up
S/N: LY91–Up

S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
RENR5059-14 159

The Electronic Control Module (ECM) has been S/N: LYH1–Up

powered for three seconds. The engine is not S/N: YAH1–Up
cranking. The battery voltage is greater than 32 VDC
for two seconds. S/N: ZAH1–Up
System Response: S/N: BPJ472–Up
The CID-FMI is logged in memory. S/N: JDJ1–Up

S/N: SBJ1–Up
Perform the following diagnostic procedure:
“Electrical Power Supply” S/N: SFJ1–Up
S/N: ZAJ1–Up
Results:
S/N: BRK287–Up
• OK – STOP. OK
S/N: SBK1–Up
i01954670 S/N: YAL1–Up
System Voltage Low S/N: FDN1515–Up

160 RENR5059-14

The Electronic Control Module (ECM) has been S/N: JDH1–Up

powered for three seconds. The engine is not S/N: LYH1–Up
cranking. The battery voltage is less than 9 VDC for
two seconds. S/N: YAH1–Up
The CID-FMI is logged in memory. S/N: BPJ472–Up

S/N: JDJ1–Up
“Electrical Power Supply” S/N: SBJ1–Up
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i01954671
S/N: SEK1–Up
System Voltage intermittent/ S/N: YAM1–Up
erratic S/N: FDN1515–Up
RENR5059-14 161

The engine is running but not cranking. One of the S/N: JCH1–Up
following conditions exist. The battery voltage is less S/N: JDH1–Up
than 9 VDC for at least 0.06 seconds. Three times in
the last seven seconds, the battery voltage was less S/N: LYH1–Up
than 9 VDC.
S/N: YAH1–Up
System Response:
S/N: ZAH1–Up
The CID-FMI is logged in memory.
S/N: BPJ472–Up
Perform the following diagnostic procedure: S/N: JDJ1–Up
“Electrical Power Supply”
S/N: SBJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
i02385789
S/N: SEK1–Up
Engine Oil Temperature open/
S/N: YAM1–Up
short to +batt
S/N: FDN1515–Up
SMCS Code: 1929-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
162 RENR5059-14
S/N: PBR1–Up i02385795
S/N: PDR1–Up
MID 036 - CID 0175 - FMI 04
S/N: YAR1–Up Engine Oil Temperature short
S/N: YBR1–Up to ground
S/N: ZBR1–Up
S/N: JM21–Up
S/N: GZS1–Up
S/N: GD31–Up
S/N: GZT1–Up
S/N: JM31–Up
S/N: YAT1–Up
S/N: JM41–Up
S/N: YBT1–Up
S/N: LD41–Up
S/N: YAW1–Up
S/N: LY71–Up
S/N: YBW1–Up
S/N: LY81–Up
S/N: BGX120–Up
S/N: LD91–Up
S/N: GZY1–Up
S/N: LY91–Up
S/N: JCY1–Up
S/N: CPA182–Up
S/N: YAZ1–Up
S/N: CNB1100–Up
The Electronic Control Module (ECM) has been S/N: CMC1107–Up
powered for at least two seconds and the ECM reads
signal voltage that is above 4.9 VDC for eight S/N: YBC1–Up
seconds.
S/N: YBD1–Up
System Response: S/N: ZAD1–Up
The ECM will log the diagnostic code. The ECM flags S/N: JDE1–Up
engine oil temperature as invalid data. The ECM sets
the engine oil temperature to the same value as the S/N: BLF166–Up
coolant temperature. If the coolant temperature
sensor has failed, one of the following values is used: S/N: JCG1–Up
• If the engine is running, the engine oil temperature S/N: SBG1–Up

is set to 65 °C (149 °F). S/N: JCH1–Up
• If the engine is not running, the engine oil S/N: JDH1–Up
temperature is set to −10 °C (14 °F).
S/N: LYH1–Up
Possible Performance Effect: S/N: YAH1–Up
• None S/N: ZAH1–Up
Troubleshooting: S/N: BPJ472–Up
S/N: JDJ1–Up

S/N: ZAJ1–Up
• OK – STOP.
S/N: BRK287–Up
RENR5059-14 163
S/N: SBK1–Up • If the engine is running, the engine oil temperature

is set to 65 °C (149 °F).
S/N: SEK1–Up
• If the engine is not running, the engine oil
S/N: YAL1–Up
temperature is set to −10 °C (14 °F).
S/N: YAM1–Up
S/N: FDN1515–Up
• None
S/N: JCN1–Up
S/N: YAN1–Up Troubleshooting:
S/N: LYP1–Up Perform the following diagnostic procedure: “Engine

S/N: YAP1–Up Sensor Open/Short Test”
S/N: ZAP1–Up Results:

S/N: ZBP1–Up • OK – STOP.
S/N: GAR1–Up i01935913
S/N: PBR1–Up
MID 036 - CID 0190 - FMI 02
S/N: PDR1–Up
Loss of Engine Speed signal
S/N: YAR1–Up
SMCS Code: 1912-038
S/N: YBR1–Up
S/N: JM21–Up
S/N: ZAR1–Up
S/N: GD31–Up
S/N: ZBR1–Up
S/N: JM31–Up
S/N: GZS1–Up
S/N: JM41–Up
S/N: GZT1–Up
S/N: LD41–Up
S/N: YAT1–Up
S/N: LY71–Up
S/N: YBT1–Up
S/N: LY81–Up
S/N: YAW1–Up
S/N: LD91–Up
S/N: YBW1–Up
S/N: LY91–Up
S/N: BGX120–Up
S/N: CPA182–Up
S/N: GZY1–Up
S/N: BMB132–Up
S/N: JCY1–Up
S/N: CNB1100–Up
S/N: YAY1–Up
S/N: YBB1–Up
S/N: YAZ1–Up
S/N: CMC1107–Up
S/N: YBC1–Up
The Electronic Control Module (ECM) has been
powered for at least two seconds and the ECM reads S/N: YBD1–Up
signal voltage that is below 0.2 VDC for eight S/N: ZAD1–Up
seconds.
S/N: JDE1–Up
System Response:
S/N: BLF166–Up
The ECM will log the diagnostic code. The ECM flags
engine oil temperature as invalid data. The ECM sets S/N: JCG1–Up
the engine oil temperature to the same value as the
S/N: SBG1–Up
coolant temperature. If the coolant temperature
sensor has failed, one of the following values is used: S/N: JCH1–Up
164 RENR5059-14

S/N: YAH1–Up The primary engine speed signal cannot be detected.
S/N: ZAH1–Up The timing gear pattern returns within one second
before being lost and the battery voltage is greater
S/N: BPJ472–Up than 9 VDC for the last two seconds. The code is
logged only if the engine has been running for three
S/N: JDJ1–Up seconds. The code will be active and logged if the
Electronic Control Module (ECM) detects an incorrect
S/N: SBJ1–Up signal for one second. The battery voltage is greater
than 9 VDC for the last two seconds.
S/N: SFJ1–Up
S/N: ZAJ1–Up System Response:
S/N: BRK287–Up The code is logged. On engines with a secondary

engine speed/timing sensor, the secondary engine
S/N: SBK1–Up speed/timing signal will be used if the primary engine
speed/timing signal is lost.
S/N: SEK1–Up
S/N: YAL1–Up Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor”
S/N: YAM1–Up
S/N: FDN1515–Up Results:
S/N: JCN1–Up • OK – STOP. OK
S/N: YAN1–Up
S/N: LYP1–Up
i01954681
S/N: YAP1–Up
S/N: ZAP1–Up
MID 036 - CID 0190 - FMI 03
S/N: ZBP1–Up
Engine Speed open/short to
+batt
S/N: GAR1–Up
SMCS Code: 1912-038
S/N: PBR1–Up
S/N: JM21–Up
S/N: PDR1–Up
S/N: GD31–Up
S/N: YAR1–Up
S/N: JM31–Up
S/N: YBR1–Up
S/N: JM41–Up
S/N: ZAR1–Up
S/N: LD41–Up
S/N: ZBR1–Up
S/N: LY71–Up
S/N: GZS1–Up
S/N: LY81–Up
S/N: GZT1–Up
S/N: LD91–Up
S/N: YAT1–Up
S/N: LY91–Up
S/N: YBT1–Up
S/N: CPA182–Up
S/N: YAW1–Up
S/N: BMB132–Up
S/N: YBW1–Up
S/N: CNB1100–Up
S/N: BGX120–Up
S/N: YBB1–Up
S/N: GZY1–Up
S/N: CMC1107–Up
S/N: JCY1–Up
S/N: YBC1–Up
S/N: YAY1–Up
RENR5059-14 165

S/N: YAH1–Up A wire on the primary engine speed/timing sensor is
S/N: ZAH1–Up disconnected and/or broken. There is a short circuit
to the +Battery terminal.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
The CID-FMI is logged in memory. On engines with a
S/N: SBJ1–Up secondary engine speed/timing sensor, the
secondary engine speed/timing signal will be used if
S/N: SFJ1–Up the primary engine speed/timing signal is lost.
S/N: ZAJ1–Up
S/N: BRK287–Up Speed/Timing Sensor”
S/N: SBK1–Up
Results:
S/N: SEK1–Up
• OK – STOP. OK
S/N: YAL1–Up
S/N: FDN1515–Up i02168582
S/N: JCN1–Up MID 036 - CID 0248 - FMI 09 Cat

S/N: YAN1–Up Data Link not communicating
S/N: LYP1–Up SMCS Code: 1901-038
S/N: YAP1–Up S/N: JM21–Up
S/N: ZAP1–Up S/N: GD31–Up
S/N: PBR1–Up S/N: LD41–Up
S/N: YAT1–Up
166 RENR5059-14

S/N: YAH1–Up The battery voltage to the Electronic Control Module
S/N: ZAH1–Up (ECM) has been above 9 VDC for the last two
seconds. The engine is not cranking. Communication
S/N: BPJ472–Up was lost for two or more seconds.
S/N: SBJ1–Up The CID-FMI is logged in memory.
S/N: SFJ1–Up
Perform the following diagnostic procedure: “Cat
S/N: ZAJ1–Up Data Link”
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. OK
S/N: SEK1–Up
S/N: YAM1–Up i02385799

S/N: JCN1–Up Personality Module mismatch
RENR5059-14 167

S/N: YAH1–Up The flash file that is used for replacement is for a
S/N: ZAH1–Up different engine family or for a different engine
application.
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
The Electronic Control Module (ECM) will not log this
S/N: SBJ1–Up code. The Caterpillar Electronic Technician (ET) will
not be able to clear the code.
S/N: SFJ1–Up
S/N: ZAJ1–Up Possible Performance Effect:
S/N: BRK287–Up Fuel injection is disabled. The engine will not start.
S/N: SBK1–Up Troubleshooting:

S/N: SEK1–Up
Check the Part Number of the Flash File
S/N: YAL1–Up
A. Use Cat ET to verify that the part number for the
S/N: YAM1–Up flash file agrees with the latest update that is
S/N: FDN1515–Up available on Service Technician Workbench
(STW), or on SIS Web.
S/N: JCN1–Up
Expected Result:
S/N: YAN1–Up
S/N: LYP1–Up The correct flash file is installed in the ECM.
S/N: YAP1–Up Results:

S/N: ZAP1–Up • OK – The correct flash file is installed in the ECM.
S/N: ZBP1–Up
Repair: The engine will not start until the 253-
S/N: GAR1–Up 02 diagnostic code is cleared. Clearing this
code requires factory passwords.
S/N: PBR1–Up
S/N: PDR1–Up Acquire factory passwords. Clear the 253-02
diagnostic code. Return the engine to service.
S/N: YAR1–Up
STOP.
S/N: YBR1–Up
S/N: ZAR1–Up
168 RENR5059-14
• Not OK – The correct flash file is not installed in S/N: JDJ1–Up

the ECM.
S/N: SBJ1–Up
Repair: Flash program the ECM with the S/N: SFJ1–Up
correct flash file. Refer to Troubleshooting,
“Flash Programming”. Verify that the problem is S/N: ZAJ1–Up
resolved.
S/N: BRK287–Up
STOP. S/N: SBK1–Up
i01961664 S/N: SEK1–Up
Electronic Control Module S/N: YAM1–Up

Error S/N: FDN1515–Up

S/N: YAH1–Up The Electronic Control Module (ECM) has detected
an internal fault.
S/N: ZAH1–Up
S/N: BPJ472–Up
RENR5059-14 169

The CID-FMI is logged in memory. Engine power and S/N: ZAH1–Up
performance may be affected. All normal functions of
the ECM may be affected. S/N: BPJ472–Up
S/N: JDJ1–Up
Perform the following diagnostic procedure: “ECM/
Personality Module” S/N: SBJ1–Up
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i01935923 S/N: SEK1–Up
Engine Timing calibration S/N: YAM1–Up

required S/N: FDN1515–Up
S/N: LYH1–Up
170 RENR5059-14

The engine speed/timing sensor has not been S/N: JCH1–Up
calibrated.
S/N: JDH1–Up
Note: This will not keep the engine from running. The
S/N: LYH1–Up
fuel injection timing may be out of adjustment.
S/N: YAH1–Up
System Response:
S/N: ZAH1–Up
The code is logged.
S/N: BPJ472–Up
Perform the following diagnostic procedure: “Engine S/N: JDJ1–Up
Speed/Timing Sensor - Calibrate”
S/N: SBJ1–Up
i01954690
S/N: SBK1–Up
S/N: SEK1–Up
MID 036 - CID 0262 - FMI 03 5
S/N: YAL1–Up
Volt Sensor DC Power Supply
S/N: YAM1–Up
short to +batt
S/N: FDN1515–Up
SMCS Code: 1408-038-NS
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
RENR5059-14 171

The Electronic Control Module (ECM) reads an S/N: SBG1–Up

analog sensor supply voltage above 5.2 VDC for two S/N: JCH1–Up
or more seconds. The ECM has been powered for
three seconds. S/N: JDH1–Up
Note: Normal voltage is 5.0 ± 0.2 VDC. S/N: LYH1–Up
The CID-FMI is logged in memory. Analog sensors S/N: ZAH1–Up

are set to the default values. S/N: BPJ472–Up
Perform the following diagnostic procedure: “Analog S/N: JDJ1–Up

Sensor Supply” S/N: SBJ1–Up

S/N: BRK287–Up
S/N: SBK1–Up
i01954691
S/N: SEK1–Up
MID 036 - CID 0262 - FMI 04 5 S/N: YAL1–Up
Volt Sensor DC Power Supply S/N: YAM1–Up
short to ground S/N: FDN1515–Up
S/N: JCN1–Up
172 RENR5059-14

The Electronic Control Module (ECM) reads an S/N: SBG1–Up

analog sensor supply voltage below 4.8 VDC for two S/N: JCH1–Up
seconds. The ECM has been powered for three
seconds. S/N: JDH1–Up
Note: Normal voltage is 5.0 ± 0.2 VDC. S/N: LYH1–Up
The CID-FMI is logged in memory. The analog S/N: ZAH1–Up

sensors are set to the default values. S/N: BPJ472–Up
Perform the following diagnostic procedure: “Analog S/N: JDJ1–Up


S/N: BRK287–Up
S/N: SBK1–Up
i01954692
S/N: SEK1–Up
Digital Sensor Supply short to S/N: YAM1–Up
+batt S/N: FDN1515–Up
S/N: JCN1–Up
RENR5059-14 173

The Electronic Control Module (ECM) reads a digital S/N: JCH1–Up

sensor supply voltage above 8.5 VDC for two S/N: JDH1–Up
seconds. S/N: LYH1–Up
Note: Normal voltage is 8.0 ± 0.4 VDC. S/N: YAH1–Up

S/N: JDJ1–Up
Perform the following diagnostic procedure: “Digital
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i01954694 S/N: SEK1–Up
Digital Sensor Supply short to S/N: YAM1–Up

ground S/N: FDN1515–Up
SMCS Code: 1408-038-NS S/N: JCN1–Up

174 RENR5059-14

The Electronic Control Module (ECM) reads a digital S/N: JCH1–Up

sensor supply voltage below 7.5 VDC for two S/N: JDH1–Up
seconds. S/N: LYH1–Up
Note: Normal voltage is 8.0 ± 0.4 VDC. S/N: YAH1–Up

S/N: JDJ1–Up
Perform the following diagnostic procedure: “Digital
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i02305005 S/N: SEK1–Up
Check Programmable S/N: YAM1–Up

Parameters S/N: FDN1515–Up

RENR5059-14 175
S/N: PBR1–Up i02385805
S/N: PDR1–Up
MID 036 - CID 0273 - FMI 00
S/N: YAR1–Up Turbo Outlet Pressure above
S/N: YBR1–Up normal
S/N: ZBR1–Up
S/N: JM21–Up
S/N: GZS1–Up
S/N: GD31–Up
S/N: GZT1–Up
S/N: JM31–Up
S/N: YAT1–Up
S/N: JM41–Up
S/N: YBT1–Up
S/N: LD41–Up
S/N: YAW1–Up
S/N: LY71–Up
S/N: YBW1–Up
S/N: LY81–Up
S/N: BGX120–Up
S/N: LD91–Up
S/N: GZY1–Up
S/N: LY91–Up
S/N: JCY1–Up
S/N: CPA182–Up
S/N: YAZ1–Up
S/N: CNB1100–Up
The Electronic Control Module (ECM) detects that S/N: CMC1107–Up
one or more of the programmable parameters have
not been programmed. S/N: YBC1–Up
System Response: S/N: YBD1–Up
The diagnostic code will only be active. Any S/N: ZAD1–Up

unprogrammed parameters are set to the default S/N: JDE1–Up
value.
S/N: BLF166–Up
S/N: JCG1–Up
The engine performance may be affected by
unprogrammed parameters. The unprogrammed S/N: SBG1–Up
parameters determine the action that is taken by the S/N: JCH1–Up
ECM. The ECM may use a default torque map or the
ECM may limit the engine to low idle. S/N: JDH1–Up
Troubleshooting: S/N: LYH1–Up
S/N: YAH1–Up
Reprogram the missing system configuration
S/N: ZAH1–Up
parameters. Refer to Troubleshooting, “System
Configuration Parameters” for additional information. S/N: BPJ472–Up
Results: S/N: JDJ1–Up
S/N: SBJ1–Up
• OK – STOP.
S/N: SFJ1–Up
S/N: ZAJ1–Up
S/N: BRK287–Up
176 RENR5059-14
S/N: SBK1–Up Possible Performance Effect:

S/N: SEK1–Up Low power
S/N: YAL1–Up Troubleshooting:
S/N: YAM1–Up
S/N: FDN1515–Up Sensor Open/Short Test”
S/N: JCN1–Up
Results:
S/N: YAN1–Up
• OK – STOP. OK
S/N: LYP1–Up
S/N: YAP1–Up • REPAIRED, OK – STOP. REPAIRED, OK
S/N: ZAP1–Up i01936079
S/N: ZBP1–Up MID 036 - CID 0273 - FMI 03

S/N: GAR1–Up Turbo Outlet Pressure open/
S/N: PBR1–Up short to +batt
S/N: PDR1–Up SMCS Code: 1052-038
S/N: YAR1–Up S/N: JM21–Up
S/N: YBR1–Up S/N: GD31–Up
S/N: ZAR1–Up S/N: JM31–Up
S/N: ZBR1–Up S/N: JM41–Up
S/N: GZS1–Up S/N: LD41–Up
S/N: GZT1–Up S/N: LY71–Up
S/N: YAT1–Up S/N: LY81–Up
S/N: YBT1–Up S/N: LD91–Up
S/N: YAW1–Up S/N: LY91–Up
S/N: YBW1–Up S/N: CPA182–Up
S/N: BGX120–Up S/N: BMB132–Up
S/N: GZY1–Up S/N: CNB1100–Up
S/N: JCY1–Up S/N: YBB1–Up
S/N: YAY1–Up S/N: CMC1107–Up
S/N: YAZ1–Up S/N: YBC1–Up
Conditions Which Generate This Code: S/N: YBD1–Up
The Electronic Control Module (ECM) reads S/N: ZAD1–Up
turbocharger outlet pressure above 200 kPa (29 psi).
The engine speed is within 50 rpm of low idle for five S/N: JDE1–Up
seconds. The diagnostic codes 262-03, 262-04, 273- S/N: BLF166–Up
03, and 273-04 are not active.
S/N: JCG1–Up
System Response:
S/N: SBG1–Up
The diagnostic code is logged in memory. The ECM
flags turbocharger outlet pressure as invalid data and S/N: JCH1–Up
a default value of 0 kPa (0 psi) is used. S/N: JDH1–Up
S/N: LYH1–Up
RENR5059-14 177

voltage that is greater than 4.8 VDC for one second.
S/N: BPJ472–Up The ECM has been powered for three seconds. The
S/N: JDJ1–Up
S/N: SFJ1–Up The code is logged. The ECM flags turbocharger

compressor outlet pressure as invalid data and a
S/N: ZAJ1–Up default value of 0 kPa (0 psi) is used.
S/N: BRK287–Up
S/N: SEK1–Up
Results:
S/N: YAL1–Up
• OK – STOP. OK
S/N: YAM1–Up
i01936089
S/N: JCN1–Up
S/N: LYP1–Up Turbo Outlet Pressure short to
S/N: YAP1–Up ground

S/N: JCG1–Up
178 RENR5059-14


S/N: SBJ1–Up The code is logged. The ECM flags turbocharger
compressor outlet pressure as invalid data and a
S/N: SFJ1–Up default value of 0 kPa (0 psi) is used.
S/N: ZAJ1–Up
S/N: BRK287–Up Sensor Open/Short Test”
S/N: SBK1–Up
Results:
S/N: SEK1–Up
• OK – STOP. OK
S/N: YAL1–Up
S/N: FDN1515–Up i01954758

S/N: YAN1–Up Atmospheric Pressure open/
RENR5059-14 179


S/N: SBJ1–Up The CID-FMI is logged in memory. The turbocharger
compressor inlet pressure sensor (if equipped) is
S/N: SFJ1–Up
used as a backup for atmospheric pressure.
S/N: ZAJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
Results:
S/N: SEK1–Up

S/N: FDN1515–Up i01954760

S/N: YAN1–Up Atmospheric Pressure short to
S/N: LYP1–Up ground
S/N: YAW1–Up
180 RENR5059-14

S/N: YAH1–Up The Electronic Control Module (ECM) reads an
S/N: ZAH1–Up atmospheric pressure signal voltage below 1.7 VDC
for one second. The ECM has been powered for
S/N: BPJ472–Up three seconds. The diagnostic codes 262-03 and
262-04 are not active.
S/N: JDJ1–Up
System Response:
S/N: SBJ1–Up
The CID-FMI is logged in memory. The turbocharger
S/N: SFJ1–Up
compressor inlet pressure sensor (if equipped) is
S/N: ZAJ1–Up used as a backup for atmospheric pressure. The
atmospheric pressure is set to a default value of
S/N: BRK287–Up 45 kPa (7 psi).
S/N: SBK1–Up
S/N: SEK1–Up Sensor Open/Short Test”
S/N: YAL1–Up Results:
S/N: YAM1–Up
• OK – STOP. OK
S/N: FDN1515–Up
S/N: JCN1–Up
i01935990
S/N: YAN1–Up
S/N: LYP1–Up MID 036 - CID 0275 - FMI 03
S/N: YAP1–Up Right Turbo Inlet Pressure
S/N: ZAP1–Up open/short to +batt
S/N: ZBP1–Up SMCS Code: 1052-038

S/N: PBR1–Up S/N: GD31–Up
S/N: GZS1–Up S/N: LD91–Up
RENR5059-14 181


S/N: SBJ1–Up The code is logged. The right turbocharger
compressor inlet pressure is set to a default value of
S/N: SFJ1–Up 45 kPa (7 psi).
S/N: ZAJ1–Up
S/N: SBK1–Up
Results:
S/N: SEK1–Up
• OK – STOP. OK
S/N: YAL1–Up
S/N: FDN1515–Up i01954762

S/N: YAN1–Up Right Turbo Inlet Pressure
S/N: LYP1–Up short to ground
182 RENR5059-14


S/N: SBJ1–Up The CID-FMI is logged in memory. The turbocharger
S/N: SFJ1–Up
45 kPa (7 psi).
S/N: ZAJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
Results:
S/N: SEK1–Up
• OK – STOP. OK
S/N: YAL1–Up
S/N: FDN1515–Up i02174525

S/N: YAN1–Up Left Turbo Inlet Pressure open/
S/N: ZBP1–Up
RENR5059-14 183


S/N: SBJ1–Up The code is logged. The left turbocharger
S/N: SFJ1–Up 45 kPa (6.5 psi).
S/N: ZAJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
Results:
S/N: SEK1–Up
• OK – STOP. OK
S/N: YAL1–Up
S/N: FDN1515–Up
S/N: JCN1–Up
S/N: YAN1–Up
184 RENR5059-14
i01936097 S/N: SBK1–Up

S/N: SEK1–Up
MID 036 - CID 0276 - FMI 04
Left Turbo Inlet Pressure short S/N: YAL1–Up
to ground S/N: YAM1–Up

S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
voltage that is less than 0.2 VDC for one second. The
S/N: BPJ472–Up ECM has been powered for three seconds. The
S/N: JDJ1–Up
S/N: SFJ1–Up The code is logged. The turbocharger compressor

inlet pressure is set to a default value of 45 kPa
S/N: ZAJ1–Up (7 psi).
S/N: BRK287–Up
RENR5059-14 185

S/N: SBJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
i01954871
S/N: SEK1–Up
Aftercooler Temperature open/ S/N: YAM1–Up
short to +batt
S/N: FDN1515–Up
SMCS Code: 1063-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up
S/N: ZAH1–Up
S/N: BPJ472–Up
186 RENR5059-14
Conditions Which Generate This Code: S/N: BLF166–Up

The Electronic Control Module (ECM) reads an S/N: JCG1–Up
output voltage that is 4.8 VDC or more for one
second. The ECM has been powered for three S/N: SBG1–Up
seconds. The CID-FMI 262-03 and/or the CID-FMI S/N: JCH1–Up
262-04 are not active.
S/N: JDH1–Up
System Response:
S/N: LYH1–Up
The CID-FMI is logged in memory. The ECM no
longer optimizes engine operation according to S/N: YAH1–Up
aftercooler temperature. The ECM flags aftercooler
temperature as invalid data. The engine monitoring S/N: ZAH1–Up
system is disabled for aftercooler temperature. S/N: BPJ472–Up

S/N: BRK287–Up
S/N: SBK1–Up
i01954877
S/N: SEK1–Up
Aftercooler Temperature short S/N: YAM1–Up
to ground S/N: FDN1515–Up
SMCS Code: 1063-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
RENR5059-14 187
S/N: BGX120–Up S/N: CMC1107–Up

S/N: GZY1–Up S/N: YBC1–Up
S/N: JCY1–Up S/N: YBD1–Up
S/N: YAY1–Up S/N: ZAD1–Up
S/N: YAZ1–Up S/N: JDE1–Up
Conditions Which Generate This Code: S/N: BLF166–Up
The Electronic Control Module (ECM) reads an S/N: JCG1–Up

output voltage that is 0.2 VDC or less for one second. S/N: SBG1–Up
CID-FMI 262-03 and/or the CID-FMI 262-04 are not S/N: JCH1–Up
active.
S/N: JDH1–Up
System Response:
S/N: LYH1–Up
The CID-FMI is logged in memory. The ECM no
longer optimizes engine operation according to S/N: YAH1–Up
aftercooler temperature. The ECM flags aftercooler S/N: ZAH1–Up
temperature as invalid data. The engine monitoring
system is disabled for aftercooler temperature. S/N: BPJ472–Up


S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
S/N: SBK1–Up
i01961675
S/N: SEK1–Up
Unfiltered Fuel Pressure S/N: YAM1–Up
misinstalled S/N: FDN1515–Up
S/N: JCN1–Up
188 RENR5059-14

The Electronic Control Module (ECM) reads a S/N: JDH1–Up

negative differential pressure between the unfiltered S/N: LYH1–Up
fuel pressure sensor and the filtered fuel pressure
sensor. The sensors may be installed incorrectly. S/N: YAH1–Up
The CID-FMI is logged in memory. The ECM flags S/N: BPJ472–Up

unfiltered fuel pressure as invalid data. The engine
S/N: JDJ1–Up
monitoring system is disabled for unfiltered fuel
pressure. S/N: SBJ1–Up
S/N: SFJ1–Up
Correctly install the sensor.
S/N: ZAJ1–Up
Results:
S/N: BRK287–Up
i01954880 S/N: SEK1–Up
Unfiltered Fuel Pressure open/ S/N: YAM1–Up

short to +batt S/N: FDN1515–Up
SMCS Code: 1261-038-NS S/N: JCN1–Up

RENR5059-14 189


System Response: S/N: LYH1–Up
The CID-FMI is logged in memory. The ECM flags S/N: YAH1–Up

fuel pressure as invalid data. The engine monitoring
S/N: ZAH1–Up
system for this feature will be disabled.
S/N: BPJ472–Up
S/N: JDJ1–Up
S/N: SBJ1–Up
Results:
S/N: SFJ1–Up
i01954883 S/N: SBK1–Up
MID 036 - CID 0289 - FMI 04 S/N: SEK1–Up
Unfiltered Fuel Pressure short S/N: YAL1–Up
to ground S/N: YAM1–Up

SMCS Code: 1261-038-NS S/N: FDN1515–Up

S/N: PBR1–Up
190 RENR5059-14

The Electronic Control Module (ECM) reads signal S/N: JCH1–Up

voltage that is below 0.2 VDC for one second. The S/N: JDH1–Up
diagnostic codes 262-03 and 262-04 are not active. S/N: LYH1–Up
The CID-FMI is logged in memory. The ECM flags S/N: ZAH1–Up

unfiltered fuel pressure as invalid data. The engine
S/N: BPJ472–Up
monitoring system is disabled for unfiltered fuel
pressure. S/N: JDJ1–Up
Perform the following diagnostic procedure: “Engine S/N: SBJ1–Up

Sensor Open/Short Test” S/N: SFJ1–Up

S/N: SBK1–Up
S/N: SEK1–Up
i01961678
S/N: YAL1–Up
Incorrect ECS Switch inputs S/N: FDN1515–Up
SMCS Code: 1901-038
S/N: JCN1–Up
RENR5059-14 191

S/N: PBR1–Up S/N: LD41–Up
One line for the Engine Control Switch (ECS) is open S/N: JDH1–Up
and one line is low. S/N: LYH1–Up
The CID-FMI is logged in memory. The Electronic S/N: ZAH1–Up
Control Module (ECM) will flag the ignition switch as
invalid data. S/N: BPJ472–Up
S/N: JDJ1–Up
Control Switch (ECS)” S/N: SBJ1–Up
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i01961679
S/N: SEK1–Up
Incorrect Remote E-Stop S/N: YAM1–Up
Switch inputs S/N: FDN1515–Up
192 RENR5059-14
S/N: YAP1–Up S/N: JM31–Up

S/N: ZBP1–Up S/N: LD41–Up
S/N: GAR1–Up S/N: LY71–Up
S/N: YBR1–Up S/N: CPA182–Up
S/N: ZAR1–Up S/N: BMB132–Up
S/N: ZBR1–Up S/N: CNB1100–Up
S/N: GZS1–Up S/N: YBB1–Up
S/N: GZT1–Up S/N: CMC1107–Up
S/N: YAT1–Up S/N: YBC1–Up
S/N: YBT1–Up S/N: YBD1–Up
S/N: YAW1–Up S/N: ZAD1–Up
S/N: YBW1–Up S/N: JDE1–Up
S/N: BGX120–Up S/N: BLF166–Up
S/N: GZY1–Up S/N: JCG1–Up
S/N: JCY1–Up S/N: SBG1–Up
S/N: YAY1–Up S/N: JCH1–Up
S/N: YAZ1–Up S/N: JDH1–Up
Conditions Which Generate This Code: S/N: LYH1–Up
One line for the customer shutdown switch is open S/N: YAH1–Up
and one line is low. S/N: ZAH1–Up
System Response: S/N: BPJ472–Up
The CID-FMI is logged in memory. S/N: JDJ1–Up
S/N: SBJ1–Up
“Emergency Stop Switch” S/N: SFJ1–Up

S/N: BRK287–Up
• OK – STOP. OK
S/N: SBK1–Up
S/N: SEK1–Up
i01954889
S/N: YAL1–Up
Pre-Lube Relay open circuit S/N: FDN1515–Up
RENR5059-14 193
S/N: YAP1–Up i01954893
S/N: ZAP1–Up
MID 036 - CID 0338 - FMI 06
S/N: ZBP1–Up Pre-Lube Relay short to
S/N: GAR1–Up ground
S/N: PBR1–Up SMCS Code: 1319-038
S/N: PDR1–Up
S/N: JM21–Up
S/N: YAR1–Up
S/N: GD31–Up
S/N: YBR1–Up
S/N: JM31–Up
S/N: ZAR1–Up
S/N: JM41–Up
S/N: ZBR1–Up
S/N: LD41–Up
S/N: GZS1–Up
S/N: LY71–Up
S/N: GZT1–Up
S/N: LY81–Up
S/N: YAT1–Up
S/N: LD91–Up
S/N: YBT1–Up
S/N: LY91–Up
S/N: YAW1–Up
S/N: CPA182–Up
S/N: YBW1–Up S/N: BMB132–Up
S/N: BGX120–Up
S/N: CNB1100–Up
S/N: GZY1–Up
S/N: YBB1–Up
S/N: JCY1–Up S/N: CMC1107–Up
S/N: YAY1–Up
S/N: YBC1–Up
S/N: YAZ1–Up
S/N: YBD1–Up
Conditions Which Generate This Code: S/N: ZAD1–Up
The Electronic Control Module (ECM) detects an S/N: JDE1–Up
open circuit at the prelube relay. The ECM detects a
short to battery voltage at the prelube relay. S/N: BLF166–Up
System Response: S/N: JCG1–Up

S/N: SBG1–Up
S/N: JCH1–Up
S/N: JDH1–Up
“Prelubrication System”
S/N: LYH1–Up
Results:
S/N: YAH1–Up
• OK – STOP. OK S/N: ZAH1–Up
• REPAIRED, OK – STOP. REPAIRED, OK S/N: BPJ472–Up
S/N: JDJ1–Up
S/N: SBJ1–Up
S/N: SFJ1–Up
S/N: ZAJ1–Up
S/N: BRK287–Up
194 RENR5059-14
S/N: SBK1–Up • OK – STOP. OK

S/N: SEK1–Up • REPAIRED, OK – STOP. OK
S/N: YAL1–Up i01954915
S/N: YAM1–Up
MID 036 - CID 0446 - FMI 05 Air
S/N: FDN1515–Up
Shutoff Relay open
S/N: JCN1–Up
SMCS Code: 1078-038
S/N: YAN1–Up
S/N: JM21–Up
S/N: LYP1–Up
S/N: GD31–Up
S/N: YAP1–Up
S/N: JM31–Up
S/N: ZAP1–Up
S/N: JM41–Up
S/N: ZBP1–Up
S/N: LD41–Up
S/N: GAR1–Up
S/N: LY71–Up
S/N: PBR1–Up
S/N: LY81–Up
S/N: PDR1–Up
S/N: LD91–Up
S/N: YAR1–Up
S/N: LY91–Up
S/N: YBR1–Up
S/N: CPA182–Up
S/N: ZAR1–Up
S/N: BMB132–Up
S/N: ZBR1–Up
S/N: CNB1100–Up
S/N: GZS1–Up
S/N: YBB1–Up
S/N: GZT1–Up
S/N: CMC1107–Up
S/N: YAT1–Up
S/N: YBC1–Up
S/N: YBT1–Up
S/N: YBD1–Up
S/N: YAW1–Up
S/N: ZAD1–Up
S/N: YBW1–Up
S/N: JDE1–Up
S/N: BGX120–Up
S/N: BLF166–Up
S/N: GZY1–Up
S/N: JCG1–Up
S/N: JCY1–Up
S/N: SBG1–Up
S/N: YAY1–Up
S/N: JCH1–Up
S/N: YAZ1–Up
S/N: JDH1–Up
S/N: LYH1–Up
circuit at the prelube relay. S/N: YAH1–Up
S/N: ZAH1–Up
System Response:
S/N: BPJ472–Up
S/N: JDJ1–Up
Perform the following diagnostic procedure: S/N: SBJ1–Up
“Prelubrication System”
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
RENR5059-14 195
S/N: BRK287–Up Results:

S/N: SBK1–Up • OK – STOP. OK
S/N: SEK1–Up
S/N: YAL1–Up
i01954913
S/N: YAM1–Up
S/N: FDN1515–Up MID 036 - CID 0446 - FMI 06 Air
S/N: JCN1–Up
Shutoff Relay short
SMCS Code: 1078-038
S/N: YAN1–Up

S/N: JDH1–Up
S/N: LYH1–Up
open circuit and/or a short circuit to battery condition. S/N: YAH1–Up
The ECM can only detect this condition when the air
shutoff relay is not energized. S/N: ZAH1–Up
S/N: BPJ472–Up
System Response:
S/N: JDJ1–Up
S/N: SBJ1–Up
Perform the following diagnostic procedure: “Air
S/N: SFJ1–Up
Shutoff System”
196 RENR5059-14
S/N: ZAJ1–Up Perform the following diagnostic procedure: “Air

Shutoff System”
S/N: BRK287–Up
S/N: SBK1–Up Results:
S/N: SEK1–Up • OK – STOP. OK

S/N: YAL1–Up
S/N: YAM1–Up
i01961681
S/N: FDN1515–Up
S/N: JCN1–Up
MID 036 - CID 0542 - FMI 02
S/N: YAN1–Up
Unfiltered Engine Oil Pressure
misinstalled
S/N: LYP1–Up
SMCS Code: 1924-038
S/N: YAP1–Up
S/N: JM21–Up
S/N: ZAP1–Up
S/N: GD31–Up
S/N: ZBP1–Up
S/N: JM31–Up
S/N: GAR1–Up
S/N: JM41–Up
S/N: PBR1–Up
S/N: LD41–Up
S/N: PDR1–Up
S/N: LY71–Up
S/N: YAR1–Up
S/N: LY81–Up
S/N: YBR1–Up
S/N: LD91–Up
S/N: ZAR1–Up
S/N: LY91–Up
S/N: ZBR1–Up
S/N: CPA182–Up
S/N: GZS1–Up
S/N: BMB132–Up
S/N: GZT1–Up
S/N: CNB1100–Up
S/N: YAT1–Up
S/N: YBB1–Up
S/N: YBT1–Up
S/N: CMC1107–Up
S/N: YAW1–Up
S/N: YBC1–Up
S/N: YBW1–Up
S/N: YBD1–Up
S/N: BGX120–Up
S/N: ZAD1–Up
S/N: GZY1–Up
S/N: JDE1–Up
S/N: JCY1–Up
S/N: BLF166–Up
S/N: YAY1–Up
S/N: JCG1–Up
S/N: YAZ1–Up
S/N: SBG1–Up
S/N: JCH1–Up
circuit to ground. The ECM can only detect this S/N: JDH1–Up
condition when the air shutoff relay is not energized.
S/N: LYH1–Up
The CID-FMI is logged in memory. S/N: ZAH1–Up
S/N: BPJ472–Up
RENR5059-14 197
S/N: JDJ1–Up Conditions Which Generate This Code:

S/N: SBJ1–Up The Electronic Control Module (ECM) reads a
negative differential pressure between the unfiltered
S/N: SFJ1–Up engine oil pressure sensor and the filtered engine oil
S/N: ZAJ1–Up pressure sensor. The sensors may be installed
incorrectly.
S/N: BRK287–Up
System Response:
S/N: SBK1–Up
The CID-FMI is logged in memory. The ECM flags
S/N: SEK1–Up the unfiltered engine oil pressure as invalid data. The
engine monitoring system is disabled for unfiltered
S/N: YAL1–Up engine oil pressure.
S/N: YAM1–Up
S/N: FDN1515–Up Correctly install the sensor.
S/N: JCN1–Up Results:
S/N: YAN1–Up
S/N: LYP1–Up
i01954911
S/N: YAP1–Up
S/N: ZAP1–Up
MID 036 - CID 0542 - FMI 03
S/N: ZBP1–Up
Unfiltered Engine Oil Pressure
open/short to +batt
S/N: GAR1–Up
SMCS Code: 1924-038
S/N: PBR1–Up
S/N: JM21–Up
S/N: PDR1–Up
S/N: GD31–Up
S/N: YAR1–Up
S/N: JM31–Up
S/N: YBR1–Up
S/N: JM41–Up
S/N: ZAR1–Up
S/N: LD41–Up
S/N: ZBR1–Up
S/N: LY71–Up
S/N: GZS1–Up
S/N: LY81–Up
S/N: GZT1–Up
S/N: LD91–Up
S/N: YAT1–Up
S/N: LY91–Up
S/N: YBT1–Up
S/N: CPA182–Up
S/N: YAW1–Up
S/N: BMB132–Up
S/N: YBW1–Up
S/N: CNB1100–Up
S/N: BGX120–Up
S/N: YBB1–Up
S/N: GZY1–Up
S/N: CMC1107–Up
S/N: JCY1–Up
S/N: YBC1–Up
S/N: YAY1–Up
S/N: YBD1–Up
S/N: YAZ1–Up
S/N: ZAD1–Up
S/N: JDE1–Up
S/N: BLF166–Up
S/N: JCG1–Up
198 RENR5059-14


S/N: SBJ1–Up The CID-FMI is logged in memory. The ECM flags oil
S/N: SFJ1–Up 500 kPa (73 psi) is used.
S/N: ZAJ1–Up
S/N: BRK287–Up
S/N: SBK1–Up
Results:
S/N: SEK1–Up
• OK – STOP. OK
S/N: YAL1–Up
S/N: FDN1515–Up i01954910

S/N: YAN1–Up Unfiltered Engine Oil Pressure
S/N: LYP1–Up short to ground
S/N: GZY1–Up
RENR5059-14 199

S/N: ZAH1–Up voltage that is below 0.2 VDC for one second. The

S/N: SBJ1–Up The CID-FMI is logged in memory. The ECM flags oil
S/N: SFJ1–Up 500 kPa (73 psi) is used.
S/N: ZAJ1–Up
S/N: SBK1–Up
Results:
S/N: SEK1–Up
• OK – STOP. OK
S/N: YAL1–Up
S/N: FDN1515–Up i02386027

S/N: YAN1–Up Ether Hold Relay open/short to
S/N: LYP1–Up ground
S/N: YBT1–Up
200 RENR5059-14

S/N: YAH1–Up The Electronic Control Module (ECM) has been
S/N: ZAH1–Up powered up for two seconds. The ECM detects an
open circuit and/or a short circuit to ground at the
S/N: BPJ472–Up output to the ether hold relay.

S/N: SBJ1–Up The CID-FMI is logged in memory. Ether injection is
disabled.
S/N: SFJ1–Up
S/N: BRK287–Up The engine may be difficult to start.

S/N: SEK1–Up
Perform the following diagnostic procedure: “Ether
S/N: YAL1–Up Injection System”
S/N: YAM1–Up Results:
S/N: FDN1515–Up
• OK – STOP. OK
S/N: JCN1–Up
S/N: YAN1–Up
i02386006
S/N: LYP1–Up
S/N: YAP1–Up MID 036 - CID 0546 - FMI 06
S/N: ZAP1–Up Ether Hold Relay short to +batt

RENR5059-14 201

S/N: YAH1–Up The Electronic Control Module (ECM) has been
S/N: ZAH1–Up powered up for two seconds. The ECM detects a
short circuit to the +Battery at the output to the ether
S/N: BPJ472–Up hold relay.

S/N: SBJ1–Up The CID-FMI is logged in memory. Ether injection is
disabled.
S/N: SFJ1–Up
S/N: BRK287–Up The engine may be difficult to start.

S/N: SEK1–Up
Perform the following diagnostic procedure: “Ether
S/N: YAL1–Up Injection System”
S/N: YAM1–Up Results:
S/N: FDN1515–Up
• OK – STOP. OK
S/N: JCN1–Up
S/N: YAN1–Up
i02338060
S/N: LYP1–Up
S/N: YAP1–Up MID 036 - CID 0799 - FMI 12
S/N: ZAP1–Up Need Service tool update

202 RENR5059-14

S/N: YAH1–Up The flash file is for a different engine family, a
S/N: ZAH1–Up different engine, or a different application. The
diagnostic code 253-02 is active.
S/N: BPJ472–Up
An attempt is made in order to reset the interlock
S/N: JDJ1–Up code with an old version of the Caterpillar Electronic
Technician (ET).
S/N: SBJ1–Up
System Response:
S/N: SFJ1–Up
S/N: ZAJ1–Up The code is not logged. The diagnostic code 253-02
will always be active when this diagnostic code is
S/N: BRK287–Up active and fuel injection will be disabled.
S/N: SBK1–Up
A. Verify that the diagnostic codes 253-02 and 799-
S/N: SEK1–Up 12 are active.
S/N: YAL1–Up
Results:
S/N: YAM1–Up
• OK – The diagnostic codes 253-02 and 799-12 are
S/N: FDN1515–Up
active.
S/N: JCN1–Up
Repair: In order to reset the ECM interlock on
S/N: YAN1–Up the new flash file, the version of Cat ET on the
S/N: LYP1–Up
RENR5059-14 203
service tool must be updated. Replace your S/N: SFJ1–Up

present version of the Cat ET with an updated
version. S/N: ZAJ1–Up
S/N: BRK287–Up
STOP.
S/N: SBK1–Up
i01954909
S/N: SEK1–Up
Left Exhaust Temperature S/N: YAM1–Up
signal abnormal S/N: FDN1515–Up
SMCS Code: 1919-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up
The Electronic Control Module (ECM) has been
S/N: ZAH1–Up powered for three seconds. The diagnostic codes
263-03 and 263-04 are not active. The sensor
S/N: BPJ472–Up frequency is greater than 1000 Hz or less than 150
Hz. The duty cycle is greater than 90 percent or less
S/N: JDJ1–Up than 10 percent.
S/N: SBJ1–Up
204 RENR5059-14

The CID-FMI is logged in memory. The status screen S/N: ZAH1–Up
on Caterpillar Electronic Technician (ET) will show
the parameter as invalid data. S/N: BPJ472–Up
S/N: JDJ1–Up
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i01936099 S/N: SEK1–Up
Right Exhaust Temperature S/N: YAM1–Up

signal abnormal S/N: FDN1515–Up
S/N: LYH1–Up
RENR5059-14 205

The Electronic Control Module (ECM) has been S/N: SBG1–Up
powered for three seconds. The diagnostic codes
262-03 and 262-04 are not active. The sensor S/N: JCH1–Up
frequency is greater than 1000 Hz or less than 150
Hz. The duty cycle is greater than 95 percent or less S/N: JDH1–Up
than 5 percent. S/N: LYH1–Up
The code is logged. The status screen on the S/N: ZAH1–Up
Caterpillar Electronic Technician (ET) will show the
parameter as invalid data. S/N: BPJ472–Up
S/N: JDJ1–Up
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – STOP. OK
S/N: BRK287–Up
i01954907 S/N: SEK1–Up

Injector Trim Codes Not S/N: YAM1–Up
Programmed S/N: FDN1515–Up

206 RENR5059-14
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up

The Electronic Control Module (ECM) detects that
one or more of the injector trim codes has not been
programmed. The ECM has been powered for three
seconds.
System Response:
The CID-FMI is logged in memory. The engine will
start. The ECM will use a default setting of 0000 for
an unprogrammed injector trim code.
Program the Missing Injector Trim Code

(s).
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector.
B. Go to the calibration screen for the injector trim
code(s).
C. Enter the injector trim code that is stamped on the
bottom of the injector for the appropriate cylinder.
Results:
• OK – The injector trim code has been entered.
Repair: After entering the injector trim code,

turn the engine control to the OFF position.
Leave the engine control in the OFF position for
three seconds. Turn the engine control to the
ON position. The diagnostic code should not be
active.
STOP.
RENR5059-14 207
Troubleshooting with an Event Code
Troubleshooting with an S/N: ZAJ1–Up

S/N: BRK287–Up
Event Code
S/N: SBK1–Up
S/N: SEK1–Up
i04524143 S/N: YAL1–Up

S/N: YAM1–Up
Event Codes
S/N: FDN1515–Up
SMCS Code: 1901-038
S/N: JCN1–Up
S/N: LYH1–Up
Event codes alert the operator that an abnormal
S/N: YAH1–Up engine operating condition such as low oil pressure
or high coolant temperature has been detected.
S/N: ZAH1–Up When the event code is generated, the event is
active.
S/N: BPJ472–Up
S/N: JDJ1–Up Active Event Codes
S/N: SBJ1–Up An active event code represents a problem with
engine operation. Correct the problem as soon as
S/N: SFJ1–Up possible.
208 RENR5059-14
Active event codes are listed in ascending numerical • The hour of the first occurrence of the code
order. The code with the lowest number is listed first.
• The hour of the last occurrence of the code
Illustration 25 is an example of the operating range of
a temperature sensor. Do not use the Illustration to • The number of occurrences of the code
troubleshoot temperature sensors.
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

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:
• The event and the time of the event
• Determine the conditions for the event. The

conditions will include the engine rpm and the
load.
Example of the typical operating range of a • Determine if there are any systems that were
temperature sensor installed by the dealer or by the customer that
(1) This area represents the normal operating range of the could cause the event.
parameter. The normal output voltage of the sensor is between
0.2 VDC and 4.2 VDC. • Determine whether any additional events
(2) In this area, the temperature above 107 °C (225 °F) is higher occurred.
than normal. The output voltage of the sensor will 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 2. Verify that the complaint is not due to normal
too low. The voltage is outside of the normal range. The engine operation. Verify that the complaint is not
electronic problem will generate a diagnostic code. Refer to due to error of the operator.
Troubleshooting, “Troubleshooting with a Diagnostic Code” for
additional information on diagnostic codes. 3. Narrow the probable cause. Consider the operator
information, the conditions of operation, and the
Logged Event Codes history of the engine.
When the ECM generates an event code, the ECM 4. Perform a visual inspection. Inspect the following
logs the code in permanent memory. The ECM has items:
an internal diagnostic clock. The ECM will record the
following information when an event code is • Fuel supply
generated:
• Oil level
RENR5059-14 209
• Oil supply
• Wiring
• Connectors
Be sure to check the connectors. Loose connections
and damaged connections are likely causes of
intermittent problems. Refer to Troubleshooting,
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.
Trip Points for the Monitoring

System
The monitoring system determines the level of action
that is taken by the ECM in response to a condition
that can damage the engine. When any of these
conditions occur, the appropriate event code will trip.
Table 29 contains conditions that are monitored and
the typical default trip points for each condition. The
trip points can be different for different flash files.
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. Use Cat ET to find the adjustable ranges
for the values.
In some cases, a most severe event will occur before
a least severe event or an event of moderate
severity.
In some cases, trip points and delay times are shared
by the different levels of severity for an event.
Table 29
Typical Default Trip Points for the Monitoring System
Delay Time in
Condition Default Setting
Seconds Default State
Altitude (atmospheric pressure)
Moderate Severity (2) 0 92 kPa (13.4 psi) On
Engine Overspeed
Least Severe (1)

0 2070 rpm On
Most Severe (3)
High Aftercooler Coolant Temperature
Least Severe (1) 102° C (216° F)

Moderate severity (2) 5 107° C (225° F) On
Most Severe (3) 107° C (225° F)
High Air Filter Restriction Pressure
Least Severe (1)

5 7 kPa (28 inch of H2O) On
Moderate Severity (2)
(continued)
210 RENR5059-14
(Table 29, contd)

Typical Default Trip Points for the Monitoring System
Delay Time in
Condition Default Setting
Seconds Default State
High Boost Pressure
Least Severe (1)

0 400 kPa (58 psi) Off
Moderate Severity (2)
High Crankcase Pressure
Least Severe (1) 3 2 kPa (8 inch of H2O)

Moderate Severity (2) 10 6 kPa (24.1 inch of H2O) On
Most Severe (3) 3 3.5 kPa (14.10 inch of H2O)
High Engine Coolant Temperature
Least Severe (1) 5 102° C (216° F)

Moderate Severity (2) 30 107 °C (225 °F) On
Most Severe (3) 5 107 °C (225 °F)
High Engine Oil Filter Restriction Pressure
Least Severe (1) 103 kPa (15 psi)

5 On
Least Severe (1) 124 kPa (18 psi) (1)
High Exhaust Temperature
Least Severe (1) 600° C (1112° F)

5 On
Moderate Severity (2) 750 °C (1382 °F)
High Fuel Filter Restriction Pressure
Least Severe (1) 5 103 kPa (15 psi) On
Aftercooler Coolant Level

Least Severe (1) On
30 Switch
Most Severe (3) Off
Low Coolant Level

Least Severe (1) 15 On
Switch
Most Severe (3) 30 Off
Low Engine Coolant Temperature
Least Severe (1) 5 80° C (176° F) )n
Low Engine Oil Pressure
Least Severe (1) 4

Map On
Most Severe (3) 9
Low Fuel Pressure

Most Severe (3) 20 221 kPa (32 psi) On
Low System Voltage
Least Severe (1) 10 20V On

(1) This setting only applies to 2.5 mW Tier II generator sets
RENR5059-14 211
i02449881 S/N: SEK1–Up

S/N: YAL1–Up
E004 Engine Overspeed
Shutdown S/N: YAM1–Up

S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: ZAH1–Up The Electronic Control Module (ECM) detects an

engine overspeed condition. Information on default
S/N: BPJ472–Up settings and ranges for this event can be found in
Troubleshooting, “Event Codes”.
S/N: JDJ1–Up
S/N: SFJ1–Up The ECM will log the event.

S/N: BRK287–Up • The engine is shut down.
S/N: SBK1–Up
212 RENR5059-14
Troubleshooting: S/N: ZAH1–Up

The operator may be operating the engine S/N: BPJ472–Up
incorrectly.
S/N: JDJ1–Up
Interview the Operator S/N: SBJ1–Up
Determine the events that caused the overspeed of S/N: SFJ1–Up

the engine. Make corrections in order to prevent the S/N: ZAJ1–Up
overspeed from recurring.
S/N: BRK287–Up
Results:
S/N: SBK1–Up
• OK – STOP. S/N: SEK1–Up
i02319442
S/N: YAL1–Up
E007 High Aftercooler S/N: YAM1–Up
Temperature Derate S/N: FDN1515–Up
S/N: LYH1–Up
S/N: YAH1–Up
RENR5059-14 213
Conditions Which Generate This Code: Results:

The Electronic Control Module (ECM) detects engine • OK – There may be an intermittent problem.
coolant temperature that is greater than the default
temperature. Information on default settings and
Repair: Monitor the operation of the engine.
ranges for this event can be found in
Troubleshooting, “Event Codes”. Repair the problem. Ensure that the repair
eliminates the problem.
System Response:
STOP.
The event is logged.
• Not OK – There is a problem with the cooling
Possible Performance Effect: system.
Low power Repair: Repair the problem. Ensure that the
repair eliminates the problem.
Troubleshooting:
• There may be a problem with the cooling system. STOP.

i02319562
• There may be a problem with the coolant
temperature sensor.
E008 High Aftercooler
Temperature Shutdown
Test Step 1. Check for “ ACTIVE”” SMCS Code: 1901-038
Diagnostic Codes.
S/N: JM21–Up
A. Start the Caterpillar Electronic Technician (ET).
S/N: GD31–Up
B. Turn the main power to the ON position.
S/N: JM31–Up
C. Check for any active diagnostic codes or logged
diagnostic codes. S/N: JM41–Up
Expected Result: S/N: LD41–Up

S/N: LY71–Up
No diagnostic codes are present.
S/N: LY81–Up
Results:
S/N: LD91–Up
• OK – No diagnostic codes are present.Proceed to S/N: LY91–Up
Test Step 2.
S/N: CPA182–Up
• Not OK – Diagnostic codes are present.
S/N: BMB132–Up
Repair: Repair the diagnostic codes that are S/N: CNB1100–Up
present. Refer to the appropriate topic in the
“Troubleshooting With a Diagnostic Code” S/N: YBB1–Up
section of this manual. Ensure that the repair
eliminates the problem. S/N: CMC1107–Up
S/N: YBC1–Up
STOP.
S/N: YBD1–Up
Test Step 2. Perform a Check of the S/N: ZAD1–Up
Cooling System. S/N: JDE1–Up
A. Perform a check of the cooling system. Refer to
S/N: BLF166–Up
the diagnostic procedure Troubleshooting,
“Coolant Temperature is Too High” for possible S/N: JCG1–Up
causes.
S/N: SBG1–Up
Expected Result: S/N: JCH1–Up
There are no problems with the cooling system. S/N: JDH1–Up
214 RENR5059-14

S/N: YAH1–Up The Electronic Control Module (ECM) detects engine
coolant temperature that is greater than the default
S/N: ZAH1–Up temperature. Information on default settings and
S/N: BPJ472–Up ranges for this event can be found in
S/N: JDJ1–Up
System Response:
S/N: SBJ1–Up
The engine will shut down after all of the conditions
S/N: SFJ1–Up for shutdown are met. The event is logged.
S/N: ZAJ1–Up
S/N: BRK287–Up
Engine shutdown
S/N: SBK1–Up
Troubleshooting:
S/N: SEK1–Up
• There may be a problem with the cooling system.
S/N: YAL1–Up
• There may be a problem with the coolant
S/N: YAM1–Up
temperature sensor.
S/N: FDN1515–Up
S/N: JCN1–Up Test Step 1. Check for “ ACTIVE””
S/N: YAN1–Up Diagnostic Codes.
S/N: LYP1–Up A. Start the Caterpillar Electronic Technician (ET).
S/N: YAP1–Up B. Turn the main power to the ON position.
S/N: ZAP1–Up C. Check for any active diagnostic codes or logged
S/N: ZBP1–Up diagnostic codes.
S/N: GAR1–Up Expected Result:

S/N: PBR1–Up No diagnostic codes are present.
S/N: PDR1–Up Results:
S/N: YAR1–Up
• OK – No diagnostic codes are present.Proceed to
S/N: YBR1–Up Test Step 2.
S/N: ZAR1–Up
S/N: ZBR1–Up
Repair: Repair the diagnostic codes that are
S/N: GZS1–Up present. Refer to the appropriate topic in the
S/N: GZT1–Up “Troubleshooting With a Diagnostic Code”
S/N: YAT1–Up eliminates the problem.
S/N: YBT1–Up STOP.
S/N: YAW1–Up
Test Step 2. Perform a Check of the
S/N: YBW1–Up
Cooling System.
S/N: BGX120–Up
A. Perform a check of the cooling system. Refer to
S/N: GZY1–Up the diagnostic procedure Troubleshooting,
S/N: JCY1–Up “Coolant Temperature is Too High” for possible
causes.
S/N: YAY1–Up
Expected Result:
S/N: YAZ1–Up
RENR5059-14 215
There are no problems with the cooling system. S/N: JDH1–Up

S/N: YAH1–Up
• OK – There may be an intermittent problem.
S/N: ZAH1–Up
S/N: BPJ472–Up
Repair the problem. Ensure that the repair
eliminates the problem. S/N: JDJ1–Up
STOP. S/N: SBJ1–Up

S/N: SFJ1–Up
• Not OK – There is a problem with the cooling
system. S/N: ZAJ1–Up
Repair: Repair the problem. Ensure that the S/N: BRK287–Up

repair eliminates the problem. S/N: SBK1–Up
STOP. S/N: SEK1–Up
i02424858 S/N: YAL1–Up
S/N: YAM1–Up
E009 High Altitude Derate
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
216 RENR5059-14
S/N: YAZ1–Up i02386058
Conditions Which Generate This Code: E012 High Crankcase Pressure

The Electronic Control Module (ECM) detects Derate
atmospheric pressure that is too low. Information on
default settings and ranges for this event can be SMCS Code: 1901-038
found in troubleshooting with an event code
Troubleshooting, “Event Codes”. S/N: JM21–Up
S/N: GD31–Up
System Response:
S/N: JM31–Up
The ECM will log the diagnostic event.
S/N: JM41–Up
S/N: LD41–Up
E009-2 (Derate)
S/N: LY71–Up
• The engine will be derated.
S/N: LY81–Up
Troubleshooting: S/N: LD91–Up
• The engine is being operated at an altitude that is S/N: LY91–Up
too high.
S/N: CPA182–Up
• There may be a problem with the atmospheric
pressure sensor. S/N: BMB132–Up
S/N: CNB1100–Up
Check for Diagnostic Codes S/N: YBB1–Up
A. Connect the Caterpillar Electronic Technician (ET) S/N: CMC1107–Up

to the service tool connector. S/N: YBC1–Up
B. Restore the electrical power to the ECM. S/N: YBD1–Up
C. Check for any active diagnostic codes or logged S/N: ZAD1–Up
diagnostic codes. Wait at least 30 seconds in
order for the codes to become active. S/N: JDE1–Up
S/N: BLF166–Up
Expected Result:
S/N: JCG1–Up
S/N: SBG1–Up
Results: S/N: JCH1–Up
• OK – The engine is still derated. The engine is S/N: JDH1–Up
being operated at an altitude that is too high.
S/N: LYH1–Up
STOP. S/N: YAH1–Up
• Not OK S/N: ZAH1–Up
Repair: Repair the diagnostic codes that are S/N: BPJ472–Up

present. Refer to the appropriate topic in the S/N: JDJ1–Up
“Troubleshooting With a Diagnostic Code”
section of this manual. S/N: SBJ1–Up
Ensure that the repair eliminates the problem. S/N: SFJ1–Up
S/N: ZAJ1–Up
STOP.
S/N: BRK287–Up
S/N: SBK1–Up
RENR5059-14 217
S/N: SEK1–Up Troubleshooting:

S/N: YAL1–Up There may be a problem with one of the following
engine components:
S/N: YAM1–Up
S/N: FDN1515–Up • Pistons
S/N: JCN1–Up • Rings
S/N: YAN1–Up • Worn valve guides

S/N: LYP1–Up • Plugged crankcase breather
S/N: YAP1–Up
S/N: ZAP1–Up Check for Worn Engine Components
S/N: ZBP1–Up A. Damaged pistons or rings can cause too much
S/N: GAR1–Up pressure in the crankcase. This condition will
cause the engine to run rough. There will be more
S/N: PBR1–Up than the normal amount of fumes (blowby) rising
S/N: PDR1–Up from the crankcase breather. The breather can
then become restricted in a very short time,
S/N: YAR1–Up causing oil leakage at gaskets and seals that
S/N: YBR1–Up would not normally have leakage. Blowby can also
be caused by worn valve guides or by a failed
S/N: ZAR1–Up turbocharger seal.
S/N: ZBR1–Up B. A plugged crankcase breather will cause
S/N: GZS1–Up excessive crankcase pressure. Leakage of the
crankshaft seal can occur. Sealing of the piston
S/N: GZT1–Up rings can be lost. This will enable crankcase
S/N: YAT1–Up blowby to further increase the crankcase pressure.
S/N: YBT1–Up C. The 8T-2700 Blowby/Air Flow Indicator is used

to check the amount of blowby. Refer to Special
S/N: YAW1–Up Instruction, SEHS8712, “Using the 8T-2700
S/N: YBW1–Up Blowby/Air Flow Indicator” for the test procedure
for checking the blowby.
S/N: BGX120–Up
Expected Result:
S/N: GZY1–Up
A thorough inspection revealed a problem.
S/N: JCY1–Up
S/N: YAY1–Up Results:
S/N: YAZ1–Up • OK – There is a problem with an engine
component.
The Electronic Control Module (ECM) detects Repair: Repair the problem. Ensure that the
crankcase pressure that is more than the trip point. repair eliminates the problem.
Information on default settings and ranges for this
event can be found in Troubleshooting, “Event STOP.
Codes”.
i02386210
System Response:
E013 High Crankcase Pressure
Shutdown
Possible Performance Effect: SMCS Code: 1901-038
Low power S/N: JM21–Up
S/N: GD31–Up
218 RENR5059-14

S/N: YAH1–Up The Electronic Control Module (ECM) detects
S/N: ZAH1–Up crankcase pressure that is more than the trip point.
S/N: BPJ472–Up event can be found in Troubleshooting, “Event
Codes”.
S/N: JDJ1–Up
System Response:
S/N: SBJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up Engine shutdown

S/N: SEK1–Up There may be a problem with one of the following
engine components:
S/N: YAL1–Up
S/N: YAM1–Up • Pistons
S/N: FDN1515–Up • Rings

S/N: JCN1–Up • Worn valve guides
S/N: YAN1–Up • Plugged crankcase breather
S/N: LYP1–Up
RENR5059-14 219
Check for Worn Engine Components S/N: BMB132–Up

A. Damaged pistons or rings can cause too much S/N: CNB1100–Up
pressure in the crankcase. This condition will
S/N: YBB1–Up
than the normal amount of fumes (blowby) rising S/N: CMC1107–Up
from the crankcase breather. The breather can
S/N: YBC1–Up
then become restricted in a very short time,
causing oil leakage at gaskets and seals that S/N: YBD1–Up
would not normally have leakage. Blowby can also
S/N: ZAD1–Up
be caused by worn valve guides or by a failed
turbocharger seal. S/N: JDE1–Up
B. A plugged crankcase breather will cause S/N: BLF166–Up
excessive crankcase pressure. Leakage of the
S/N: JCG1–Up
rings can be lost. This will enable crankcase S/N: SBG1–Up
blowby to further increase the crankcase pressure.
S/N: JCH1–Up
C. The 8T-2700 Blowby/Air Flow Indicator is used
S/N: JDH1–Up
to check the amount of blowby. Refer to Special
Instruction, SEHS8712, “Using the 8T-2700 S/N: LYH1–Up
Blowby/Air Flow Indicator” for the test procedure
S/N: YAH1–Up
for checking the blowby.
S/N: ZAH1–Up
Expected Result:
S/N: BPJ472–Up
A thorough inspection revealed a problem.
S/N: JDJ1–Up
Results: S/N: SBJ1–Up
• OK – There is a problem with an engine S/N: SFJ1–Up
component.
S/N: ZAJ1–Up
S/N: SBK1–Up
i02449991
S/N: YAL1–Up
E015 High Engine Coolant S/N: YAM1–Up
Temperature Derate S/N: FDN1515–Up
220 RENR5059-14
S/N: ZAR1–Up C. Check the mixture of antifreeze and water. Ensure

that the recommendations in the Operation and
S/N: ZBR1–Up
Maintenance Manual are followed.
S/N: GZS1–Up
D. Check the water temperature regulators. A water
S/N: GZT1–Up temperature regulator that does not open, or a
water temperature regulator that only opens part
S/N: YAT1–Up
of the way can cause overheating.
S/N: YBT1–Up
E. Check the water pump. A water pump with a
S/N: YAW1–Up damaged impeller does not pump enough coolant.
Remove the water pump and check for damage to
S/N: YBW1–Up
the impeller.
S/N: BGX120–Up
F. If the cooling system for this application is
S/N: GZY1–Up equipped with a fan, check the operation of the
fan. A fan that is not turning at the correct speed
S/N: JCY1–Up
can cause improper air speed across the radiator
S/N: YAY1–Up core. The lack of proper air flow across the
radiator core can cause the coolant not to cool to
S/N: YAZ1–Up
the proper temperature differential.
Conditions Which Generate This Code: G. Check for air in the cooling system. Air can enter
The Electronic Control Module (ECM) detects engine the cooling system in different ways. The most
coolant temperature that exceeds the trip point common causes of air in the cooling system are
temperature. Information on default settings and the incorrect filling of the cooling system and
ranges for this event can be found in combustion gas leakage into the cooling system.
Troubleshooting, “Event Codes”. Combustion gas can get into the system through
System Response:
damaged cylinder head gasket.
The ECM will log the event.
H. Check the cooling system hoses and clamps.
Possible Performance Effect: Damaged hoses with leaks can normally be seen.
• The engine power is derated. operation. The soft areas of the hose can become
kinked or crushed during operation. These areas
Troubleshooting: of the hose can restrict the coolant flow. Hoses
There may be a problem with the engine. become soft and/or get cracks after a period of
time. The inside of a hose can deteriorate, and the
Test Step 1. Check the Engine's Cooling flow.
System
I. If the cooling system for this application is equipped
A. Verify that the cooling system is filled to the proper with an expansion tank, check the shunt line for
level. If the coolant level is too low, air will get into the expansion tank. The shunt line must be
the cooling system. Air in the cooling system will submerged in the expansion tank. A restriction of
cause a reduction in coolant flow. the shunt line from the expansion tank to the inlet
B. Check the radiator. If the engine is equipped with a of the jacket water pump will cause a reduction in
SCAC cooling system or a heat exchanger, check water pump efficiency. A reduction in water pump
for a restriction to coolant flow in the system. efficiency will result in low coolant flow.
J. If the cooling system for this application is
a. Check for debris or damage between the fins of
equipped with an aftercooler, check the
the radiator core. Debris between the fins of the
aftercooler. A restriction of air flow through the air
radiator core restricts air flow through the
to air aftercooler can cause overheating. Check for
radiator core.
debris or deposits which would prevent the free
b. Check internally for debris, dirt, or deposits on flow of air through the aftercooler.
the radiator core. Debris, dirt, or deposits will
restrict the flow of coolant through the radiator. Results:
RENR5059-14 221
Test Step 2. Check the Engine's Air Inlet S/N: GD31–Up

and Exhaust Systems S/N: JM31–Up
A. Check for a restriction in the air inlet system. A S/N: JM41–Up
restriction of the air that is coming into the engine
can cause high cylinder temperatures. High S/N: LD41–Up
cylinder temperatures cause higher than normal S/N: LY71–Up
temperatures in the cooling system.
S/N: LY81–Up
B. Check for a restriction in the exhaust system. A
restriction of the air that is coming out of the S/N: LD91–Up
engine can cause high cylinder temperatures. S/N: LY91–Up
Results: S/N: CPA182–Up
S/N: BMB132–Up
Test Step 3. Check for an Extreme
Operating Environment S/N: CNB1100–Up
A. Consider high ambient temperatures. When S/N: YBB1–Up

ambient temperatures are too high for the rating of S/N: CMC1107–Up
the cooling system, there is not enough of a
temperature difference between the ambient air S/N: YBC1–Up
and coolant temperatures. S/N: YBD1–Up
B. Consider high altitude operation. The cooling S/N: ZAD1–Up
capability of the cooling system is reduced at
higher altitudes. A pressurized cooling system that S/N: JDE1–Up
is large enough to keep the coolant from boiling S/N: BLF166–Up
must be used.
S/N: JCG1–Up
C. The engine may be running in the lug condition.
When the load that is applied to the engine is too S/N: SBG1–Up
large, the engine will run in the lug condition. S/N: JCH1–Up
When the engine is running in the lug condition,
engine rpm does not increase with an increase of S/N: JDH1–Up
fuel. This lower engine rpm causes a reduction in S/N: LYH1–Up
coolant flow through the system.
S/N: YAH1–Up
Expected Result: S/N: ZAH1–Up
A thorough inspection of the engine revealed a S/N: BPJ472–Up
problem.
S/N: JDJ1–Up
Results:
S/N: SBJ1–Up
• OK – There is a problem with the engine. S/N: SFJ1–Up
Repair: Repair the problem. Ensure that the S/N: ZAJ1–Up
S/N: BRK287–Up
i02450007 S/N: SEK1–Up
E016 High Engine Coolant S/N: YAL1–Up
Temperature Shutdown S/N: YAM1–Up


S/N: YAN1–Up
222 RENR5059-14
S/N: LYP1–Up A. Verify that the cooling system is filled to the proper
S/N: YAP1–Up
the cooling system. Air in the cooling system will
S/N: ZAP1–Up cause a reduction in coolant flow.
S/N: ZBP1–Up B. Check the radiator. If the engine is equipped with a
SCAC cooling system or a heat exchanger, check
S/N: GAR1–Up
for a restriction to coolant flow in the system.
S/N: PBR1–Up
S/N: PDR1–Up the radiator core. Debris between the fins of the
S/N: YAR1–Up radiator core restricts air flow through the
radiator core.
S/N: YBR1–Up
b. Check internally for debris, dirt, or deposits on
S/N: ZAR1–Up the radiator core. Debris, dirt, or deposits will
S/N: ZBR1–Up restrict the flow of coolant through the radiator.
S/N: GZS1–Up C. Check the mixture of antifreeze and water. Ensure
S/N: GZT1–Up Maintenance Manual are followed.
S/N: YAT1–Up D. Check the water temperature regulators. A water
S/N: YBT1–Up temperature regulator that does not open, or a
S/N: YAW1–Up of the way can cause overheating.
S/N: YBW1–Up E. Check the water pump. A water pump with a
S/N: BGX120–Up damaged impeller does not pump enough coolant.
S/N: GZY1–Up the impeller.
S/N: JCY1–Up F. If the cooling system for this application is
S/N: YAY1–Up equipped with a fan, check the operation of the
S/N: YAZ1–Up can cause improper air speed across the radiator
Conditions Which Generate This Code: core. The lack of proper air flow across the
The Electronic Control Module (ECM) detects engine the proper temperature differential.
coolant temperature that exceeds the trip point
temperature. Information on default settings and G. Check for air in the cooling system. Air can enter
ranges for this event can be found in the cooling system in different ways. The most
Troubleshooting, “Event Codes”. common causes of air in the cooling system are
the incorrect filling of the cooling system and
System Response: combustion gas leakage into the cooling system.
The ECM will log the event. Combustion gas can get into the system through
Possible Performance Effect: damaged cylinder head gasket.
• The engine is shutdown. H. Check the cooling system hoses and clamps.
Damaged hoses with leaks can normally be seen.
Troubleshooting: Hoses that have no visual leaks can soften during
operation. The soft areas of the hose can become
There may be a problem with the engine.
Test Step 1. Check the Engine's Cooling become soft and/or get cracks after a period of
System time. The inside of a hose can deteriorate, and the
flow.
RENR5059-14 223
I. If the cooling system for this application is equipped Results:

with an expansion tank, check the shunt line for
the expansion tank. The shunt line must be • OK – There is a problem with the engine.
submerged in the expansion tank. A restriction of
the shunt line from the expansion tank to the inlet Repair: Repair the problem. Ensure that the
of the jacket water pump will cause a reduction in
water pump efficiency. A reduction in water pump
STOP.
efficiency will result in low coolant flow.
i02450016
aftercooler. A restriction of air flow through the air
E017 High Engine Coolant
to air aftercooler can cause overheating. Check for Temperature Warning
debris or deposits which would prevent the free SMCS Code: 1901-038
flow of air through the aftercooler.
S/N: JM21–Up
Results:
S/N: GD31–Up
Test Step 2. Check the Engine's Air Inlet S/N: JM31–Up
A. Check for a restriction in the air inlet system. A S/N: LD41–Up
restriction of the air that is coming into the engine
can cause high cylinder temperatures. High S/N: LY71–Up
cylinder temperatures cause higher than normal S/N: LY81–Up
S/N: LD91–Up
B. Check for a restriction in the exhaust system. A
restriction of the air that is coming out of the S/N: LY91–Up
engine can cause high cylinder temperatures. S/N: CPA182–Up
Results: S/N: BMB132–Up
S/N: CNB1100–Up
Test Step 3. Check for an Extreme
Operating Environment S/N: YBB1–Up
A. Consider high ambient temperatures. When S/N: CMC1107–Up

ambient temperatures are too high for the rating of S/N: YBC1–Up
temperature difference between the ambient air S/N: YBD1–Up
and coolant temperatures. S/N: ZAD1–Up
B. Consider high altitude operation. The cooling S/N: JDE1–Up
higher altitudes. A pressurized cooling system that S/N: BLF166–Up
is large enough to keep the coolant from boiling S/N: JCG1–Up
must be used.
S/N: SBG1–Up
When the load that is applied to the engine is too S/N: JCH1–Up
large, the engine will run in the lug condition. S/N: JDH1–Up
engine rpm does not increase with an increase of S/N: LYH1–Up
fuel. This lower engine rpm causes a reduction in S/N: YAH1–Up
S/N: ZAH1–Up
Expected Result: S/N: BPJ472–Up
A thorough inspection of the engine revealed a S/N: JDJ1–Up
problem.
224 RENR5059-14

S/N: SFJ1–Up The ECM will log the event.
S/N: BRK287–Up
• There are no performance effects.
S/N: SBK1–Up
Troubleshooting:
S/N: SEK1–Up
There may be a problem with the engine.
S/N: YAL1–Up
S/N: YAM1–Up Test Step 1. Check the Engine's Cooling
S/N: FDN1515–Up System
S/N: JCN1–Up A. Verify that the cooling system is filled to the proper
S/N: YAN1–Up the cooling system. Air in the cooling system will
S/N: LYP1–Up cause a reduction in coolant flow.
S/N: YAP1–Up B. Check the radiator. If the engine is equipped with a

SCAC cooling system or a heat exchanger, check
S/N: ZAP1–Up for a restriction to coolant flow in the system.
S/N: ZBP1–Up
S/N: GAR1–Up the radiator core. Debris between the fins of the
radiator core restricts air flow through the
S/N: PBR1–Up
radiator core.
S/N: PDR1–Up
S/N: YAR1–Up the radiator core. Debris, dirt, or deposits will
S/N: YBR1–Up restrict the flow of coolant through the radiator.
S/N: ZAR1–Up C. Check the mixture of antifreeze and water. Ensure

S/N: ZBR1–Up Maintenance Manual are followed.
S/N: GZS1–Up D. Check the water temperature regulators. A water
S/N: GZT1–Up temperature regulator that does not open, or a
S/N: YAT1–Up of the way can cause overheating.
S/N: YBT1–Up E. Check the water pump. A water pump with a
S/N: YAW1–Up damaged impeller does not pump enough coolant.
S/N: YBW1–Up the impeller.
S/N: BGX120–Up F. If the cooling system for this application is
S/N: GZY1–Up equipped with a fan, check the operation of the
S/N: JCY1–Up can cause improper air speed across the radiator
S/N: YAY1–Up core. The lack of proper air flow across the
S/N: YAZ1–Up the proper temperature differential.
The Electronic Control Module (ECM) detects engine
coolant temperature that exceeds the trip point
temperature. Information on default settings and
ranges for this event can be found in
RENR5059-14 225
G. Check for air in the cooling system. Air can enter A. Consider high ambient temperatures. When
the cooling system in different ways. The most ambient temperatures are too high for the rating of
common causes of air in the cooling system are the cooling system, there is not enough of a
the incorrect filling of the cooling system and temperature difference between the ambient air
combustion gas leakage into the cooling system. and coolant temperatures.
Combustion gas can get into the system through
B. Consider high altitude operation. The cooling
damaged cylinder head gasket.
higher altitudes. A pressurized cooling system that
H. Check the cooling system hoses and clamps. is large enough to keep the coolant from boiling
Damaged hoses with leaks can normally be seen. must be used.
operation. The soft areas of the hose can become
When the load that is applied to the engine is too
large, the engine will run in the lug condition.
become soft and/or get cracks after a period of
engine rpm does not increase with an increase of
fuel. This lower engine rpm causes a reduction in
flow.
I. If the cooling system for this application is equipped Expected Result:
with an expansion tank, check the shunt line for
A thorough inspection of the engine revealed a
the expansion tank. The shunt line must be problem.
submerged in the expansion tank. A restriction of
the shunt line from the expansion tank to the inlet Results:
of the jacket water pump will cause a reduction in
water pump efficiency. A reduction in water pump • OK – There is a problem with the engine.
efficiency will result in low coolant flow.
Repair: Repair the problem. Ensure that the
J. If the cooling system for this application is repair eliminates the problem.
aftercooler. A restriction of air flow through the air STOP.
to air aftercooler can cause overheating. Check for
i02319568
debris or deposits which would prevent the free
E021 High Exhaust
Results: Temperature Derate
SMCS Code: 1901-038
Test Step 2. Check the Engine's Air Inlet
A. Check for a restriction in the air inlet system. A S/N: GD31–Up
restriction of the air that is coming into the engine S/N: JM31–Up
can cause high cylinder temperatures. High
cylinder temperatures cause higher than normal S/N: JM41–Up
temperatures in the cooling system. S/N: LD41–Up
B. Check for a restriction in the exhaust system. A S/N: LY71–Up
restriction of the air that is coming out of the
engine can cause high cylinder temperatures. S/N: LY81–Up
S/N: LD91–Up
Results:
S/N: LY91–Up
Test Step 3. Check for an Extreme S/N: CPA182–Up
Operating Environment
S/N: BMB132–Up
S/N: CNB1100–Up
S/N: YBB1–Up
226 RENR5059-14

S/N: YAH1–Up The Electronic Control Module (ECM) detects a high
S/N: ZAH1–Up exhaust temperature. Information on default settings
and ranges for this event can be found in
S/N: BPJ472–Up Troubleshooting, “Event Codes”.
S/N: SBJ1–Up The ECM will derate the engine's power. The event
code will be logged.
S/N: SFJ1–Up
S/N: BRK287–Up Loss of power

S/N: SEK1–Up Probable causes for a high exhaust temperature
S/N: YAL1–Up • Aftercooler
S/N: YAM1–Up
S/N: FDN1515–Up
• Fuel injectors
S/N: JCN1–Up
• Accessory equipment
S/N: YAN1–Up
S/N: LYP1–Up
Check for the following Probable Causes
S/N: YAP1–Up
A. Normal inlet manifold pressure with high exhaust
S/N: ZAP1–Up temperature can be caused by blockage of the fins
S/N: ZBP1–Up of the aftercooler core.
S/N: GAR1–Up B. Check the air inlet manifold pressure. Check for air
inlet restrictions and/or leaks. A one degree
S/N: PBR1–Up increase in the inlet manifold temperature will
S/N: PDR1–Up increase the exhaust temperature by
approximately three degrees. Check for leaks
S/N: YAR1–Up between the exhaust manifold and the
S/N: YBR1–Up turbocharger. Check for exhaust restrictions. Refer
S/N: ZAR1–Up manual for more information.
S/N: ZBR1–Up
S/N: GZS1–Up
RENR5059-14 227
C. Faulty injectors that deliver too much fuel will S/N: ZAD1–Up
increase exhaust temperatures. Connect
S/N: JDE1–Up
Caterpillar Electronic Technician (ET) in order to
determine if any diagnostic codes for the injector S/N: BLF166–Up
solenoids are present. Check that the injector trim
S/N: JCG1–Up
codes have been entered. Perform the “Injector
Solenoid Test” . Observe that the injector S/N: SBG1–Up
solenoids are being energized on Cat ET. Perform
S/N: JCH1–Up
the “Cylinder Cutout Test” . Locate the misfiring
cylinder. Refer to the diagnostic functional test S/N: JDH1–Up
Troubleshooting, “Injector Solenoids”.
S/N: LYH1–Up
D. Check all flywheel and damper driven equipment
S/N: YAH1–Up
for proper operation. Ensure that the accessory
equipment is not lugging down the engine. S/N: ZAH1–Up

S/N: JDJ1–Up
A problem was identified.
S/N: SBJ1–Up
Results:
S/N: SFJ1–Up
• OK – A problem was identified. S/N: ZAJ1–Up
Repair: Correct the problem. S/N: BRK287–Up
i02319569 S/N: SEK1–Up

S/N: YAL1–Up
E031 Air Inlet Restriction
S/N: YAM1–Up
Derate
S/N: FDN1515–Up
SMCS Code: 1901-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
228 RENR5059-14
S/N: YAW1–Up Repair: Repair the diagnostic codes that are

S/N: YBW1–Up “Troubleshooting With a Diagnostic Code”
S/N: BGX120–Up section of this manual. Ensure that the repair
S/N: GZY1–Up
STOP.
S/N: JCY1–Up
S/N: YAY1–Up Test Step 2. Perform a Check of the Air
S/N: YAZ1–Up Inlet System.
A. Check for restrictions in the air inlet system. Check
the air filter.
The Electronic Control Module (ECM) detects inlet air
restriction that is above the default pressure. Expected Result:
event can be found in Troubleshooting, “Event There are no problems with the air inlet system.
Codes”.
Results:
System Response:
• OK – There are no problems with the air inlet
The event is logged. When the air inlet restriction system. There may be an intermittent problem.
exceeds 7 kPa (28 inches of H2O) the ECM will
derate the engine. The ECM will derate the engine in Repair: Monitor the operation of the engine.
increments of 2 percent per 1 kPa (4 inches of H2O)
up to a maximum derate level of 25 percent. Air filter
restriction is determined by measuring the eliminates the problem.
atmospheric pressure and the turbocharger inlet
pressures and calculating the difference. STOP.
Possible Performance Effect: • Not OK – There is a problem with the air inlet
system.
Low power
Troubleshooting: repair eliminates the problem.
• There may be a problem with the air inlet system. STOP.
• There may be a problem with the atmospheric i02386238
pressure sensor or the left or right turbocharger
inlet pressure sensors. E038 Low Engine Coolant
Temperature Warning
Test Step 1. Check for “ ACTIVE”” SMCS Code: 1901-038
Diagnostic Codes.
S/N: JM21–Up
S/N: GD31–Up
B. Turn the main power to the ON position.
S/N: JM31–Up
C. Check for any active diagnostic codes or logged
diagnostic codes. S/N: JM41–Up
S/N: LD41–Up
Expected Result:
S/N: LY71–Up
S/N: LY81–Up
Results:
S/N: LD91–Up
• OK – No diagnostic codes are present.Proceed to S/N: LY91–Up
Test Step 2.
S/N: CPA182–Up
• Not OK – Diagnostic codes are present. S/N: BMB132–Up
RENR5059-14 229

S/N: YAH1–Up The Electronic Control Module (ECM) detects a low
S/N: ZAH1–Up coolant temperature. Information on default settings
S/N: SBJ1–Up The event code will be logged.
S/N: SFJ1–Up
S/N: ZAJ1–Up
None
S/N: BRK287–Up
Troubleshooting:
S/N: SBK1–Up
Probable causes for a low coolant temperature
S/N: SEK1–Up
• Faulty water temperature regulator
S/N: YAL1–Up
S/N: YAM1–Up • Long idle periods
S/N: FDN1515–Up • Very light loads
S/N: JCN1–Up
S/N: YAN1–Up Check for the following Probable Causes
S/N: LYP1–Up A. A regulator that is stuck open can cause
overcooling. Overcooling also occurs when the
S/N: YAP1–Up water temperature regulator is stuck between the
S/N: ZAP1–Up following positions: open position and closed
position. Coolant leaks that are around the water
S/N: ZBP1–Up temperature regulator can cause overcooling. An
S/N: GAR1–Up example would be a leak in the vent line.
S/N: PBR1–Up B. When the engine is running with no load, only a

small quantity of fuel is burned. Therefore, the
S/N: PDR1–Up heat from the engine is removed too fast. The
S/N: YAR1–Up check valve in the vent line may be missing, or the
orifice in the vent line may be missing. When the
S/N: YBR1–Up check valve or the orifice is missing, too much
S/N: ZAR1–Up heat is removed from the engine.
230 RENR5059-14
C. Very light loads or a very slow engine speed can S/N: LYH1–Up
cause overcooling. This overcooling is caused by
S/N: YAH1–Up
the low heat of the engine. The installation of
shutters helps to correct this condition. S/N: ZAH1–Up

S/N: JDJ1–Up
A problem was found in the cooling system.
S/N: SBJ1–Up
Results:
S/N: SFJ1–Up
• OK – A problem was found in the cooling system. S/N: ZAJ1–Up
Repair: Correct the problem. S/N: BRK287–Up
i02319570 S/N: SEK1–Up

S/N: YAL1–Up
E040 Low Engine Oil Pressure
S/N: YAM1–Up
Shutdown
S/N: FDN1515–Up
SMCS Code: 1901-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
RENR5059-14 231
Conditions Which Generate This Code: • OK – There are no problems with engine oil
pressure. There may be an intermittent problem.
The Electronic Control Module (ECM) detects engine
oil pressure that is below the default trip point. Repair: Monitor the operation of the engine.
System Response:
STOP.
• Not OK – There are problems with engine oil
Engine shutdown pressure.
Troubleshooting: Repair: Repair the problem. Ensure that the
• There may be a problem with the engine
lubrication system.
STOP.
• There may be a problem with the engine oil i02319571
pressure sensor.
E043 Low System Voltage
Test Step 1. Check for “ ACTIVE”” Warning
Diagnostic Codes. SMCS Code: 1901-038
A. Start the Caterpillar Electronic Technician (ET). S/N: JM21–Up
B. Turn the main power to the ON position. S/N: GD31–Up
C. Check for any active diagnostic codes or logged S/N: JM31–Up
diagnostic codes.
S/N: JM41–Up
Expected Result: S/N: LD41–Up
No diagnostic codes are present. S/N: LY71–Up
Results: S/N: LY81–Up
• OK – No diagnostic codes are present.Proceed to S/N: LD91–Up

Test Step 2. S/N: LY91–Up
• Not OK – Diagnostic codes are present. S/N: CPA182–Up
S/N: BMB132–Up
present. Refer to the appropriate topic in the S/N: CNB1100–Up
section of this manual. Ensure that the repair S/N: YBB1–Up
eliminates the problem. S/N: CMC1107–Up
STOP. S/N: YBC1–Up
S/N: YBD1–Up
Engine Lubrication System. S/N: ZAD1–Up
A. Perform a check of the engine lubrication system. S/N: JDE1–Up

Refer to the diagnostic procedure S/N: BLF166–Up
Troubleshooting, “Low Engine Oil Pressure”.
S/N: JCG1–Up
Expected Result: S/N: SBG1–Up
There are no problems with engine oil pressure. S/N: JCH1–Up
Results: S/N: JDH1–Up
232 RENR5059-14

S/N: YAH1–Up The Electronic Control Module (ECM) detects supply
voltage that is below 20 VDC. Information on default
S/N: ZAH1–Up settings and ranges for this event can be found in

S/N: SBJ1–Up The event is logged.
S/N: SFJ1–Up Possible Performance Effect:
S/N: ZAJ1–Up None
S/N: BRK287–Up
Troubleshooting:
S/N: SBK1–Up
• There may be a problem with the batteries.
S/N: SEK1–Up
• There may be a problem with the electrical
S/N: YAL1–Up connections.
S/N: YAM1–Up
S/N: FDN1515–Up Test Step 1. Check for “ ACTIVE””
S/N: JCN1–Up Diagnostic Codes.
S/N: YAN1–Up A. Start the Caterpillar Electronic Technician (ET).
S/N: LYP1–Up B. Turn the main power to the ON position.
S/N: YAP1–Up C. Check for any active diagnostic codes or logged
diagnostic codes.
S/N: ZAP1–Up
S/N: ZBP1–Up Expected Result:
S/N: GAR1–Up No diagnostic codes are present.
S/N: PBR1–Up Results:

S/N: PDR1–Up
S/N: YAR1–Up Test Step 2.
S/N: YBR1–Up • Not OK – Diagnostic codes are present.
S/N: ZAR1–Up
S/N: ZBR1–Up present. Refer to the appropriate topic in the
S/N: GZS1–Up section of this manual. Ensure that the repair
S/N: GZT1–Up eliminates the problem.
S/N: YAT1–Up STOP.

S/N: YBT1–Up
S/N: YAW1–Up Batteries.
S/N: YBW1–Up A. Measure no-load voltage at the battery posts.
S/N: BGX120–Up Refer to the Testing and Adjusting manual for the
proper procedures to check the batteries.
S/N: GZY1–Up
B. Load test the batteries. Use the 4C-4911 Battery
S/N: JCY1–Up Load Tester. Refer to the Operating Manual,
S/N: YAY1–Up SEHS9249. Refer to Special Instruction,
SEHS7633.
S/N: YAZ1–Up
RENR5059-14 233
Expected Result: S/N: YBD1–Up

The no-load voltage at the batteries should be at S/N: ZAD1–Up
least 23.5 VDC, and the batteries should pass the
load test. S/N: JDE1–Up
S/N: BLF166–Up
Results:
S/N: JCG1–Up
• OK – The no-load voltage at the batteries is at
least 23.5 VDC, and the batteries pass the load S/N: SBG1–Up
test. There may be an intermittent problem. S/N: JCH1–Up
Repair: Monitor the operation of the engine. S/N: JDH1–Up
S/N: LYH1–Up
S/N: YAH1–Up
STOP.
S/N: ZAH1–Up
• Not OK – The no-load voltage at the batteries is S/N: BPJ472–Up
less than 23.5 VDC, and/or the batteries fail the
load test. S/N: JDJ1–Up
Repair: The batteries or the alternator are S/N: SBJ1–Up

causing the problem. Recharge the batteries or S/N: SFJ1–Up
replace the batteries. Verify that the original
condition is resolved. Refer to the Testing and S/N: ZAJ1–Up
Adjusting manual for information on the
charging system. S/N: BRK287–Up
S/N: SBK1–Up
STOP.
S/N: SEK1–Up
i02386293
S/N: YAL1–Up
E095 Fuel Filter Restriction S/N: YAM1–Up
Warning S/N: FDN1515–Up
SMCS Code: 1901-038
S/N: JCN1–Up
234 RENR5059-14
S/N: YBT1–Up STOP.

S/N: YAW1–Up
Test Step 2. Perform a Check of the Fuel
S/N: YBW1–Up System
S/N: BGX120–Up A. Check the fuel tank for foreign objects which may
S/N: GZY1–Up block the fuel supply. Prime the fuel system if you
perform any of the following procedures:
S/N: JCY1–Up
• Replacing the fuel filters
S/N: YAY1–Up
S/N: YAZ1–Up • Working on the low pressure fuel supply circuit
Conditions Which Generate This Code: • Replacing fuel injectors
The Electronic Control Module (ECM) detects fuel B. Prime the fuel supply circuit with the hand priming
filter differential pressure that is above the trip point. pump and by cranking the engine in 30 second
Information on default settings and ranges for this cycles. After you crank the engine, stop for two
event can be found in Troubleshooting, “Event
Codes”. minutes. This will allow the starting motor to cool.
Loosen the vent plug on the fuel return. The plug
System Response: is located on the rear upper left side of the engine
block. Hand prime the engine again if air in fuel
The ECM will log the event. continues. A sight glass in the supply line is helpful
in diagnosing air in the fuel.
C. Cold weather adversely affects the characteristics
None
of the fuel. Refer to the Operation and
Troubleshooting: Maintenance Manual for information on improving
• There may be a problem with the fuel system. operation. Check the fuel pressure while the
engine is cranking. Check the fuel pressure at the
• There may be a problem with the filtered fuel
filter. If the pressure is low, check for plugged fuel
sensor or the unfiltered fuel sensor.
filters. If the fuel pressure is still low, check the
following items: fuel transfer pump, fuel transfer
pump coupling and fuel pressure regulating valve.
Test Step 1. Check for “ ACTIVE””
Check for a combustion problem.
Diagnostic Codes
A. Start the Caterpillar Electronic Technician (ET). Expected Result:
B. Check for any active diagnostic codes or logged There are no problems with the fuel system.
diagnostic codes.
Results:
Expected Result:
• OK – There may be an intermittent problem.
There are no diagnostic codes that are present.
Results: Repair the problem. Ensure that the repair
• OK – There are no diagnostic codes that are
present.Proceed to Test Step 2. STOP.
• Not OK – There are diagnostic codes that are • Not OK – There are problems with the fuel system.
present.
Repair: Repair the diagnostic codes that are repair eliminates the problem.
“Troubleshooting With a Diagnostic Code” STOP.
RENR5059-14 235
i02300974 S/N: SEK1–Up

S/N: YAL1–Up
E099 Engine Oil Filter
Restriction Warning S/N: YAM1–Up

S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: ZAH1–Up The Electronic Control Module (ECM) detects a

problem with the engine's oil filter differential
S/N: BPJ472–Up pressure. Information on default settings and ranges
for this event can be found in Troubleshooting, “Event
S/N: JDJ1–Up Codes”.
S/N: SBJ1–Up
System Response:
S/N: SFJ1–Up
S/N: ZAJ1–Up
S/N: BRK287–Up
E099 (Warning)
S/N: SBK1–Up
• None
236 RENR5059-14
Troubleshooting: Repair: Refer to the appropriate topic in the

“Troubleshooting Without a Diagnostic Code”
• There may be a problem with the oil filters. section of this manual. Ensure that the repair
• There may be a problem with the oil sensors.
STOP.
Test Step 1. Check for “ ACTIVE”” i02450095
Diagnostic Codes.
E100 Low Engine Oil Pressure
Warning
B. Turn the main power to the ON position. The SMCS Code: 1901-038
engine should be OFF.
C. Check for any active diagnostic codes or logged S/N: JM21–Up
diagnostic codes. S/N: GD31–Up
Expected Result: S/N: JM31–Up
No diagnostic codes are present. S/N: JM41–Up

S/N: LD41–Up
Results:
S/N: LY71–Up
Test Step 2. S/N: LY81–Up
S/N: LD91–Up
S/N: LY91–Up
S/N: CPA182–Up
“Troubleshooting With a Diagnostic Code” S/N: BMB132–Up
eliminates the problem. S/N: CNB1100–Up
S/N: YBB1–Up
STOP.
S/N: CMC1107–Up
Test Step 2. Perform a Check of the S/N: YBC1–Up
Lubrication System.
S/N: YBD1–Up
A. Check for dirty oil filters.
S/N: ZAD1–Up
Expected Result: S/N: JDE1–Up
There are problems with the oil filters. S/N: BLF166–Up
Results: S/N: JCG1–Up
S/N: SBG1–Up
• OK – The oil filters are dirty.
S/N: JCH1–Up
Repair: Replace the oil filters with new oil
filters. Ensure that the repair eliminates the S/N: JDH1–Up
problem. S/N: LYH1–Up
STOP. S/N: YAH1–Up
• Not OK – There are problems with the lubrication S/N: ZAH1–Up

system. S/N: BPJ472–Up
S/N: JDJ1–Up
S/N: SBJ1–Up
RENR5059-14 237
S/N: SFJ1–Up System Response:

S/N: ZAJ1–Up The ECM will log the event.
S/N: BRK287–Up Possible Performance Effect:
S/N: SBK1–Up
• There are no performance effects.
S/N: SEK1–Up
Troubleshooting:
S/N: YAL1–Up
S/N: YAM1–Up Check the Engine's Lubrication System
S/N: FDN1515–Up A. Check the engine oil level. If the oil level is below
the oil pump's supply tube, the oil pump will not
S/N: JCN1–Up
have the ability to supply enough lubrication to the
S/N: YAN1–Up engine components. If the engine oil level is low,
add engine oil in order to obtain the correct engine
S/N: LYP1–Up
oil level.
S/N: YAP1–Up
B. Check the following problems that may occur to
S/N: ZAP1–Up the engine oil pump:
S/N: ZBP1–Up a. Air leakage in the supply side of the oil pump
S/N: GAR1–Up will also cause cavitation and loss of oil
pressure. Check the supply side of the oil pump
S/N: PBR1–Up and make necessary repairs.
S/N: PDR1–Up
b. Oil pump gears that have too much wear will
S/N: YAR1–Up cause a reduction in oil pressure. Repair the
engine oil pump.
S/N: YBR1–Up
S/N: ZAR1–Up c. If the engine is equipped with a scavenge pump,
the scavenge pump may not be supplying oil to
S/N: ZBR1–Up the main engine oil pump.
S/N: GZS1–Up C. The inlet screen of the oil suction tube for the
S/N: GZT1–Up engine oil pump can have a restriction. This
restriction will cause cavitation and a loss of
S/N: YAT1–Up engine oil pressure. Check the inlet screen on the
S/N: YBT1–Up oil pickup tube and remove any material that may
be restricting engine oil flow. Low engine oil
S/N: YAW1–Up pressure may also be the result of the oil pickup
S/N: YBW1–Up tube that is drawing in air. Check the joints of the
oil pickup tube for cracks or a damaged O-ring
S/N: BGX120–Up seal.
S/N: GZY1–Up D. If the engine oil bypass valves are held in the open
S/N: JCY1–Up position, a reduction in the oil pressure can be the
result. This may be due to debris in the engine oil.
S/N: YAY1–Up If the engine oil bypass valves are stuck in the
S/N: YAZ1–Up open position, remove each engine oil bypass
valve and clean each bypass valve in order to
Conditions Which Generate This Code: correct this problem. You must also clean each
bypass valve bore.
engine oil pressure that falls below the trip point. E. Engine oil that is contaminated with fuel or coolant
Information on default settings and ranges for this will cause low engine oil pressure. High engine oil
event can be found in Troubleshooting, “Event level in the crankcase can be an indication of
Codes”.
contamination.
238 RENR5059-14
F. Excessive clearance at engine bearings will cause S/N: SBG1–Up

low engine oil pressure. Check the engine
S/N: JCH1–Up
components for excessive bearing clearance.
S/N: JDH1–Up
G. An oil line that is open, broken, or disconnected
will cause low engine oil pressure. S/N: LYH1–Up
Expected Result: S/N: YAH1–Up

S/N: ZAH1–Up
An inspection of the engine's lubrication system
indicated a problem. S/N: BPJ472–Up
Results: S/N: JDJ1–Up
S/N: SBJ1–Up
• OK – There is a problem in the engine's lubrication
system. S/N: SFJ1–Up
Repair: Repair the problem. Ensure that the S/N: ZAJ1–Up

repair eliminates the problem. S/N: BRK287–Up
i04001515 S/N: SEK1–Up
E101 High Crankcase Pressure S/N: YAL1–Up
Warning S/N: YAM1–Up

S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
RENR5059-14 239
S/N: JCY1–Up Results:

S/N: YAY1–Up • The condition is corrected. – STOP. OK
S/N: YAZ1–Up
• The condition is not corrected. Continue to test
Conditions Which Generate This Code: Step 3.
The engine crankcase pressure has exceeded the

setpoint and the delay time has expired. Test Step 3. Check for Worn Engine
Components
System Response:
A. Damaged pistons or rings can cause too much
The event code will be logged. pressure in the crankcase. This condition will
Possible Performance Effect: than the normal fumes (blowby) rising from the
None crankcase breather. The breather can then
become restricted quickly, causing oil leakage at
Troubleshooting: gaskets and seals that would not normally have
leakage. Blowby can also be caused by worn
There may be a problem with one of the following valve guides or by a failed turbocharger seal.
engine components:
B. The 8T-2700 Blowby/Air Flow Indicator is used
• Plugged crankcase breather to check the amount of blowby. Refer to Special
• Crankcase pressure sensor Instruction, SEHS8712, “Using the 8T-2700
Blowby/Air Flow Indicator” for the test procedure
• Worn engine components for checking the blowby.
Expected Result:
Test Step 1. Check the Crankcase A thorough inspection revealed a problem.
Breather
Results:
A. Check for a plugged crankcase breather.
A plugged crankcase breather will cause • OK – There is a problem with an engine
excessive crankcase pressure. Leakage of the component.
rings can be lost. The crankcase blowby will Repair: Repair the problem. Ensure that the
increase the crankcase pressure. repair eliminates the problem.
Results: STOP.
i02507604
• The crankcase breather is plugged.
Repair: Clean the crankcase breather. E162 High Boost Pressure

SMCS Code: 1052-038-HQ
STOP. OK
S/N: JM21–Up
• The crankcase breather is not plugged. Continue
to Test Step 2. S/N: GD31–Up
S/N: JM31–Up
Test Step 2. Check the Crankcase
S/N: JM41–Up
Pressure Sensor
S/N: LD41–Up
A. Inspect the crankcase pressure sensor for
cleanliness. If the sensor is fouled, clean the S/N: LY71–Up
sensor. If the condition is corrected, put the engine
S/N: LY81–Up
back in service. If the condition is not corrected,
proceed to the next step. S/N: LD91–Up
B. Replace the crankcase pressure sensor with a S/N: LY91–Up
sensor that is known to be good.
S/N: CPA182–Up
240 RENR5059-14

S/N: YAH1–Up The Electronic Control Module (ECM) detects a
S/N: ZAH1–Up problem with the engine's boost pressure.
Codes”.
S/N: JDJ1–Up
System Response:
S/N: SBJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up E162(1)
S/N: SBK1–Up • The engine may experience low power.

S/N: SEK1–Up E162(2)
S/N: YAL1–Up • Engine power will be derated.
S/N: YAM1–Up
S/N: FDN1515–Up Check for “ ACTIVE”” Diagnostic Codes.
S/N: JCN1–Up A. Start the Caterpillar Electronic Technician (ET).
S/N: YAN1–Up B. Restore the electrical power to the ECM. The
S/N: LYP1–Up engine should be OFF.
S/N: YAP1–Up C. Check for any active diagnostic codes or logged

diagnostic codes. Wait at least 30 seconds in
S/N: ZAP1–Up order for the codes to become active.
S/N: ZBP1–Up
Expected Result:
S/N: GAR1–Up
S/N: PBR1–Up
Results:
S/N: PDR1–Up
S/N: YAR1–Up • OK – No diagnostic codes are present.
S/N: YBR1–Up
RENR5059-14 241
Repair: Check the “turbine nozzle ring” for S/N: SBG1–Up

excessive carbon buildup. If necessary, clean
the “turbine nozzle ring” . S/N: JCH1–Up
S/N: JDH1–Up
Talk to the operator. Excessive engine load can
result in high boost pressure. S/N: LYH1–Up
If an intermittent problem is suspected, refer to S/N: YAH1–Up
the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”. S/N: ZAH1–Up
S/N: BPJ472–Up
STOP.
S/N: JDJ1–Up
S/N: SBJ1–Up
Repair: Repair the diagnostic codes that are S/N: SFJ1–Up
“Troubleshooting With a Diagnostic Code” S/N: ZAJ1–Up
section of this manual.
S/N: BRK287–Up
Ensure that the repair eliminates the problem.
S/N: SBK1–Up
i02457000 S/N: YAL1–Up
E173 High Exhaust S/N: YAM1–Up
Temperature Warning S/N: FDN1515–Up

242 RENR5059-14
S/N: JCY1–Up S/N: BMB132–Up

S/N: YAY1–Up S/N: CNB1100–Up
S/N: YAZ1–Up S/N: YBB1–Up
Conditions Which Generate This Code: S/N: CMC1107–Up
The temperature of the engine exhaust has S/N: YBC1–Up

exceeded the trip point. Refer to Troubleshooting, S/N: YBD1–Up
“Event Codes” for the trip point.
S/N: ZAD1–Up
System Response:
S/N: JDE1–Up
The event code is logged.
S/N: BLF166–Up
S/N: JCG1–Up
• There are no performance effects. S/N: SBG1–Up
S/N: JCH1–Up
Evaluate the Air Inlet and Exhaust S/N: JDH1–Up
System
S/N: LYH1–Up
Check the air inlet manifold pressure. Check for leaks
between the exhaust manifold and the turbocharger. S/N: YAH1–Up
Check for exhaust restrictions. Refer to Testing and S/N: ZAH1–Up
Adjusting, “Air Inlet and Exhaust System”.
S/N: BPJ472–Up
Expected Result:
S/N: JDJ1–Up
The reason for the high exhaust temperature was
S/N: SBJ1–Up
determined.
S/N: SFJ1–Up
Results:
S/N: ZAJ1–Up
• OK – The reason for the high exhaust temperature S/N: BRK287–Up
was determined.
S/N: SBK1–Up
STOP.
S/N: SEK1–Up
i02342285
S/N: YAL1–Up
E190 Engine Overspeed S/N: YAM1–Up
RENR5059-14 243

S/N: GZT1–Up S/N: LD91–Up
S/N: YAT1–Up S/N: LY91–Up
S/N: YBT1–Up S/N: CPA182–Up
S/N: YAW1–Up S/N: BMB132–Up
S/N: YBW1–Up S/N: CNB1100–Up
S/N: BGX120–Up S/N: YBB1–Up
S/N: GZY1–Up S/N: CMC1107–Up
S/N: JCY1–Up S/N: YBC1–Up
S/N: YAY1–Up S/N: YBD1–Up
S/N: YAZ1–Up S/N: ZAD1–Up
Conditions Which Generate This Code: S/N: JDE1–Up
The Electronic Control Module (ECM) detects an S/N: BLF166–Up

overspeed condition. Information on default settings S/N: JCG1–Up
Troubleshooting, “Event Codes”. S/N: SBG1–Up
System Response: S/N: JCH1–Up
Injection will be disabled until engine speed is 100 S/N: JDH1–Up

rpm below the setpoint for overspeed. The event
code will be logged. S/N: LYH1–Up
S/N: YAH1–Up
S/N: ZAH1–Up
None
S/N: BPJ472–Up
Troubleshooting:
S/N: JDJ1–Up
The operator may be operating the machine
incorrectly. S/N: SBJ1–Up
S/N: SFJ1–Up
Talk to the Operator S/N: ZAJ1–Up
Determine the events that caused the overspeed S/N: BRK287–Up
condition.
S/N: SBK1–Up
Results:
S/N: SEK1–Up
• OK – STOP. S/N: YAL1–Up
i02319600 S/N: YAM1–Up
E198 Low Fuel Pressure S/N: FDN1515–Up
SMCS Code: 1250-038-LP S/N: JCN1–Up

244 RENR5059-14
S/N: ZBP1–Up STOP.

S/N: GAR1–Up i02406202
S/N: PBR1–Up E255 Diagnostic Reset

S/N: PDR1–Up SMCS Code: 1901-038
S/N: YAR1–Up
S/N: JM21–Up
S/N: YBR1–Up
S/N: GD31–Up
S/N: ZAR1–Up
S/N: JM31–Up
S/N: ZBR1–Up
S/N: JM41–Up
S/N: GZS1–Up
S/N: LD41–Up
S/N: GZT1–Up
S/N: LY71–Up
S/N: YAT1–Up
S/N: LY81–Up
S/N: YBT1–Up
S/N: LD91–Up
S/N: YAW1–Up
S/N: LY91–Up
S/N: YBW1–Up
S/N: CPA182–Up
S/N: BGX120–Up
S/N: BMB132–Up
S/N: GZY1–Up
S/N: CNB1100–Up
S/N: JCY1–Up
S/N: YBB1–Up
S/N: YAY1–Up
S/N: CMC1107–Up
S/N: YAZ1–Up
S/N: YBC1–Up
Conditions Which Generate This Code: S/N: YBD1–Up
The Electronic Control Module (ECM) detects a S/N: ZAD1–Up
problem with the engine's fuel pressure. Information
on default settings and ranges for this event code can S/N: JDE1–Up
be found in Troubleshooting, “Event Codes”.
S/N: BLF166–Up
System Response:
S/N: JCG1–Up
The event code will be logged. S/N: SBG1–Up
Possible Performance Effect: S/N: JCH1–Up
The engine will be shutdown. S/N: JDH1–Up
S/N: LYH1–Up
Perform a Check of the Fuel System
S/N: YAH1–Up
A. Perform a check of the fuel system. Refer to the
appropriate topic in Testing and Adjusting for S/N: ZAH1–Up
possible causes.
S/N: BPJ472–Up
Expected Result: S/N: JDJ1–Up
There is a problem with the fuel system. S/N: SBJ1–Up

S/N: ZAJ1–Up
• OK – There is a problem with the fuel system.
S/N: BRK287–Up
S/N: SBK1–Up
Repair the problem.
RENR5059-14 245
S/N: SEK1–Up Check that the Diagnostic Reset Switch

S/N: YAL1–Up has been Toggled
S/N: YAM1–Up A. Talk to the operator. Ensure that the diagnostic
reset switch had been toggled by the operator.
S/N: FDN1515–Up
B. Use Caterpillar Electronic Technician (ET) to
S/N: JCN1–Up check for any diagnostic codes or event codes that
S/N: YAN1–Up remain active.
S/N: LYP1–Up Expected Result:

S/N: YAP1–Up The operator toggled the diagnostic reset switch.
S/N: ZAP1–Up
Results:
S/N: ZBP1–Up
• OK – The diagnostic reset switch has been
S/N: GAR1–Up toggled.
S/N: PBR1–Up
Repair: If the diagnostic reset switch has been
S/N: PDR1–Up toggled, the system is operating properly.
Investigate any engine derate or any engine
S/N: YAR1–Up shutdown event that had been latched prior to
S/N: YBR1–Up the reset function. Make the necessary repairs
prior to returning the engine to service.
S/N: ZAR1–Up
STOP.
S/N: ZBR1–Up
S/N: GZS1–Up • Not OK – The diagnostic reset switch has not been
toggled.
S/N: GZT1–Up
Repair: If the diagnostic reset switch has not
S/N: YAT1–Up
been toggled, there may be a problem with the
S/N: YBT1–Up circuit for the diagnostic reset switch.
Troubleshoot the circuit and/or the switch.
S/N: YAW1–Up Verify the proper operation of the switch prior to
S/N: YBW1–Up returning the engine to service.
S/N: BGX120–Up STOP.

S/N: GZY1–Up i02342292
S/N: JCY1–Up E264 Emergency Stop

S/N: YAY1–Up Activated
S/N: YAZ1–Up SMCS Code: 1901-038
Conditions Which Generate This Code: S/N: JM21–Up
The Electronic Control Module (ECM) detected the S/N: GD31–Up
activation of the diagnostic reset switch.
S/N: JM31–Up
System Response:
S/N: JM41–Up
If the condition that caused the code is no longer
present, the ECM will clear all diagnostic codes and S/N: LD41–Up
event codes. Any engine derate or any engine S/N: LY71–Up
shutdown event that has been latched will also be
cleared. The electrical power to the ECM does not S/N: LY81–Up
need to be cycled in order to reset a latched
condition. S/N: LD91–Up
S/N: LY91–Up
246 RENR5059-14

S/N: ZAH1–Up open circuit on the emergency stop input to the ECM.
S/N: BPJ472–Up System Response:

S/N: JDJ1–Up The ECM disables the injection signals to the injector
solenoids.
S/N: SBJ1–Up
S/N: SFJ1–Up Possible Performance Effect:
The engine will shut down.
S/N: ZAJ1–Up
S/N: BRK287–Up Verify the Cause of the Emergency Stop
S/N: SBK1–Up Shutdown
S/N: SEK1–Up A. Talk to the operator and determine the reason for
the emergency stop shutdown.
S/N: YAL1–Up
B. Verify that the condition for the emergency stop
S/N: YAM1–Up
shutdown has been resolved.
S/N: FDN1515–Up
Expected Result:
S/N: JCN1–Up
The reason for the emergency stop shutdown has
S/N: YAN1–Up been determined. The reason for the emergency stop
S/N: LYP1–Up shutdown has been resolved.
S/N: YAP1–Up Results:

S/N: ZAP1–Up • OK – The reason for the emergency stop
S/N: ZBP1–Up shutdown has been determined. The reason for
the emergency stop shutdown has been resolved.
S/N: GAR1–Up
Repair: The emergency stop condition can be
S/N: PBR1–Up reset by performing the following steps:
S/N: PDR1–Up A. Reset the emergency stop switch to the OFF
S/N: YAR1–Up position.
RENR5059-14 247
B. Cycle power to the ECM. If a “Diagnostic S/N: SFJ1–Up

Reset” switch is installed, toggle the
“Diagnostic Reset” switch in order to clear S/N: ZAJ1–Up
the emergency stop condition without S/N: BRK287–Up
shutting off power to the ECM.
S/N: SBK1–Up
STOP.
S/N: SEK1–Up
i02342295
S/N: YAL1–Up
E272 Inlet Air Restriction S/N: YAM1–Up
S/N: YAH1–Up The Electronic Control Module (ECM) detects a
S/N: ZAH1–Up problem with the engine's air inlet system.
Codes”.
S/N: JDJ1–Up
S/N: SBJ1–Up
248 RENR5059-14
System Response: S/N: YBC1–Up

The event code will be logged. S/N: YBD1–Up
Possible Performance Effect: S/N: ZAD1–Up
None S/N: JDE1–Up

S/N: BLF166–Up
Troubleshooting:
S/N: JCG1–Up
There may be a problem with the engine's air inlet
system. S/N: SBG1–Up
S/N: JCH1–Up
Check the Engine's Air Inlet System
S/N: JDH1–Up
A. Check the air intake system for plugged air filters
or for damaged air filters. If an air intake S/N: LYH1–Up
precleaner is installed verify the proper operation S/N: YAH1–Up
of the air intake precleaner.
S/N: ZAH1–Up
Expected Result:
S/N: BPJ472–Up
A thorough inspection of the air inlet system revealed S/N: JDJ1–Up
a problem.
S/N: SBJ1–Up
Results:
S/N: SFJ1–Up
• OK – There is a problem with the air inlet system. S/N: ZAJ1–Up
S/N: SBK1–Up
i02342298 S/N: YAL1–Up
E279 High Aftercooler S/N: YAM1–Up

Temperature Warning S/N: FDN1515–Up

RENR5059-14 249
S/N: YAT1–Up E. Check the water pump. A water pump with a

damaged impeller does not pump enough coolant.
S/N: YBT1–Up
S/N: YAW1–Up the impeller.
S/N: YBW1–Up F. If the cooling system for this application is
equipped with a fan, check the operation of the
S/N: BGX120–Up
S/N: GZY1–Up can cause improper air speed across the radiator
core. The lack of proper air flow across the
S/N: JCY1–Up
S/N: YAY1–Up the proper temperature differential.
S/N: YAZ1–Up G. Check for air in the cooling system. Air can enter
the cooling system in different ways. The most
Conditions Which Generate This Code: common causes of air in the cooling system are
The Electronic Control Module (ECM) detects a the incorrect filling of the cooling system and
problem with the engine's cooling system. combustion gas leakage into the cooling system.
Information on default settings and ranges for this Combustion gas can get into the system through
event can be found in Troubleshooting, “Event inside cracks, a damaged cylinder head, or a
Codes”. damaged cylinder head gasket.
System Response: H. Check the cooling system hoses and clamps.
Damaged hoses with leaks can normally be seen.
The event code will be logged.
Possible Performance Effect: operation. The soft areas of the hose can become
None of the hose can restrict the coolant flow. Hoses
become soft and/or get cracks after a period of
Troubleshooting:
There may be a problem with the engine's cooling loose particles of the hose can restrict the coolant
system. flow.
I. If the cooling system for this application is equipped
Check the Engine's Cooling System with an expansion tank, check the shunt line for
A. Verify that the cooling system is filled to the proper the expansion tank. The shunt line must be
level. If the coolant level is too low, air will get into submerged in the expansion tank. A restriction of
the cooling system. Air in the cooling system will the shunt line from the expansion tank to the inlet
cause a reduction in coolant flow. of the jacket water pump will cause a reduction in
water pump efficiency. A reduction in water pump
B. Check the radiator, the SCAC cooling system or efficiency will result in low coolant flow.
the heat exchanger for a restriction to coolant flow.
a. Check for debris or damage between the fins of equipped with an aftercooler, check the
the radiator core. Debris between the fins of the aftercooler. A restriction of air flow through the air
radiator core restricts air flow through the to air aftercooler can cause overheating. Check for
radiator core. debris or deposits which would prevent the free
the radiator core. Debris, dirt, or deposits will K. Check for a restriction in the air inlet system. A
restrict the flow of coolant through the radiator. restriction of the air that is coming into the engine
can cause high cylinder temperatures. High
C. Check the mixture of antifreeze and water. Make
cylinder temperatures cause higher than normal
sure that the recommendations in the Operation
and Maintenance Manual are followed.
L. Check for a restriction in the exhaust system. A
D. Check the water temperature regulator. A water
restriction of the air that is coming out of the
temperature regulator that does not open, or a
engine can cause high cylinder temperatures.
of the way can cause overheating.
250 RENR5059-14
M. Consider high ambient temperatures. When S/N: CMC1107–Up

ambient temperatures are too high for the rating of
S/N: YBC1–Up
temperature difference between the ambient air S/N: YBD1–Up
and coolant temperatures.
S/N: ZAD1–Up
N. Consider high altitude operation. The cooling
S/N: JDE1–Up
higher altitudes. A pressurized cooling system that S/N: BLF166–Up
is large enough to keep the coolant from boiling
S/N: JCG1–Up
must be used.
S/N: SBG1–Up
O. The engine may be running in the lug condition.
When the load that is applied to the engine is too S/N: JCH1–Up
large, the engine will run in the lug condition.
S/N: JDH1–Up
engine rpm does not increase with an increase of S/N: LYH1–Up
fuel. This lower engine rpm causes a reduction in
S/N: YAH1–Up
S/N: ZAH1–Up
Expected Result:
S/N: BPJ472–Up
A thorough inspection of the cooling system revealed
a problem. S/N: JDJ1–Up
S/N: SBJ1–Up
Results:
S/N: SFJ1–Up
• OK – There is a problem with the cooling system.
S/N: ZAJ1–Up
S/N: SBK1–Up
STOP.
S/N: SEK1–Up
i02426883
S/N: YAL1–Up
E552 Low Aftercooler Coolant S/N: YAM1–Up
Level S/N: FDN1515–Up
RENR5059-14 251
S/N: GZT1–Up B. After allowing the engine to cool, check the

coolant level. Refer to the Operation and
S/N: YAT1–Up
Maintenance Manual for the proper procedure.
S/N: YBT1–Up
Expected Result:
S/N: YAW1–Up
The coolant level is low.
S/N: YBW1–Up
S/N: BGX120–Up Results:
S/N: GZY1–Up • OK – The coolant level is low.

S/N: JCY1–Up
Repair: Check the cooling system for leaks.
S/N: YAY1–Up Repair any problems that are found. Refill the
cooling system to the proper level.
S/N: YAZ1–Up
STOP.
The Electronic Control Module (ECM) has detected a • Not OK – The coolant level is not low.
low coolant level. Information on default settings and
ranges for this event code can be found in Repair: There may be a problem with the
Troubleshooting, “Event Codes”. coolant level sensor. Refer to the diagnostic
functional test Troubleshooting, “Coolant Level
System Response: Sensor” in order to verify that the coolant level
sensor is operating correctly.
Ensure that any repairs eliminate the problem.
STOP.
E552-1 (Warning)
i02386299
None
E552-2 (Derate) E2087 Air Intake Shutoff
The engine power will be derated.
Closed
SMCS Code: 1078-038
E552-3 (Shutdown)
S/N: JM21–Up
S/N: GD31–Up
Troubleshooting:
S/N: JM31–Up
• The coolant level is most likely low.
S/N: JM41–Up
• There may be a problem with the coolant level S/N: LD41–Up
sensor.
S/N: LY71–Up
S/N: LY81–Up
Check the Coolant Level
S/N: LD91–Up
S/N: LY91–Up
S/N: CPA182–Up
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, S/N: BMB132–Up
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system S/N: CNB1100–Up
pressure cap slowly in order to relieve the
pressure. S/N: YBB1–Up
S/N: CMC1107–Up
A. Stop the engine.
S/N: YBC1–Up
252 RENR5059-14

S/N: YAH1–Up The engine's Electronic Control Module (ECM) will
S/N: ZAH1–Up trip the air intake shutoff if one of the following
conditions is active.
S/N: BPJ472–Up
• Active emergency stop switch
S/N: JDJ1–Up
• Engine overspeed condition
S/N: SBJ1–Up
• “Air intake shutoff tripped detection” indicates a
S/N: SFJ1–Up tripped condition.
S/N: ZAJ1–Up
System Response:
S/N: BRK287–Up
S/N: SBK1–Up
S/N: SEK1–Up
The engine will be shutdown.
S/N: YAL1–Up
S/N: YAM1–Up Troubleshooting:
S/N: FDN1515–Up The operator may be operating the engine

incorrectly. An emergency shutdown was initiated.
S/N: JCN1–Up
S/N: YAN1–Up Talk to the Operator
S/N: LYP1–Up Determine the events that caused the overspeed
condition. Determine the events that initiated the
S/N: YAP1–Up emergency shutdown.
S/N: ZAP1–Up
Results:
S/N: ZBP1–Up
• OK – STOP.
S/N: GAR1–Up
i02320143
S/N: PBR1–Up
S/N: PDR1–Up E2088 Air Intake Shutoff
S/N: YAR1–Up Detection Circuit Detected but
S/N: YBR1–Up
Not Installed
SMCS Code: 1078-038
S/N: ZAR1–Up
S/N: ZBR1–Up S/N: JM21–Up
S/N: GZS1–Up S/N: GD31–Up
S/N: GZT1–Up S/N: JM31–Up
S/N: YAT1–Up S/N: JM41–Up

RENR5059-14 253

S/N: YAH1–Up The engine's Electronic Control Module (ECM) has
S/N: ZAH1–Up detected a problem with the air intake shutoff.
Codes”.
S/N: JDJ1–Up
System Response:
S/N: SBJ1–Up
S/N: SFJ1–Up
S/N: BRK287–Up The engine will still be shutdown.

S/N: SEK1–Up The parameter for the air intake shutoff may be set to
“Not Installed” .
S/N: YAL1–Up
S/N: YAM1–Up Check the Programmable Parameters
S/N: FDN1515–Up Determine the setting of the parameter. The Air
S/N: JCN1–Up Intake Shutoff Detection Circuit Detected but Not
Installed parameter may need to be set to “Installed” .
S/N: YAN1–Up
Results:
S/N: LYP1–Up
S/N: YAP1–Up • OK – STOP.
S/N: ZAP1–Up
254 RENR5059-14
i02426634 S/N: SEK1–Up

S/N: YAL1–Up
E2143 Low Engine Coolant
Level S/N: YAM1–Up
SMCS Code: 1395-038-LO S/N: FDN1515–Up

S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: ZAH1–Up The Electronic Control Module (ECM) has detected a

low coolant level. Information on default settings and
S/N: BPJ472–Up ranges for this event code can be found in
S/N: JDJ1–Up
S/N: SFJ1–Up The event code will be logged.

S/N: BRK287–Up E2143-1 (Warning)
S/N: SBK1–Up None
RENR5059-14 255
E2143-2 (Derate)
The engine power will be derated.
E2143-3 (Shutdown)
Troubleshooting:
• The coolant level is most likely low.
• There may be a problem with the coolant level
sensor.
Check the Coolant Level

ous burns. To open the cooling system filler cap,
components are cool. Loosen the cooling system
pressure.
A. Stop the engine.

B. After allowing the engine to cool, check the
coolant level. Refer to the Operation and
Maintenance Manual for the proper procedure.
Expected Result:
The coolant level is low.
Results:
• OK – The coolant level is low.
Repair: Check the cooling system for leaks.

Repair any problems that are found. Refill the
cooling system to the proper level.
STOP.
• Not OK – The coolant level is not low.
Repair: There may be a problem with the

coolant level sensor. Refer to the diagnostic
functional test Troubleshooting, “Coolant Level
Sensor ” in order to verify that the coolant level
sensor is operating correctly.
Ensure that any repairs eliminate the problem.
STOP.
256 RENR5059-14
Diagnostic Functional S/N: ZAJ1–Up

S/N: BRK287–Up
Tests
S/N: SBK1–Up
S/N: SEK1–Up
i02386300 S/N: YAL1–Up

S/N: YAM1–Up
Air Shutoff System
S/N: FDN1515–Up
SMCS Code: 1078-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up
S/N: ZAH1–Up
S/N: BPJ472–Up
S/N: JDJ1–Up
S/N: SBJ1–Up
S/N: SFJ1–Up
RENR5059-14 257
System Operation Description:

The Electronic Control Module (ECM) has the ability
to stop the engine in an emergency situation by
shutting off the intake air supply. The ECM activates
two relays which energize the two air shutoff
solenoids. The solenoids trip the air shutoff valves.
The presence of a switch at each air shutoff valve
informs the ECM that the air shutoff solenoids have
activated. Unless the air shutoff valves are manually
opened, the ECM will not attempt to restart the
engine.
There are two conditions which cause the engine
control to activate the air shutoff relay. The first
condition occurs when the operator initiates a remote
shutdown. If the customer's emergency stop is
activated, the shutdown inputs to the ECM are open.
This signals the ECM to turn on the output for the air
shutoff relays. The ECM will hold the air shutoff
relays active for 1.5 seconds. The second condition
occurs for an engine overspeed. The engine
overspeed could be an actual overspeed or a
simulated overspeed. The simulated overspeed can
be obtained by using the overspeed verify switch.
When the overspeed verify switch is activated, the
ECM will activate the output for the air shutoff relays
at 75 percent of the overspeed setpoint.
The air shutoff relays can also be activated without
the aid of the ECM. When the emergency stop on the
instrument panel is depressed, the air shutoff relays
are activated. The air shutoff timer will allow the air
shutoff relays to deactivate after 2.5 seconds in order
to prevent damage to the air shutoff solenoids.
Regardless of the reason for activation, the engine
control must be turned to OFF/RESET mode for
three seconds in order to reset the ECM and the air
shutoff timer. The operator must manually open the
air shutoff valves in order to reset the switches at the
air shutoff valves.
258 RENR5059-14
Typical example
F. Check the customer connector (allen head screw)

Test Step 1. Inspect Electrical for the proper torque. Refer to the diagnostic
Connections and Wiring functional test Troubleshooting, “Inspecting
Electrical Connectors” for details.
A. Turn the battery disconnect switch to the OFF
position. G. Check the harness and the wiring for abrasion and
for pinch points.
B. Turn the engine control to the OFF/RESET mode.
Expected Result:
C. Thoroughly inspect the ECM connectors J1/P1
and J2/P2. Inspect all of the other connectors that All connectors, pins, and sockets are completely
are associated with the air shutoff circuit. Refer to coupled and/or inserted, and the harness and wiring
the diagnostic functional test Troubleshooting, are free of corrosion, of abrasion and of pinch points.
“Inspecting Electrical Connectors” for details.
Results:
D. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated • OK – The connectors and wiring are OK.Proceed
with the circuit. to Test Step 2.
E. Check the ECM connector (allen head screw) for • Not OK – The connectors and/or wiring are not
the proper torque. Refer to the diagnostic OK.
functional test Troubleshooting, “Inspecting
Electrical Connectors” for details. Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
RENR5059-14 259
STOP. Repair Complete F. If a second air shutoff relay is installed, repeat the
above steps for the other air shutoff relay.
Test Step 2. Test the Air Shutoff System
Expected Result:
position. The voltage measures 24 ± 3 VDC.
B. Turn the engine control to the OFF/RESET mode. Results:

C. Connect the Caterpillar Electronic Technician
• OK – The voltage measures 24 ± 3 VDC for 1.5
(ET). seconds. The relay is operating correctly.Proceed
D. Turn the engine control to the STOP mode. The to Test Step 4.
engine should be off.
• Not OK – The voltage did not measure 24 ± 3 VDC
E. Turn the battery disconnect switch to the ON for 1.5 seconds.Proceed to Test Step 5.
position.
F. Access the override on Cat ET. Activate the Test Step 4. Test for Voltage at the Air
override for the air shutoff. Shutoff Solenoids
G. Disable the override for the air shutoff. A. Turn the engine control to the OFF/RESET mode.
Turn the battery disconnect switch to the OFF
Expected Result: position.
The air shutoff relay activates. The air shutoff relay B. At the air shutoff solenoid, disconnect the wires
deactivates after 1.5 seconds. While the air shutoff that go to the air shutoff solenoid.
relay was active, the air shutoff solenoid activated.
C. Use a voltmeter to measure the voltage at the air
Results: shutoff solenoid. Connect the voltmeter across the
wires that were removed from the solenoid in the
• OK – The air shutoff solenoid activated correctly. previous step.
Repair: The problem may be intermittent. If the D. Turn the engine control to the STOP mode. The
problem is intermittent, refer to the diagnostic engine should be off. Turn the battery disconnect
functional test Troubleshooting, “Inspecting switch to the ON position.
Electrical Connectors”.
E. Access the override on Cat ET. Activate the
STOP. OK override for the air shutoff.
F. Disable the override for the air shutoff.
• Not OK – The air shutoff solenoid failed to
activate.Proceed to Test Step 3. G. If a second air shutoff solenoid is installed, repeat
the above steps for the other air shutoff solenoid.
Test Step 3. Test for Voltage from the Air
Expected Result:
Shutoff Relay
A. Turn the engine control to the OFF/RESET mode. The voltage measures 24 ± 3 VDC.
Turn the battery disconnect switch to the OFF
Results:
position.
B. The output wires to the solenoids are • OK – The voltage measures 24 ± 3 VDC for 1.5
852-RD(Red) and 200-BK(Black). Connect a seconds. The circuit is operating correctly to this
voltmeter between 852-RD(Red) on the air shutoff point.
relay and the −Battery terminal.
Repair: Temporarily install a new air shutoff
C. Turn the engine control to the STOP mode. The solenoid. Ensure that the problem is no longer
engine should be off. Turn the battery disconnect present. Reinstall the old solenoid. If the
switch to the ON position. problem returns, replace the air shutoff
solenoid.
D. Access the override on Cat ET. Activate the
override for the air shutoff. STOP. Repair Complete
E. Disable the override for the air shutoff. • Not OK – The voltage did not measure 24 ± 3 VDC
for 1.5 seconds. System voltage was not available
260 RENR5059-14
at the air shutoff solenoid. There is a problem in C. Check the resistance at the connector of the air
the wiring between the air shutoff solenoid and the shutoff timer. Check the resistance between wire
air shutoff relay. 200-BK(Black) on pin 2 and the −Battery terminal.
Repair: Repair the connectors or wiring and/or D. Check the resistance at the connector of the air
replace the connectors or wiring. shutoff timer. Check the resistance between wire
F708-RD(Red) on pin 3 and wire 354-RD(Red) on
STOP. Repair Complete pin 1.
Test Step 5. Test for Voltage at the Coil of Expected Result:

the Air Shutoff Relay The resistance of the wire on pin 1 is less than 10
Ohms. The resistance between the wires on pin 2
A. Turn the engine control to the OFF/RESET mode.
and pin 3 is approximately 260 Ohms if one relay is
Turn the battery disconnect switch to the OFF present. The resistance between the wires on pin 2
position. and pin 3 is approximately 130 Ohms when two
relays are present.
B. Remove wire F708-RD(Red) from the coil of the
air shutoff relay. If two air shutoff relays are Results:
present disconnect wire F708-RD(Red) from both
coils of the relays. Connect a voltmeter between • OK – The resistance on the wires meets the above
wire F708-RD(Red) of the air shutoff relay and the requirements. The relay coils are OK. The relay's
−Battery terminal. normally open contacts may be faulty.
C. Turn the engine control to the STOP mode. The Repair: Temporarily install a new air shutoff
engine should be off. Turn the battery disconnect solenoid. Ensure that the problem is no longer
switch to the ON position. present. If the problem still exists, the air shutoff
relay is OK. Replace the air shutoff timer. Verify
D. Access the override on Cat ET. Activate the
that this solves the problem.
override for the air shutoff.
This test will cause a 446-05 CID-FMI to be STOP. Repair Complete
logged. Be sure to delete this CID-FMI when this
test is completed. • Not OK – The resistance does not meet the above
requirements. Check the coil of the air shutoff
E. Disable the override for the air shutoff. relay for an open. The coil resistance should be
F. If a second air shutoff relay is installed, repeat the approximately 260 Ohms.
above steps for the other air shutoff relay.
Repair: Replace the air shutoff relay if the coil
G. Reconnect all wires. of the relay is faulty. Repair the connectors or
wiring and/or replace the connectors or wiring.
Expected Result:
STOP. Repair Complete
The voltage measures 24 ± 3 VDC.
Results: Test Step 7. Test the Output Voltage from

the ECM
• OK – The voltage measures 24 ± 3 VDC for 1.5
seconds. Voltage from the ECM was present. A. Turn the engine control to the OFF/RESET mode.
Proceed to Test Step 6. Turn the battery disconnect switch to the OFF
position.
• Not OK – The voltage did not measure 24 ± 3 B. Disconnect P2 from the ECM. Remove the wire
VDC. The voltage from the ECM was not present.
F708-RD(Red) from P2-13.
C. Install a jumper wire at P2-13. Reconnect ECM
Test Step 6. Check the Resistance at the connector P2.
Connector of the Air Shutoff Timer. D. Connect the voltmeter between the wire jumper in
A. Turn the engine control to the OFF/RESET mode. P2-13 and the −Battery terminal.
Turn the battery disconnect switch to the OFF E. Turn the engine control to the STOP mode. The
position. engine should be off. Turn the battery disconnect
B. Disconnect the connector to the air shutoff timer. switch to the ON position.
RENR5059-14 261
F. Access the override on Cat ET. Activate the S/N: CNB1100–Up

override for the air shutoff.
S/N: YBB1–Up
Note: This test will cause a 446-05 CID-FMI to be S/N: CMC1107–Up
logged. Be sure to delete this CID-FMI when this test
is completed. S/N: YBC1–Up
G. Disable the override for the air shutoff. S/N: YBD1–Up
H. Turn the engine control to the OFF/RESET mode. S/N: ZAD1–Up

Turn the battery disconnect switch to the OFF S/N: JDE1–Up
position. Remove the wire jumper.
S/N: BLF166–Up
Expected Result: S/N: JCG1–Up
The voltage measures 24 ± 3 VDC for 1.5 seconds. S/N: SBG1–Up
Results: S/N: JCH1–Up
• OK – The voltage measures 24 ± 3 VDC for 1.5 S/N: JDH1–Up

seconds. Voltage from the ECM was present. S/N: LYH1–Up
There is a problem in the wiring between the ECM
and the air shutoff relay. S/N: YAH1–Up
S/N: ZAH1–Up
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. S/N: BPJ472–Up
STOP. Repair Complete S/N: JDJ1–Up

S/N: SBJ1–Up
• Not OK – The voltage did not measure 24 ± 3 VDC
for 1.5 seconds. The voltage from the ECM was S/N: SFJ1–Up
not present.
S/N: ZAJ1–Up
Repair: Replace the ECM. Refer to the S/N: BRK287–Up
diagnostic procedure Troubleshooting,
“Replacing the ECM”. S/N: SBK1–Up
STOP. Repair Complete S/N: SEK1–Up

S/N: YAL1–Up
i02417903
S/N: YAM1–Up
Analog Sensor Supply S/N: FDN1515–Up
SMCS Code: 1439-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
262 RENR5059-14
S/N: ZBR1–Up Note: The sensors are not protected from

overvoltage. A short from the supply line to the
S/N: GZS1–Up +Battery may damage the sensors. If the CID-FMI
S/N: GZT1–Up 262-03 is logged, it is possible that all of the sensors
have been damaged. Repair the sensor supply and
S/N: YAT1–Up check for any “ACTIVE” sensor diagnostic codes in
order to determine if a sensor has failed.
S/N: YBT1–Up
The +5 V diagnostic code is probably caused by a
S/N: YAW1–Up short circuit to ground or a short circuit to another
S/N: YBW1–Up voltage source in the harness.
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up

Use this procedure to troubleshoot the system when
one of the following diagnostic codes is active or
easily repeated:
• 262-03 5 Volt Sensor DC Power Supply short to
+batt
• 262-04 5 Volt Sensor DC Power Supply short to

ground
The Electronic Control Module (ECM) supplies a
regulated voltage of 5.0 ± 0.2 VDC to the following
sensors:
• Aftercooler temperature sensor
• Unfiltered engine oil pressure sensor

• Filtered engine oil pressure sensor
• Left turbocharger inlet pressure sensor

• Right turbocharger inlet pressure sensor
• Atmospheric pressure sensor

• Crankcase pressure sensor
• Turbocharger outlet pressure sensor

• Unfiltered fuel pressure sensor
• Filtered fuel pressure sensor

The supply for the +5 V engine pressure sensor is
routed from the ECM to terminal A of each pressure
sensor connector. The sensor common from the
ECM connector goes to terminal B of each sensor
connector. The sensor supply is output short circuit
protected. A short circuit to the battery will not
damage the circuit inside the ECM.
RENR5059-14 263
Schematic
264 RENR5059-14
Illustration 28 g01161474 Illustration 29 g01161487

P1 ECM connector P2 ECM connector
(P1-2) Analog sensor power (P2-3) Atmospheric pressure
(P1-3) Analog sensor common (P2-36) Turbocharger outlet pressure
(P1-6) Aftercooler temperature (P2-38) Left turbocharger inlet pressure
(P1-7) Coolant temperature (P2-39) Right turbocharger inlet pressure
(P1-16) Filtered oil pressure (P2-46) Crankcase pressure
(P1-17) Unfiltered oil pressure
(P1-18) Analog sensor power
(P1-35) Analog sensor common
(P1-24) Filtered fuel pressure
(P1-25) Unfiltered fuel pressure
Sensor connector
RENR5059-14 265
Test Step 1. Inspect Electrical

Connectors and Wiring
position.
B. Thoroughly inspect the J1/P1 ECM connector and
the J2/P2 ECM connector. Inspect all of the
connectors that are associated with the circuit.
Connectors” for details.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connectors that are associated
with the circuit.
D. Check the ECM connector (allen head screw) for
the proper torque. Refer to Troubleshooting,
E. Check the harness and wiring for abrasion and for
pinch points from the sensors back to the ECM.
Typical sensor locations
(1) Engine oil pressure sensor 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.
Results:
• OK – The harness and connectors appear to be

OK.Proceed to Test Step 3.
• Not OK – There is a problem with the connectors

and/or wiring.

replace the connectors or wiring. 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. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
B. Turn the battery disconnect switch to the ON
position.
Typical sensor locations C. Monitor the active diagnostic code screen on Cat
(2) Turbocharger inlet pressure sensor ET. Check and record any active diagnostic codes.
(3) Boost pressure sensor
(4) Filtered fuel pressure sensor Note: Wait at least 15 seconds in order for the
(5) Inlet manifold pressure sensor
(6) Atmospheric pressure sensor
diagnostic codes to become active.
(7) Unfiltered fuel pressure sensor
266 RENR5059-14
Expected Result: E. Turn the battery disconnect switch to the OFF

position.
One of the following diagnostic codes is active:
F. Reconnect all of the sensors.
• 262-03
Expected Result:
• 262-04
The voltage is 5.0 ± 0.2 VDC.
Results:
Results:
• OK A 262-03 diagnostic code is active. Proceed to
Test Step 3. • OK – The voltage is correct.
• OK A 262-04 diagnostic code is active. Proceed to Repair: Replace all wires to the original
Test Step 4. configuration. Clear all diagnostic codes. Check
for active diagnostic codes. If the problem is
• Not OK – No diagnostic code is active. intermittent, refer to the diagnostic functional
test Troubleshooting, “Inspecting Electrical
Repair: The problem is no longer present. If the Connectors”.
problem is intermittent, refer to
Troubleshooting, “Inspecting Electrical STOP.
Connectors”.
• Not OK – The voltage is not 5.0 ± 0.2 VDC. The
STOP. OK voltage is incorrect.Proceed to Test Step 5.
Test Step 3. Check the Supply Voltage at Test Step 4. Disconnect the +5 V Sensors
the Sensor Connector while you Monitor the Active Diagnostic
A. Turn the battery disconnect switch to the OFF Codes
position. A. Monitor the active diagnostic code screen on Cat
B. Disconnect all of the following analog sensors at ET. Check and record any active diagnostic codes.
the sensor connector:
Note: Wait at least 15 seconds in order for the
• Coolant temperature sensor diagnostic codes to become active.
• Aftercooler temperature sensor B. Disconnect the following sensors one at a time at

the sensor connector as you monitor Cat ET:
• Aftercooler temperature sensor
• Unfiltered fuel pressure sensor
• Filtered fuel pressure sensor
C. Turn the battery disconnect switch to the ON
position. • Unfiltered fuel pressure sensor
D. Measure the voltage between terminal A (5 V • Filtered fuel pressure sensor

analog supply) and terminal B (sensor common) at
the sensor connectors. Expected Result:
RENR5059-14 267
The 262-04 diagnostic code deactivates when a • Not OK – A resistance measurement is less than
particular sensor is disconnected. 20,000 Ohms. The +5 V supply wire is shorted in
the engine harness or the +5 V supply wire is
Results: shorted to engine ground.
• OK – The 262-04 diagnostic code deactivates. Repair: Repair the wire or replace the wire.
The diagnostic code is not active after a specific Clear all logged diagnostic codes. Replace all
sensor is disconnected. wires to the original configuration. Verify that
the repair eliminates the problem.
Repair: Reconnect the sensor that is suspected
of causing the problem. If the problem returns STOP.
after the reconnection of the sensor, disconnect
the sensor. If the problem disappears after the Test Step 6. Check the +5 V Supply and
disconnection of the sensor, replace the sensor.
Reconnect all wires to the original configuration. the Sensor Common for an Open Circuit
Clear all diagnostic codes. Verify that the repair A. Install a wire jumper between P1-2 (+5 V Supply)
eliminates the problem. and P1-3 (sensor common).
STOP. Note: Wiggle the harness during the following
measurements in order to reveal any intermittent
• Not OK – The 262-04 diagnostic code stays short condition.
active. Leave the sensors disconnected. Proceed
to Test Step 5. B. Record the resistance at each analog sensor
connector between terminal A and terminal B.
Test Step 5. Check the +5 V Supply Wire C. Remove the wire jumpers.
for a Short to Engine Ground or a Short
to another Wire in the Harness Expected Result:
A. Turn the battery disconnect switch to the OFF The resistance is less than 5 Ohms for each
measurement.
position.
B. Disconnect the J2/P2 ECM connector. Disconnect Results:
the J1/P1 ECM connector.
• OK – The resistance check does not indicate an
C. Leave the analog sensors disconnected at the open circuit in the engine harness.Proceed to Test
sensor connectors. Step 7.
Note: Wiggle the harness during the following • Not OK – A resistance measurement is greater
measurements in order to reveal any intermittent than 5 Ohms. The +5 V supply wire or the sensor
short condition. common has excessive resistance.
D. Measure the resistance between P1-2 (+5 V Repair: Repair the wires or replace the wires.
Supply) and all of the remaining pins on the P1 Clear all logged diagnostic codes. Reconnect
and P2 ECM connectors. all wires to the original configuration. Verify that
a. Measure the resistance from the ECM
connector P1-2 to the ECM ground strap. STOP.
Expected Result:
Test Step 7. Check the +5 V Supply at the
Each resistance measurement is more than 20,000 ECM
Ohms.
A. Remove the wire 997-RD(Red) from ECM
Results: connector P1-2 (+5 V Supply). Install a wire
jumper with socket terminals on both ends into P1-
• OK – The resistance check does not indicate a 2.
short in the engine harness or a short to engine
ground.Proceed to Test Step 6. a. Remove the wire 993-BK(Black) from ECM
connector P1-3 (sensor common). Install a wire
jumper with socket terminals on both ends into
P1-3.
268 RENR5059-14
Note: Disconnecting the common sensor wire from S/N: CPA182–Up

the ECM will generate an open circuit diagnostic
code for all sensors that are connected to the S/N: BMB132–Up
sensor common. Troubleshoot the original S/N: CNB1100–Up
diagnostic code. Delete the logged diagnostic
codes when you are finished. S/N: YBB1–Up
B. Reconnect ECM connectors J1/P1 and J2/P2. S/N: CMC1107–Up
C. Turn the battery disconnect switch to the ON S/N: YBC1–Up

position. S/N: YBD1–Up
D. Measure the voltage between the wire jumper in S/N: ZAD1–Up
P1-2 and the wire jumper in P1-3.
S/N: JDE1–Up
E. Turn the battery disconnect switch to the OFF
position. S/N: BLF166–Up
F. Reconnect all wires to the original configuration. S/N: JCG1–Up

S/N: SBG1–Up
Expected Result:
S/N: JCH1–Up
The voltage is 5.0 ± 0.2 VDC.
S/N: JDH1–Up
• OK – The voltage is 5.0 ± 0.2 VDC. The voltage is S/N: YAH1–Up
correct.
S/N: ZAH1–Up
Repair: Clear all diagnostic codes. Check for S/N: BPJ472–Up
active diagnostic codes. If the problem is
intermittent, refer to Troubleshooting, S/N: JDJ1–Up
S/N: SBJ1–Up
STOP. S/N: SFJ1–Up
• Not OK – The voltage is not 5.0 ± 0.2 VDC. The S/N: ZAJ1–Up
voltage is incorrect.
S/N: BRK287–Up
Repair: Replace the ECM. Refer to S/N: SBK1–Up
Troubleshooting, “Replacing the ECM”.
S/N: SEK1–Up
STOP. S/N: YAL1–Up
i02417966
S/N: YAM1–Up
CAN Data Link S/N: FDN1515–Up

RENR5059-14 269
S/N: YBR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: GZS1–Up
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up

The CAN data link is used for communication
between the following modules: engine's Electronic
Control Module (ECM), customer devices and
various display modules. Two 120 Ohm terminating
resistors must be installed in the wiring harness in
order for the CAN data link to function properly.
Typical example
270 RENR5059-14
• Not OK – The resistance is approximately 120 ± 6

Test Step 1. Check for Connector Ohms. A terminating resistor is missing or
damaged.
Damage.
A. Turn the battery disconnect switch to the OFF Repair: If a termination resistor is missing,
position. install the missing resistor. If both resistors are
present, measure the resistance between pin A
B. Turn the breaker to the OFF position. and pin B of the termination resistor. The
resistance should measure 120 ± 3 Ohms.
C. Thoroughly inspect the ECM connectors J1/P1 Replace the termination resistor if the
and J2/P2. Inspect all of the other connectors. resistance is not 120 ± 3 Ohms.
Refer to the diagnostic functional test
Troubleshooting, “Inspecting Electrical Refer to the schematic in order to determine the
missing resistor.
D. Perform a 45 N (10 lb) pull test on each of the Verify that the repair eliminates the problem.
wires in the ECM connector that are associated
STOP.
with the circuit.
E. Check the ECM connectors (allen head screw) for Test Step 3. Check for a Short Circuit in
the proper torque. Refer to Troubleshooting, the Harness.
A. Disconnect the J1/P1 ECM connector, the
F. Check the harness and the wiring for abrasion and generator connector , and the thermocouple
for pinch points. connector.
Expected Result: B. Remove the terminating resistors from the
harness for the CAN data link.
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are Note: Wiggle the harness during the following
free of corrosion, of abrasion and of pinch points. measurements in order to reveal an intermittent
condition.
Results:
C. Measure the resistance between P1-50 (CAN data
• OK – The connectors and wiring are OK.Proceed link +) and the remaining terminals on the P1
to Test Step 2. connector.
• Not OK – The connectors and/or wiring are not D. Measure the resistance between P1-50 (CAN data
OK. link +) and the engine ground.
Repair: Repair the connectors or wiring and/or E. Measure the resistance between Pin-35 (CAN
replace the connectors or wiring. data link +) and the remaining terminals on the
generator connector.
F. Measure the resistance between Pin-35 (CAN data
link +) and the engine ground.
Test Step 2. Verify the Proper Installation
of the Terminating Resistors. Expected Result:
A. Verify that the terminating resistors are installed The resistance is greater than 20000 Ohms.
on the ends of the data link.
Results:
B. Disconnect J1/P1 ECM connector and measure
the resistance between P1-50 (CAN data link +) • OK – The resistance is greater than 20000 Ohms.
and P1-34 (CAN data link -). Proceed to Test Step 4.
Expected Result: • Not OK – The resistance is less than 20000 Ohms.

The resistance is approximately 60 ± 3 Ohms. Repair: There is a short in the harness wiring.
Repair the connectors or wiring and/or replace
Results: the connectors or wiring.
• OK – The resistance is within the range.Proceed Verify that the repair eliminates the problem.
to Test Step 3.
RENR5059-14 271
STOP. i02386323
Test Step 4. Check for an Open Circuit in Cat Data Link

the Harness. SMCS Code: 1901-038
A. All connections should remain disconnected. S/N: JM21–Up
B. Fabricate a jumper wire. Short pin G and pin F on S/N: GD31–Up
S/N: JM31–Up
C. Measure the resistance between Pin-35 (CAN
data link +) and Pin-36 (CAN data link -) at the S/N: JM41–Up
generator connector. S/N: LD41–Up
D. Short pin 2 and pin 3 on the thermocouple S/N: LY71–Up
connector.
S/N: LY81–Up
E. Measure the resistance between Pin-35 (CAN
data link +) and Pin-36 (CAN data link -) at the S/N: LD91–Up
generator connector. S/N: LY91–Up
F. Short pin A and pin B on any remaining connectors S/N: CPA182–Up
in the generator connector circuit.
S/N: BMB132–Up
G. Measure the resistance between Pin-35 (CAN
data link +) and Pin-36 (CAN data link -) at the S/N: CNB1100–Up
generator connector. S/N: YBB1–Up
H. Short pin A and pin B on any connectors in the S/N: CMC1107–Up
ECM circuit.
S/N: YBC1–Up
I. Measure the resistance between P-50 (CAN data
link +) and P-34 (CAN data link -) at the ECM S/N: YBD1–Up
connector. S/N: ZAD1–Up
The resistance is less than 5 Ohms. S/N: BLF166–Up

S/N: JCG1–Up
Results:
S/N: SBG1–Up
• OK – The resistance is less than 5 Ohms.
S/N: JCH1–Up
Repair: The harness for the CAN data link is S/N: JDH1–Up
OK.
S/N: LYH1–Up
STOP.
S/N: YAH1–Up
• Not OK – The resistance is greater than 5 Ohms. S/N: ZAH1–Up
Repair: There is an open in the harness wiring. S/N: BPJ472–Up
Repair the connectors or wiring and/or replace
S/N: JDJ1–Up
the connectors or wiring. Make the necessary
repairs. S/N: SBJ1–Up
Verify that the repair eliminates the problem. S/N: SFJ1–Up
STOP. S/N: ZAJ1–Up

S/N: BRK287–Up
S/N: SBK1–Up
S/N: SEK1–Up
272 RENR5059-14
S/N: YAL1–Up The ECM communicates with the Caterpillar

Electronic Technician (ET) in order to share status
S/N: YAM1–Up and diagnostic information. The Cat ET can also be
used to configure the ECM parameters on the
S/N: FDN1515–Up
engine. This information will not be available if
S/N: JCN1–Up communications fail between the ECM and the Cat
ET.
S/N: YAN1–Up
S/N: LYP1–Up
S/N: YAP1–Up
S/N: ZAP1–Up
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up
S/N: PDR1–Up
S/N: YAR1–Up
S/N: YBR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: GZS1–Up
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up

The Cat Data Link is used for communication
between electronic modules. The Cat Data Link is
used to communicate information from the Electronic
Control Module (ECM) to the Electronic Monitoring
System (EMS). The Cat Data Link is used for
programming and troubleshooting the ECM.
The ECM communicates with the EMS in order to
share engine information and diagnostics that may
affect engine operation.
RENR5059-14 273
Typical example
• Not OK – The connectors and/or wiring need

Test Step 1. Check for Connector repair.
Damage Repair: Repair the connectors and/or wiring or
A. Turn the engine control switch to the OFF/RESET replace the connectors and/or wiring.
mode. The engine should be off.
B. Turn the battery disconnect switch to the OFF
position. Test Step 2. Check for Electrical Shorts in
C. Thoroughly inspect the ECM connectors J1/P1 the Harness
and J2/P2. Inspect all of the other connectors.
A. Disconnect the ECM connector and disconnect
the generator connector.
Connectors” for details. B. Disconnect any module that is connected to the
Cat Data Link.
wires in the ECM connector that are associated C. Measure the resistance at the following points.
with the circuit. Wiggle the harness during the measurement in
order to reveal an intermittent short.
E. Check the ECM connectors (allen head screw) for
the proper torque. Refer to Troubleshooting, • Cat Data Link + to Cat Data Link −
• Cat Data Link + to −Battery terminal
F. Check the harness and the wiring for abrasion and
for pinch points. • Cat Data Link − to −Battery terminal
Expected Result: • Cat Data Link + to +Battery terminal

All connectors, pins, and sockets are completely • Cat Data Link − to +Battery terminal
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points. • Cat Data Link + to engine ground
Results: • Cat Data Link − to engine ground
• OK – The connectors and wiring are OK.Proceed Expected Result:
to Test Step 2.
274 RENR5059-14
The resistance is greater than 20,000 Ohms for each Repair: The harness is OK. There could be a
measurement. problem with a module or with the ECM.
Connect the suspect module on another
Results: engine. If the problem returns on the other
engine, replace the suspect module. Turn the
• OK – The resistance is greater than 20,000 Ohms. battery disconnect switch to the OFF position.
Proceed to Test Step 3. Turn the battery disconnect switch to the ON
position. If the diagnostic code is still present,
• Not OK – The resistance is less than 20,000 replace the ECM. Refer to the diagnostic
Ohms. There is a short in the harness or in the procedure Troubleshooting, “Replacing the
connectors. ECM”.
Repair: Repair the connector and/or wiring or STOP.

replace the connector and/or wiring.
• Not OK – The resistance is greater than five Ohms
STOP. Repair Complete for each measurement.
Test Step 3. Check the Resistance Repair: There is an open circuit or there is
excessive resistance in the harness. Repair the
through the Harness for an Open Circuit connectors and/or wiring or replace the
A. Turn the engine control to the OFF/RESET mode. connectors and/or wiring.
The engine should be off.
position. i02410017
C. Disconnect the ECM connector and the generator Coolant Level Sensor
connector.
SMCS Code: 1439-038-CLT
D. Disconnect any module that is connected to the
Cat Data Link. S/N: JM21–Up
E. Short the wires of the Cat Data Link together. S/N: GD31–Up
Create the short at P1-9 and P1-8 of the primary S/N: JM31–Up
ECM connector.
S/N: JM41–Up
F. Set an ohmmeter on the 200 ohm scale. Measure
the resistance between the terminals of the Cat S/N: LD41–Up
Data Link + and the Cat Data Link −. Measure the S/N: LY71–Up
resistance at the connectors for the ECM.
Measure the resistance between the terminals of S/N: LY81–Up
any module that was connected to the Cat Data S/N: LD91–Up
Link. Wiggle the harness during the
measurements in order to reveal an intermittent S/N: LY91–Up
open condition. S/N: CPA182–Up
G. Short the wires of the Cat Data Link together. S/N: BMB132–Up
Create the short at Pin-13 and Pin-14 of the
generator connector. S/N: CNB1100–Up
H. Reconnect all connectors and modules. S/N: YBB1–Up
S/N: CMC1107–Up
Expected Result:
S/N: YBC1–Up
The resistance is less than five Ohms for each
measurement. S/N: YBD1–Up
Results: S/N: ZAD1–Up

S/N: JDE1–Up
• OK – The resistance is less than five Ohms for
each measurement. S/N: BLF166–Up
S/N: JCG1–Up
RENR5059-14 275

S/N: LYH1–Up System Operation Description:
S/N: YAH1–Up Use this procedure to troubleshoot any suspect
S/N: ZAH1–Up problems with the following sensors:
S/N: BPJ472–Up • Engine coolant level sensor

S/N: JDJ1–Up • Coolant level sensor for the Separate Circuit
Aftercooler (SCAC)
S/N: SBJ1–Up
This procedure covers the following event codes:
S/N: SFJ1–Up
S/N: ZAJ1–Up • E2143 Low Engine Coolant Level
S/N: BRK287–Up • E552 Low Aftercooler Coolant Level

S/N: SBK1–Up The coolant level sensor monitors the engine coolant
level in order to warn the operator in the event that
S/N: SEK1–Up the coolant level is low. The coolant level sensor is
located on the side of the expansion tank.
S/N: YAL1–Up
S/N: YAM1–Up
S/N: FDN1515–Up
S/N: JCN1–Up
S/N: YAN1–Up
S/N: LYP1–Up
S/N: YAP1–Up
S/N: ZAP1–Up
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up Coolant level sensor
(1) Sensor
S/N: PDR1–Up (2) Sensor probe (brass dowel)
(3) Plastic cover
S/N: YAR1–Up
S/N: YBR1–Up Coolant level sensor (1) contains no moving parts.
The sensor provides the same function as a switch.
S/N: ZAR1–Up The state of the switch is dependent on the
capacitance value that is detected. The sensor
S/N: ZBR1–Up contains a probe (2) that is covered with plastic (3).
S/N: GZS1–Up When the probe is immersed in coolant, the sensor
S/N: GZT1–Up senses a particular capacitance. The sensor's
electronics react by sinking the signal to the digital
S/N: YAT1–Up return (ground).
S/N: YBT1–Up When the probe is not immersed in coolant, the
capacitance value changes. The change in the
S/N: YAW1–Up capacitance value is detected by the sensor's
electronic circuits. The sensor sources approximately
S/N: YBW1–Up
+5 VDC to the signal wire. The Electronic Control
S/N: BGX120–Up Module (ECM) detects the voltage and the ECM
activates the event code.
S/N: GZY1–Up
276 RENR5059-14
The event code is probably caused by a low coolant

level. The next likely cause is a problem with a wiring
harness or with the sensor. The least likely cause is a
problem with the ECM.
Typical location of the coolant level sensor
(4) Coolant level sensor
Schematic for coolant level sensor
A. Remove electrical power from the ECM.

ous burns. To open the cooling system filler cap,
components are cool. Loosen the cooling system
pressure.
Test Step 1. Inspect the Electrical

Connectors and the Wiring
RENR5059-14 277
Engine view
(5) J2/P2 connectors
B. Thoroughly inspect connectors (5). Inspect the

connectors for sensor (4). Refer to
Troubleshooting, “Electrical Connectors - Inspect”
for details.
278 RENR5059-14
P2 ECM connector
(P1-15) SCAC coolant level sensor (P2-57) +8 V digital supply (P2-65) +8 V digital supply
(P1-30) Engine coolant level sensor (P2-66) Digital sensor return
C. Perform a 45 N (10 lb) pull test on each of the • Not OK – There is a problem with the connectors
wires that are associated with the circuit for the and/or the wiring.
coolant level sensor.
Repair: Repair the wiring and connectors or
D. Check the allen head screw on each ECM replace the wiring or the connectors. Ensure
connector for the proper torque. Refer to that all of the seals are properly connected.
Troubleshooting, “Electrical Connectors - Inspect” Verify that the repair eliminates the problem.
for the correct torque values.
Expected Result:
coupled and/or inserted, and the harness and wiring Test Step 2. Check the Supply Voltage at
the Sensor Connector
Results: A. Disconnect the coolant level sensor.
• OK – The connectors and wiring are OK.Proceed B. Restore electrical power to the ECM.
to Test Step 2.
RENR5059-14 279
• OK – The status is “Low” when the sensor is

disconnected.Proceed to Test Step 4.
• Not OK – The status is “OK” when the sensor is

disconnected.Proceed to Test Step 5.
Test Step 4. Short the Harness and

Monitor the Status of “ Coolant Level””
A. Restore electrical power to the ECM and monitor
Harness connector for the coolant level sensor
the status of “Coolant Level” on Cat ET.
(A) +8 VDC
(B) Return B. Install a jumper wire between terminals B (return)
and C (signal) on the harness connector for the
C. Measure the voltage between terminals A (+8 coolant level sensor.
VDC) and B (return) at the harness connector for
the coolant level sensor. C. Monitor the status of “Coolant Level” on Cat ET
while the jumper wire is installed.
D. Remove electrical power from the ECM.
D. Remove the jumper wire.
Expected Result:
E. Remove electrical power from the ECM.
The voltage measurement is 8.0 ± 0.4 VDC.
Expected Result:
Results:
The status changes from “Low” to “OK” when the
jumper wire is installed.
• OK – The voltage measurement is 8.0 ± 0.4 VDC.
The supply voltage is reaching the sensor.Proceed Results:
to Test Step 3.
• OK – The status changes from “Low” to “OK” when
• Not OK – The voltage measurement is not 8.0 ± the jumper wire is installed. The ECM and the
0.4 VDC. The digital sensor supply voltage is not wiring to the coolant level sensor are OK.
reaching the sensor.
Repair: Perform the following procedure:
Repair: Refer to Troubleshooting, “Digital
Sensor Supply Circuit - Test”.
STOP. STOP
Pressurized System: Hot coolant can cause
Test Step 3. Disconnect the Coolant Level serious burns. To open the cooling system
Sensor and Monitor the Status of filler cap, stop the engine and wait until the
cooling system components are cool. Loos-
“ Coolant Level”” en the cooling system pressure cap slowly
in order to relieve the pressure.
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. Refer to A. Drain the coolant below the level of the
Troubleshooting, “Electronic Service Tools”. coolant level sensor.
B. Disconnect the coolant level sensor connectors. B. Restore electrical power to the ECM and
monitor the status of “Coolant Level” on Cat
C. Restore electrical power to the ECM.
ET.
D. Monitor the status of “Coolant Level” on Cat ET. C. Remove electrical power from the ECM.
E. Remove electrical power from the ECM.
If the status of the “Coolant Level” is “OK” ,
replace the sensor. Verify that the problem is
Expected Result: resolved.
The status changes from “OK” to “Low” when the If the status for the coolant level is “Low” ,
sensor is disconnected. connect the sensor. Fill the cooling system
according to the procedure in the Operation
Results: and Maintenance Manual. Return the engine
to service.
280 RENR5059-14
STOP. STOP Table 30

Resistance Measurements for the Circuit for the Cool-
• Not OK – Shorting the harness does not affect the ant Level Sensors
status on Cat ET.Proceed to Test Step 5.
Connector and Terminal Terminal
Test Step 5. Check for Opens in the P1-30 (engine coolant level) All of the other terminals on the P2
OR connector
Wiring P1-15 (SCAC coolant level)
All of the terminals on the P1
A. Remove electrical power from the ECM. connector
B. Disconnect the J2/P2 ECM connector and the Engine ground
connector for the coolant level sensor.
C. Measure the resistance between the following Expected Result:
terminals:
Each check of the resistance indicates an open
• P2 (digital sensor supply +8 V) to A (digital circuit.
sensor supply +8 V)
Results:
• P2 (digital sensor return) to B (digital sensor
return) • OK – Each check of the resistance indicates an
open circuit.Proceed to Test Step 7.
• P2 (coolant level sensor) to C (coolant level
sensor) • Not OK – At least one check of the resistance
does not indicate an open circuit. There is a
Expected Result: problem in the harness. There may be a problem
in a connector.
The resistance is less than five Ohms for each
measurement. Repair: Repair the wire and/or the connector,
when possible. Replace parts, if necessary.
Results: Verify that the problem is resolved.
• OK – The resistance is less than five Ohms for STOP. STOP

each measurement. There are no opens in the
wiring.Proceed to Test Step 6. Test Step 7. Create a Short Circuit at the
• Not OK – The resistance is greater than five Ohms ECM
for each measurement. There is an open circuit or A. Remove P2-5 sensor return and P2-6 low coolant
excessive resistance in the harness or the level signal.
connectors.
B. Install the ends of a jumper wire into locations P2-
Repair: Repair the circuit. 5 and P2-6. This will create a short circuit at the
ECM connectors.
C. Restore electrical power to the ECM and monitor
STOP. the status of “Coolant Level” on Cat ET.
D. Remove the jumper wire. Monitor the status of
Test Step 6. Check the Wiring for a Short
“Coolant Level” on Cat ET.
Circuit
A. Remove electrical power from the ECM. Expected Result:
Note: Wiggle the harness during the following The status is “Low” when the jumper wire is not
measurements in order to reveal an intermittent connected. The status is “OK” when the jumper wire
condition. is connected.
B. Measure the resistance between the points that Results:

are listed in Table 30 . Be sure to wiggle the wires
in the harnesses as you make each resistance • OK – The status is “Low” when the jumper wire is
not connected. The status is “OK” when the
measurement.
jumper wire is connected. The ECM is properly
reading the switch input.
RENR5059-14 281
Repair: Perform the following procedure: S/N: ZAD1–Up

A. Remove the jumper wire from the ECM S/N: JDE1–Up
connector.
S/N: BLF166–Up
B. Install the two terminals into the correct
locations on the ECM connector. Perform a S/N: JCG1–Up
pull test on the two wires in order to verify
S/N: SBG1–Up
proper installation of the terminals.
S/N: JCH1–Up
The problem appears to be resolved. The
original problem was probably caused by a S/N: JDH1–Up
poor electrical connection. Return the engine
to service. S/N: LYH1–Up
S/N: YAH1–Up
STOP. STOP
S/N: ZAH1–Up
• Not OK – The status is “Low” when the jumper
wire is connected. The ECM is not reading the S/N: BPJ472–Up
switch input. S/N: JDJ1–Up
Repair: Temporarily install a new ECM. Refer S/N: SBJ1–Up
to Troubleshooting, “Replacing the ECM”.
S/N: SFJ1–Up
If the new ECM works correctly, install the
original ECM and verify that the problem S/N: ZAJ1–Up
returns. If the new ECM works correctly and the S/N: BRK287–Up
original ECM does not work correctly, replace
the original ECM. Verify that the problem is S/N: SBK1–Up
resolved.
S/N: SEK1–Up
STOP. STOP S/N: YAL1–Up
i02418036
S/N: YAM1–Up
Digital Sensor Supply S/N: FDN1515–Up

282 RENR5059-14
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up

Use this procedure if one of the following diagnostic
codes is active or logged:
• 263-03 Digital Sensor Supply short to +batt
• 263-04 Digital Sensor Supply short to ground

The digital sensor supply in the Electronic Control
Module (ECM) supplies 8.0 ± 0.4 VDC to terminal A
of the digital sensors. Terminal B of the digital
sensors is connected to the digital return.
The digital sensor supply is output short circuit
protected. The ECM is protected from a short to
ground and a short to +Battery condition. The digital
sensor is not protected against short circuits.
RENR5059-14 283
Schematic
284 RENR5059-14
Illustration 42 g01162303 Illustration 43 g01162233

P1 ECM connector P2 ECM connector
(P1-4) +8 V digital supply (P2-56) +8 V digital supply
(P1-5) Digital return
Sensor connector
Test Step 1. Inspect Electrical

position.
RENR5059-14 285
C. Thoroughly inspect the J1/P1 and J1/P1 ECM • 263-04

connectors. Thoroughly inspect all connectors that
are related to the circuit. Refer to Troubleshooting, Results:
• OK A 263-03 diagnostic code is active. Proceed to
D. Perform a 45 N (10 lb) pull test on each of the Test Step 3.
wires in the ECM connector and the sensor
connectors that are associated with the active • OK A 263-04 diagnostic code is active. Proceed to
diagnostic code. Test Step 4.
E. Check the ECM connector (allen head screw) for • Not OK No diagnostic code for the digital supply is
the proper torque. Refer to Troubleshooting, active. A problem is suspected with a sensor
“Inspecting Electrical Connectors” for details. output signal. In order to verify that the sensor is
receiving the correct supply voltage, proceed to
F. Check the harness and wiring for abrasions and for Test Step 3.
pinch points from the sensors back to the ECM.
Expected Result: Test Step 3. Check the Voltage on the +8

V Supply Wire
inserted and coupled. The harness and wiring are A. Turn the engine control to the OFF/RESET mode.
free of corrosion, of abrasion, and of pinch points. All
connections and grounds are tight and free of B. Turn the battery disconnect switch to the OFF
corrosion. position.
C. Disconnect all of the digital sensors at the sensor
Results:
connectors.
• OK – The harness and wiring are OK.Proceed to D. Turn the engine control to the STOP mode.
Test Step 2.
E. Turn the battery disconnect switch to the ON
• Not OK – There is a problem in the connectors position.
and/or wiring.
F. Measure the voltage between terminal A and
Repair: Repair the connectors or wiring and/or terminal B at each of the sensor connectors.
of the seals are properly in place and ensure Expected Result:
that the connectors are completely coupled. The voltage is 8.0 ± 0.4 VDC.
Results:
STOP.
• OK – The voltage is 8.0 ± 0.4 VDC. The voltage is
correct.
Codes Repair: Replace all wires to the original
configuration. Clear all diagnostic codes. Check
A. Connect Caterpillar Electronic Technician (ET) to for active diagnostic codes. If the problem is
the service tool connector. intermittent, refer to Troubleshooting,
B. Turn the engine control to the STOP mode. “Inspecting Electrical Connectors”.
C. Turn the battery disconnect switch to the ON STOP.

position.
• Not OK – The voltage is not 8.0 ± 0.4 VDC at one
D. Monitor the active diagnostic code screen on Cat of the sensor connectors.Proceed to Test Step 5.
ET. Check and record any active diagnostic codes.
Note: Wait at least 15 seconds in order for the Test Step 4. Disconnect the +8 V Sensor
diagnostic codes to become active. while you Monitor the Active Diagnostic
Codes
Expected Result:
A. Turn the engine control to the STOP mode.
One of the following diagnostic codes is active:
• 263-03 position.
286 RENR5059-14
C. Monitor the active diagnostic code screen on Cat b. Measure the resistance between P2-56 (+8 V
ET. Check and record any active diagnostic codes. digital supply) and engine ground.
Note: Wait at least 15 seconds in order for the Expected Result:
The resistance is more than 20,000 Ohms.
D. Disconnect the digital sensors one at a time while
you monitor Cat ET. Results:
E. Wait for 15 seconds after the sensor is • OK – The resistance is more than 20,000 Ohms.
disconnected. Check for an active diagnostic code The resistance measurement does not indicate a
on Cat ET. short in the engine harness or a short to engine
ground.Proceed to Test Step 6.
Expected Result:
• Not OK – A resistance measurement is less than
The 263-04 diagnostic code deactivates when a 20,000 Ohms. The +8 V digital supply wire is
particular sensor is disconnected. shorted in the engine harness or the +8 V digital
supply wire is shorted to engine ground.
Results:
Repair: Repair the wire or replace the wire.
• OK – The 263-04 diagnostic code deactivates Clear all logged diagnostic codes. Replace all
after disconnecting the suspect sensor. wires to the original configuration. Verify that
Repair: Reconnect the sensor. If the problem
returns after the reconnection of the sensor, STOP.
disconnect the sensor. If the problem
disappears after the disconnection of the
sensor, replace the sensor. Reconnect all wires Test Step 6. Check the +8 V Supply and
to the original configuration. Clear all diagnostic the Sensor Return for an Open Circuit
codes. Verify that the repair eliminates the
problem. A. Install a wire jumper between pin P1-4 (+8 V
digital supply) and pin P1-5 (digital return).
STOP. B. Install a wire jumper between pin P2-56 (+8 V
digital supply) and pin P1-5 (digital return).
• Not OK – The 263-04 diagnostic code stays
active. Leave the sensor(s) disconnected. Note: Wiggle the harness during the following
Proceed to Test Step 5. measurements in order to reveal any intermittent
short condition.
Test Step 5. Check the +8 V Supply Wire
C. Measure the resistance between terminal A and
for a Short to Engine Ground or a Short terminal B on each sensor connector.
to another Wire in the Harness
D. Remove the wire jumpers.
Expected Result:
position. The resistance is less than 5 Ohms.
C. Disconnect the J1/P1 and J2/P2 ECM connectors.
Results:
D. Leave the digital sensor(s) disconnected at the
sensor connectors. • OK – The resistance is less than 5 Ohms. The
resistance measurements do not indicate an open
Note: Wiggle the harness during the following circuit in the engine harness.Proceed to Test Step
measurements in order to reveal any intermittent 7.
short condition.
• Not OK – A resistance measurement is greater
E. Measure the resistance between P1-4 (+8 V digital than 5 Ohms. The +8 V digital supply wire or the
supply) and every terminal on ECM connector P1 sensor common has excessive resistance.
and ECM connector P2.
Repair: Repair the wires or replace the wires.
a. Measure the resistance between P1-4 (+8 V Clear all logged diagnostic codes. Reconnect
digital supply) and engine ground. all wires to the original configuration. Verify that
RENR5059-14 287
STOP. i02417338
Test Step 7. Check the +8 V Supply at the Direct Fuel Control Mode
ECM SMCS Code: 1901-038
A. Remove the wire A700-RD(Red) from ECM S/N: JM21–Up
connector P1-4 (+8 V digital supply). Remove the
wire R800-RD(Red) from ECM connector P2-56 S/N: GD31–Up
(+8 V digital supply). Install a wire jumper with S/N: JM31–Up
socket terminals on both ends into P1-4 and install
a wire jumper with socket terminals on both ends S/N: JM41–Up
into P2-56. S/N: LD41–Up
B. Remove the wire A235-BK(Black) from ECM S/N: LY71–Up
connector P1-5 (digital return). Install a wire
jumper with socket terminals on both ends into P1- S/N: LY81–Up
5. S/N: LD91–Up
C. Reconnect ECM connector J1/P1 and J2/P2. S/N: LY91–Up
D. Turn the engine control to the STOP mode. S/N: CPA182–Up
E. Turn the battery disconnect switch to the ON S/N: BMB132–Up
position.
S/N: CNB1100–Up
F. Measure the voltage between the wire jumper in
P1-4 and the wire jumper in P1-5. Measure the S/N: YBB1–Up
voltage between the wire jumper in P2-56 and the S/N: CMC1107–Up
wire jumper in P1-5.
S/N: YBC1–Up
G. Turn the engine control switch to the OFF/RESET
mode. S/N: YBD1–Up
H. Turn the battery disconnect switch to the OFF S/N: ZAD1–Up

position. S/N: JDE1–Up
I. Reconnect all wires to the original configuration. S/N: BLF166–Up
The voltage is 8.0 ± 0.4 VDC. S/N: SBG1–Up

S/N: JCH1–Up
Results:
S/N: JDH1–Up
• OK – The voltage is 8.0 ± 0.4 VDC. The voltage is
correct. S/N: LYH1–Up
S/N: YAH1–Up
Repair: Clear all diagnostic codes. Check for
active diagnostic codes. If the problem is S/N: ZAH1–Up
intermittent, refer to Troubleshooting,
“Inspecting Electrical Connectors”. S/N: BPJ472–Up
S/N: JDJ1–Up
STOP.
S/N: SBJ1–Up
• Not OK – The voltage is not 8.0 ± 0.4 VDC. The
S/N: SFJ1–Up
voltage is incorrect.
S/N: ZAJ1–Up
Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”. S/N: BRK287–Up
S/N: SBK1–Up
STOP.
S/N: SEK1–Up
288 RENR5059-14
S/N: YAL1–Up The input to the signal converter is a 0 to 200 mA

signal. The signal is received from the external
S/N: YAM1–Up governor. The output signal from the signal converter
S/N: FDN1515–Up is a Pulse Width Modulated signal (PWM).
S/N: JCN1–Up The output signal varies with the current to the signal
converter. The ECM calculates the desired fuel from
S/N: YAN1–Up the PWM signal.
S/N: LYP1–Up The duty cycle for a valid signal is between 5 and 95
percent. If an invalid signal is received, the engine
S/N: YAP1–Up will automatically be set to a minimum fuel setting
and the engine will shut down.
S/N: ZAP1–Up
S/N: ZBP1–Up The following functions are not used in direct fuel
control mode.
S/N: GAR1–Up
• Low idle
S/N: PBR1–Up
• Crank terminate speed
S/N: PDR1–Up
• Cooldown speed
S/N: YAR1–Up
S/N: YBR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: GZS1–Up
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up

Perform this procedure if the “Direct Fuel Control
Mode” is “ON” and a 91-08 Throttle Position Signal
Abnormal diagnostic code is active.
The direct fuel control mode enables the engine to be
controlled by an external governor. You must install
the components of the signal converter for the direct
fuel control in order to operate in direct fuel control
mode. The configuration parameter must be
programmed to “ON” in order for the Electronic
Control Module (ECM) to respond properly to the
external governor.
RENR5059-14 289
Typical example
• Not OK – The connectors and/or wiring are not

Test Step 1. Check for Connector OK.
Damage Repair: Repair the connectors or wiring and/or
A. Turn the Engine Control Switch (ECS) to the OFF/ replace the connectors or wiring.
RESET position.
position. Test Step 2. Check the Current Input to
C. Thoroughly inspect the ECM connectors J1/P1 the Signal Converter
A. Measure the current to the signal converter.
Troubleshooting, “Inspecting Electrical Note: Some external governors may only be able to
Connectors” for details. output approximately 150 mA. This should not be
seen as a problem with the external governor.
wires in the ECM connector that are associated Expected Result:
with the circuit.
The current range is between 0 and 200 mA.
E. Check the allen head screw on each ECM
connector for the proper torque. Refer to Results:
Connectors” for the correct torque values. • OK – The current is within the correct range.
for pinch points. • Not OK – The current is not within the correct
range.
Expected Result:
Repair: Replace the external governor that is
coupled and/or inserted. The harness and wiring are supplying the controlling current.
free of corrosion, of abrasion, and of pinch points.
Results:
Test Step 3. Check the Voltage at the
• OK – The connectors and wiring are OK.Proceed Battery
to Test Step 2.
290 RENR5059-14
A. Turn the circuit breaker for the battery to the OFF A. Connect the Caterpillar Electronic Technician (ET)
position. to the service tool connector. Start Cat ET.
B. Turn the ECS to the OFF/RESET position. B. Turn the ECS to the STOP position.
C. Measure no-load battery voltage at the battery C. Observe the throttle position reading on Cat ET.
terminals. Refer to Testing and Adjusting, “Test
D. Vary the current to the signal converter.
Tools for the Electrical System” for the proper
procedures to check the batteries. Expected Result:
D. Load test the batteries. Use the 4C-4911 Battery
The throttle position on Cat ET varies from 5 percent
Load Tester. Refer to the Operating Manual, to 85 percent as the current input is adjusted from 0
SEHS9249. Refer to Special Instruction, mA to 200 mA.
SEHS7633.
Results:
Expected Result:
• OK – The throttle position on Cat ET corresponds
The voltage is 24 ± 3 VDC. with the current input.
Results: Repair: Check the system for any diagnostic
codes.
• OK – The voltage measures 24 ± 3 VDC.Proceed
to Test Step 4. STOP.
• Not OK – The voltage is not 24 ± 3 VDC. • Not OK – The throttle position does not
correspond to the current input.Proceed to Test
Repair: The batteries or the alternator are Step 6.
causing the problem. Recharge the batteries or
replace the batteries. Verify that the original
condition is resolved. Refer to Testing and Test Step 6. Check the Signal from the
Adjusting, “Electrical System”. Signal Converter
STOP. Repair Complete A. Remove the signal wire from the signal converter.
B. Set the multimeter to “VDC” .
Test Step 4. Check the Voltage at the C. Press the “Hz” button twice so that the “%” symbol
Signal Converter is displayed.
A. Connect one probe of the voltmeter to the D. Place one probe on the signal wire of the signal
+Battery terminal at the signal converter. converter.
B. Connect one probe of the voltmeter to the E. Place the other probe on the −Battery terminal of
−Battery terminal at the signal converter. the signal converter.
Expected Result: F. Monitor the output of the percent duty cycle from
the signal converter.
The voltage is 24 ± 3 VDC.
G. Adjust the current input from a low current setting
Results: to a high current setting.
• OK – The voltage is 24 ± 3 VDC.Proceed to Test Note: The throttle position on Cat ET will not match
Step 5. the percent duty cycle on the multimeter.
• Not OK – The voltage is not 24 ± 3 VDC. Expected Result:
Repair: Check the wiring and/or the connectors The duty cycle is between 3 and 5 percent at the low
setting and above 85 percent at the high setting.
that are between the battery and the signal
converter. Repair the wiring and/or connectors.
Results:
• OK – The correct signal is being supplied.Proceed
to Test Step 7.
Test Step 5. Check the Fuel Position
RENR5059-14 291
• Not OK – The duty cycle is not correct on the i02386338

multimeter.
Electrical Power Supply
Repair: Temporarily install another signal
converter. Verify that the problem is no longer SMCS Code: 1401-038
present. Reinstall the old signal converter. If the
S/N: JM21–Up
problem returns, replace the signal converter.
S/N: GD31–Up
S/N: JM31–Up
Test Step 7. Check the Signal at the ECM S/N: JM41–Up
A. Turn the ECS to the STOP position. S/N: LD41–Up
B. Replace the signal wire on the signal converter. S/N: LY71–Up
C. Set the multimeter to “VDC” . S/N: LY81–Up
D. Press the “Hz” button twice so that the “%” symbol S/N: LD91–Up
is displayed.
S/N: LY91–Up
E. Measure the voltage between the signal wire at
ECM connector P1-10 and the digital reference at S/N: CPA182–Up
ECM connector P1-05. S/N: BMB132–Up
F. Monitor the output of the percent duty cycle on the S/N: CNB1100–Up
multimeter.
S/N: YBB1–Up
G. Monitor the percent throttle position on Cat ET.
S/N: CMC1107–Up
H. Vary the input current to the signal converter.
S/N: YBC1–Up
Expected Result: S/N: YBD1–Up
The duty cycle is between 3 and 5 percent at the low S/N: ZAD1–Up
setting and above 85 percent at the high setting. The
percent throttle position is between 5 and 85 percent. S/N: JDE1–Up
Results: S/N: BLF166–Up

S/N: JCG1–Up
• OK – The duty cycle and the throttle position are
correct. S/N: SBG1–Up
S/N: JCH1–Up
Repair: Check the system for any diagnostic
codes. S/N: JDH1–Up
STOP. S/N: LYH1–Up

S/N: YAH1–Up
• Not OK-Duty Cycle – The duty cycle is not correct.
S/N: ZAH1–Up
Repair: There is a problem in the wiring
between the signal wire at ECM connector P1- S/N: BPJ472–Up
10 and the signal converter. S/N: JDJ1–Up
STOP. S/N: SBJ1–Up
• Not OK-Throttle Position – The duty cycle is OK. S/N: SFJ1–Up

The throttle position is incorrect. S/N: ZAJ1–Up
Repair: Replace the ECM. Refer to the S/N: BRK287–Up
S/N: SBK1–Up
“Replacing the ECM”.
S/N: SEK1–Up
STOP.
292 RENR5059-14
S/N: YAL1–Up The electrical power for the engine comes through a
15 amp circuit breaker to the battery terminals on the
S/N: YAM1–Up ECM. The presence of three +Battery connections
S/N: FDN1515–Up and three −Battery connections to the ECM reduce
harness resistance. All of these connections must be
S/N: JCN1–Up complete in order to ensure proper engine operation.
S/N: YAN1–Up The electrical power for the generator set control
comes through a 25 amp circuit breaker to the relay
S/N: LYP1–Up module and to the high voltage ground bar.
S/N: YAP1–Up
S/N: ZAP1–Up
S/N: ZBP1–Up
S/N: GAR1–Up
S/N: PBR1–Up
S/N: PDR1–Up
S/N: YAR1–Up
S/N: YBR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: GZS1–Up
S/N: GZT1–Up
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up

A signal from the engine control is provided to the
keyswitch input of the Electronic Control Module
(ECM) that tells the ECM the position of the switch.
When the ECM senses battery voltage to the
keyswitch input of the ECM, the ECM will power up.
The keyswitch input receives battery voltage when
the engine control is in the AUTO, RUN or STOP
mode. If the voltage is removed from the keyswitch
input, the ECM will power down. Cycling power to the
keyswitch input of the ECM will reset the ECM and all
active diagnostic codes.
RENR5059-14 293
• OK – The connectors and wiring are OK.Proceed

Test Step 1. Inspect the Electrical to Test Step 2.
Connectors and Wiring • Not OK – The connectors and/or wiring are not
A. Turn the engine control to the OFF/RESET mode. OK.
B. Turn the battery disconnect switch to the OFF Repair: Repair the connectors and/or wiring or
position. replace the connectors and/or wiring.
C. Thoroughly inspect the ECM connectors J1/P1 STOP. Repair Complete
Test Step 2. Check the Voltage to the
Connectors” for details. ECM
D. Perform a 45 N (10 lb) pull test on each of the A. Remove ECM connector J1/P1.
wires in the ECM connector that are associated B. Turn the battery disconnect switch to the ON
with the circuit. position.
E. Check the ECM connector (allen head screw) for C. Turn the engine control to the STOP mode.
the proper torque. Refer to the diagnostic
functional test Troubleshooting, “Inspecting D. Measure the voltage between P1-63 and P1-52.
Electrical Connectors” for details. E. Measure the voltage between P1-65 and P1-53.
F. Check the customer connector (allen head screw) F. Measure the voltage between P1-67 and P1-55.
for the proper torque. Refer to the diagnostic
functional test Troubleshooting, “Inspecting G. Turn the engine control to the OFF/RESET mode.
Electrical Connectors” for details. H. Turn the battery disconnect switch to the OFF
G. Check the harness and the wiring for abrasion and position.
for pinch points. I. Reconnect ECM connector J1/P1.
Expected Result: Expected Result:
All connectors, pins, and sockets are completely The voltage is 24 ± 3 VDC from the voltage at the
coupled and/or inserted. The harness and wiring are battery terminals.
free of corrosion, of abrasion and of pinch points.
Results:
Results:
294 RENR5059-14
• OK – The voltage is 24 ± 3 VDC from the voltage D. Turn the battery disconnect switch to the ON
at the battery terminals. The ECM is receiving the position.
correct voltage.Proceed to Test Step 6.
E. Turn the engine control to the STOP mode.
• Not OK – The voltage is not 24 ± 3 VDC from the F. Measure the voltage between P3-18 and P3-39 at
voltage at the battery terminals. The voltage is
the generator and engine harness connector J3/
incorrect. The battery or the alternator may be
P3.
causing the problem.Proceed to Test Step 3.
G. Turn the engine control to the OFF/RESET mode.
• Not OK - ECM Keyswitch – The voltage is not 24 ±
3 VDC.Proceed to Test Step 4. H. Turn the battery disconnect switch to the OFF
position.
Test Step 3. Check the Battery Voltage I. Replace all wires.
A. Measure no-load voltage at the battery terminals.
Expected Result:
B. Load test the batteries. Use the 4C-4911 Battery
Load Tester. Refer to the Operating Manual, The voltage is 24 ± 3 VDC.
SEHS9249. Refer to Special Instruction,
Results:
SEHS7633.
• OK – The voltage is 24 ± 3 VDC.
Expected Result:
The no-load voltage at the batteries should be at Repair: The wire from the ECM to the
least 24 ± 3 VDC, and the batteries should pass the connector J3/P3 and/or the connectors are
load test. damaged. Repair the connectors and/or wiring
or replace the connectors and/or wiring.
Results:
• OK – The no-load voltage at the batteries is 24 ± 3
VDC, and the batteries pass the load test. • Not OK – The voltage is not 24 ± 3 VDC.Proceed
to Test Step 5.
Repair: There is a problem in the harness.
Repair the connectors and/or wiring or replace Test Step 5. Check the Voltage to the
the connectors and/or wiring between the
battery and the ECM.
Generator Set Control
A. Remove wires J3-5 and J3-39 from the generator
STOP. Repair Complete and engine harness connector J3/P3.
• Not OK – The battery voltage is incorrect and/or B. Turn the battery disconnect switch to the ON
the battery fails the load test. position.
C. Turn the engine control to the STOP mode.
Repair: The batteries or the alternator are
causing the problem. Recharge the batteries or D. Measure the voltage between J3-5 and J3-39 at
replace the batteries. Verify that the original the generator and engine harness connector J3/
condition is resolved. P3.
STOP. Repair Complete E. Turn the engine control switch to the OFF/RESET
mode.
Test Step 4. Check the Voltage from the F. Turn the battery disconnect switch to the OFF
Generator Set Control position.
A. Disconnect the generator and the engine harness G. Replace all wires.
connector J3/P3.
Expected Result:
B. Remove wires P3-18 and P3-39 from the engine
harness connector J3/P3. The voltage is 24 ± 3 VDC.
C. Reconnect the generator and the engine harness
Results:
connector J3/P3.
• OK – The voltage is 24 ± 3 VDC.
RENR5059-14 295
Repair: There is a problem in the generator set Repair: Check the system for any diagnostic
control or in the harness wiring between the codes.
engine and the generator. Check the generator
set control for diagnostic codes. Check the STOP.
engine control for proper operation. Repair the
connectors and/or wiring between the generator • Not OK – If the ECM is getting the correct voltage
set control+ and the harness connector for the at the +Battery terminal, but the ECM does not
generator and engine J3/P3. supply the correct voltages to the sensors, replace
the ECM.
Repair: Refer to the diagnostic procedure
• Not OK – The voltage is not 24 ± 3 VDC. Troubleshooting, “Replacing the ECM”.
Repair: Check the battery disconnect switch for STOP. Repair Complete
proper operation. Ensure that the EMCPB is not
tripped. Repair the connectors and/or wiring or i02386427
replace the connectors and/or wiring between
the battery and the engine connector J3/P3. Emergency Stop Switch
SMCS Code: 1901-038
S/N: JM21–Up
Test Step 6. Check the Voltage of the
S/N: GD31–Up
Sensor Power Supplies at the ECM
Connector S/N: JM31–Up
A. Remove wires P1-18, P1-35, P1-04, and P1-05 S/N: JM41–Up

from ECM connector P1. Install wire jumpers into S/N: LD41–Up
the following sockets: P1-18, P1-35, P1-14 and
P1-05. S/N: LY71–Up
B. Turn the battery disconnect switch to the ON S/N: LY81–Up

position. S/N: LD91–Up
C. Turn the engine control to the STOP mode. S/N: LY91–Up
D. Measure the voltage from the analog sensor S/N: CPA182–Up
supply P1-18 to the analog sensor return P1-35 at
the wire jumpers. S/N: BMB132–Up
E. Measure the voltage from digital sensor supply S/N: CNB1100–Up

P1-04 to the digital sensor return P1-05 at the wire S/N: YBB1–Up
jumpers.
S/N: CMC1107–Up
F. Turn the engine control to the OFF/RESET mode.
S/N: YBC1–Up
G. Turn the battery disconnect switch to the OFF
position. S/N: YBD1–Up
H. Remove the wire jumpers and replace ECM S/N: ZAD1–Up

connector J1/P1. S/N: JDE1–Up
Expected Result: S/N: BLF166–Up
The analog voltage supply is 5.0 ± 0.2 VDC between S/N: JCG1–Up
P1-36 and P1-30. The digital voltage supply is 8.0 ± S/N: SBG1–Up
0.4 VDC between P1-35 and P1-29.
S/N: JCH1–Up
Results:
S/N: JDH1–Up
• OK – The sensor power supplies are functioning S/N: LYH1–Up
properly. The ECM is powered up. The problem is
not in the electrical system. There may be a S/N: YAH1–Up
mechanical problem.
296 RENR5059-14
S/N: ZAH1–Up System Operation Description:

S/N: BPJ472–Up The customer's emergency stop switch sends a
signal to two terminals on the Electronic Control
S/N: JDJ1–Up Module (ECM). The signals are used to determine if
S/N: SBJ1–Up the emergency stop switch is active. The emergency
stop switch is active when the switch is in the open
S/N: SFJ1–Up state and the two signals are held high. The
emergency stop switch is inactive when the switch is
S/N: ZAJ1–Up in the closed state and the two signals are held low.
S/N: BRK287–Up If the ECM is powering up and one of the signals from
the emergency stop switch is in a different state from
S/N: SBK1–Up
the other signal, the ECM determines that one of the
S/N: SEK1–Up signals is faulty. If one of the signals from the
emergency stop switch is in a different state from the
S/N: YAL1–Up other signal, the ECM will generate a diagnostic code
that remains active until power to the ECM is cycled.
S/N: YAM1–Up The ECM will not allow the crank cycle to begin if the
S/N: FDN1515–Up signals are opposite of each other. The ECM will
allow the engine to be started manually in this state.
S/N: JCN1–Up
The ECM monitors the emergency stop signals at all
S/N: YAN1–Up times. If the engine is running and one of the signals
from the emergency stop switch changes states, the
S/N: LYP1–Up engine will continue to run. The ECM initiates an
emergency stop shutdown only when both signals
S/N: YAP1–Up
are in the open state during engine operation.
S/N: ZAP1–Up
When a signal from the emergency stop switch is
S/N: ZBP1–Up received, the air shutoff solenoid is activated.
S/N: GAR1–Up The ECM will not allow the starting sequence to
begin when the emergency stop switch is activated.
S/N: PBR1–Up The engine will not be able to restart until the
following conditions are met:
S/N: PDR1–Up
S/N: YAR1–Up • The engine rpm must equal zero.
S/N: YBR1–Up • The emergency stop inputs must go low.
S/N: ZAR1–Up • The ECM has been reset.

S/N: ZBR1–Up Note: If one of the signals from the emergency stop
switch is in a different state from the other signal, the
S/N: GZS1–Up
screen for the Caterpillar Electronic Technician (ET)
S/N: GZT1–Up will display the warning “INVALID DATA” .
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up
RENR5059-14 297
Typical schematic
Expected Result:
Test Step 1. Inspect Electrical All connectors, pins, and sockets are completely
Connectors and Wiring coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion and of pinch points.
B. Turn the battery disconnect switch to the OFF Results:
position.
C. Thoroughly inspect the ECM connectors J1/P1 to Test Step 2.
Refer to the diagnostic functional test • Not OK – The connectors and/or wiring are not
Troubleshooting, “Inspecting Electrical OK.
D. Perform a 45 N (10 lb) pull test on each of the replace the connectors or wiring.
with the circuit. STOP. Repair Complete
E. Check the ECM connector (allen head screw) for
Test Step 2. Check the OFF Status of the
functional test Troubleshooting, “Inspecting Emergency Stop Push Button (ESPB)
Electrical Connectors” for details. A. Pull out the ESPB in order to deactivate the push
F. Check the customer connector (allen head screw) button. Some versions of the ESPB must be
for the proper torque. Refer to the diagnostic turned clockwise before you pull out the ESPB.
functional test Troubleshooting, “Inspecting B. Connect the Cat ET to the service tool connector
Electrical Connectors” for details. J60/P60. Start Cat ET.
G. Check the harness and the wiring for abrasion and C. Turn the battery disconnect switch to the ON
for pinch points. position.
298 RENR5059-14
D. Turn the engine control to the STOP mode. A. Turn the engine control to the OFF/RESET mode.
E. Monitor the status of the emergency stop on Cat B. Turn the battery disconnect switch to the OFF
ET. position.
Expected Result: C. Connect Cat ET to the service tool connector J60/

P60. Start Cat ET.
The ESPB pulls out. The emergency stop indicates
OFF on Cat ET. D. Locate a suitable jumper wire.
E. Connect P1-23 and P1-28 to P2-29 at ECM
Results: connector P1 and P2.
• OK – The ESPB pulls out. The emergency stop F. Turn the battery disconnect switch to the ON
indicates OFF on the Cat ET.Proceed to Test Step position.
3.
G. Turn the engine control to the STOP mode.
• ESPB Does not pull out. H. Monitor the status of the emergency stop on Cat
ET.
Repair: Replace the ESPB.
I. Turn the engine control to the OFF/RESET mode.
STOP.
J. Turn the battery disconnect switch to the OFF
• Not OK – The ESPB pulls out. The emergency position.
stop does not indicate OFF on Cat ET.Proceed to
K. Remove the wire jumper.
Test Step 4.
Expected Result:
Test Step 3. Check the ON Status of the
ESPB The parameter for the emergency stop switch
displays “OFF” when the jumper is installed. The
A. Push in the ESPB in order to activate the push parameter for the emergency stop switch displays
button. “ON” when the jumper is removed.
B. Connect Cat ET to the service tool connector J60/ Results:

P60. Start Cat ET.
• OK – The problem is not with the ECM.Proceed to
C. Turn the battery disconnect switch to the ON Test Step 5.
position.
D. Turn the engine control to the STOP mode. • Not OK – The parameter is incorrect.
E. Monitor the status of the emergency stop on Cat Repair: Replace the ECM. Refer to the
ET. diagnostic procedure Troubleshooting,
Expected Result:
The emergency stop indicates ON on the Cat ET.
Results:
Test Step 5. Check the Switches and the
Wiring
• OK – The emergency stop indicates ON. A. Disconnect connector P1 from ECM connector J1.
Repair: The problem may be intermittent. B. Activate the emergency stop switch.
Check the harness and all electrical
connections of the ESPB circuit. Perform the C. Measure the resistance between P2-29 and P1-
diagnostic functional test Troubleshooting, 23.
“Inspecting Electrical Connectors”. D. Measure the resistance between P2-29 and P1-
28.
STOP.
Expected Result:
• NOT OK – The emergency stop does not indicate
ON on Cat ET.Proceed to Test Step 4. The resistance measurement indicates an open
circuit.
Test Step 4. Test the ECM
RENR5059-14 299
Results: S/N: LY81–Up
• OK – The measured resistance indicates an open S/N: LD91–Up

circuit.Proceed to Test Step 6. S/N: LY91–Up
• Not OK – The resistance measurement does not S/N: CPA182–Up
indicate an open circuit. There is a short circuit in
S/N: BMB132–Up
the emergency stop switch.
S/N: CNB1100–Up
Repair: Repair the switch or wiring and/or
replace the switch or wiring. S/N: YBB1–Up
S/N: CMC1107–Up
S/N: YBC1–Up
Test Step 6. Deactivate the Emergency S/N: YBD1–Up
Shutdown Switch
S/N: ZAD1–Up
A. Deactivate the emergency shutdown switch.
S/N: JDE1–Up
B. Measure the resistance between P2-29 and P1-
23. S/N: BLF166–Up
C. Measure the resistance between P2-29 and P1- S/N: JCG1–Up

28. S/N: SBG1–Up
Expected Result: S/N: JCH1–Up
The resistance is less than 10 Ohms. S/N: JDH1–Up

S/N: LYH1–Up
Results:
S/N: YAH1–Up
• OK – The resistance is less than 10 Ohms. The
emergency shutdown switch is OK. S/N: ZAH1–Up
S/N: BPJ472–Up
Repair: Check for any diagnostic codes.
S/N: JDJ1–Up
STOP.
S/N: SBJ1–Up
• Not OK – The resistance is greater than 10 Ohms. S/N: SFJ1–Up
There is an open circuit in the emergency
shutdown switch. S/N: ZAJ1–Up
S/N: BRK287–Up
Repair: Repair the switch or wiring and/or
replace the switch or wiring. S/N: SBK1–Up
i02408861 S/N: YAL1–Up

S/N: YAM1–Up
Engine Control Switch (ECS)
S/N: FDN1515–Up
SMCS Code: 1901-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
300 RENR5059-14
S/N: PBR1–Up If the signals to the start/run/stop input of the ECM

are in opposite states, the ECM determines that one
S/N: PDR1–Up of the signals is faulty. When this happens the ECM
will keep the last good input. When the diagnostic
S/N: YAR1–Up
code activates and the switch is in the “STOP”
S/N: YBR1–Up position, the engine will not start. When the
diagnostic activates and the switch is in the “RUN”
S/N: ZAR1–Up position, the engine will continue to run.
S/N: ZBR1–Up Note: For the troubleshooting of applications that are
equipped with an EMCP 3, refer to Systems
S/N: GZS1–Up Operation, Troubleshooting, Testing and Adjusting,
S/N: GZT1–Up RENR7902.
S/N: YAT1–Up
S/N: YBT1–Up
S/N: YAW1–Up
S/N: YBW1–Up
S/N: BGX120–Up
S/N: GZY1–Up
S/N: JCY1–Up
S/N: YAY1–Up
S/N: YAZ1–Up

The 336-02 diagnostic code is generated when the
two start/run/stop inputs to the Engine Control
Module (ECM) are not complementary. The status for
the Engine Control Switch will display “Abnormal/
Incorrect Data” while the fault is active.
The Electronic Modular Control Panel 3 (EMCP 3)
controls the starting and stopping of the engine. The
engine parameters for the total number of crank
cycles and the engine cooldown must be
programmed to zero (0).
The following inputs for the engine control are
located on the panel for the EMCP 3: “RUN” ,
“AUTO” and “STOP” . These switches control a
primary input and a secondary input to the ECM. The
primary input to the ECM is over the J1939 data link.
The secondary input is a set of relay contacts in the
EMCP 3 that are normally open to digital return. If the
primary input is lost the ECM will look to the
secondary input. The engine parameter for the
secondary input must be set to the enabled state in
order for the secondary input to be recognized. When
the “RUN” switch is pushed on the panel for the
EMCP 3 the start/run/stop inputs 1 and 2 to the ECM
are pulled low.
RENR5059-14 301
Schematic for the ECS with EMCP 3
Test Step 2. Check for a CID-FMI.

Test Step 1. Check for Connector A. Connect the Caterpillar Electronic Technician
Damage. (ET).
A. Set the EMCP 3 to the STOP position. B. Turn the battery disconnect switch to the ON
B. Turn the battery disconnect switch to the OFF position.
position. C. Set the EMCP 3 to the STOP position.
C. Thoroughly inspect the ECM connectors J1/P1 D. Observe the logged diagnostic codes on Cat ET.
Refer to the diagnostic functional test E. Observe the status screen on Cat ET.
Expected Result:
Cat ET indicates a CID-FMI 336-02.
wires in the ECM connector that are associated Cat ET indicates that the status for the Engine
with the circuit. Control Switch is “Abnormal/Incorrect Data” .
E. Check the allen head screw on each ECM Results:
connector for the proper torque. Refer to
Troubleshooting, “Inspecting Electrical • OK – Cat ET indicates a CID-FMI 336-02 and Cat
Connectors” for the correct torque values. ET indicates that the status for the Engine Control
Switch is “Abnormal/Incorrect Data” .Proceed to
F. Check the harness and the wiring for abrasion and Test Step 3.
for pinch points.
• Not OK – Cat ET does not indicate a CID-FMI
Expected Result: 336-02 and “Abnormal/Incorrect Data” .
coupled and/or inserted, and the harness and wiring Repair: The problem may be intermittent. If the
are free of corrosion, of abrasion and of pinch points. problem is intermittent, perform the diagnostic
Results: Electrical Connectors”.
• OK – The connectors and wiring are okay.Proceed STOP.

to Test Step 2.
Test Step 3. Check the Wiring for an Open
• Not OK – The connectors and/or wiring are not Condition
okay.
A. Turn the EMCP 3 to the STOP position.
Repair: Repair the connectors and/or wiring or
replace the connectors and/or wiring.
position.
STOP.
302 RENR5059-14
C. Disconnect the J1/P1 ECM connector. Repair: Replace the ECM. Refer to the
D. Check for continuity between P1-22 start/run/stop “Replacing the ECM”.
2 and P1-21 start/run/stop 1 with a resistance
measurement. STOP.
Expected Result: i02386446
A short circuit condition exists. Engine Sensor Open/Short

Results: Test
SMCS Code: 1901-038
• OK A short circuit condition exists. Proceed to
Test Step 4. S/N: JM21–Up
• Not OK – A short circuit condition does not exist S/N: GD31–Up

between P1-22 and P1-21. S/N: JM31–Up
Repair: There is an open circuit between P1-22 S/N: JM41–Up
and P1-21. Repair the wires or replace the
wires between P1-22 and P1-21. Verify that the S/N: LD41–Up
problem has been resolved. S/N: LY71–Up
STOP. S/N: LY81–Up
S/N: LD91–Up
Test Step 4. Check ECM For Proper
Operation S/N: LY91–Up
A. Remove the wire F716 from P1-21. Install a S/N: CPA182–Up

jumper wire with a socket terminal into PA-21. S/N: BMB132–Up
B. Remove the wire F716 from P1-22. Install a S/N: CNB1100–Up
jumper wire with a socket terminal into P1-22.
S/N: YBB1–Up
C. Remove the wire E998 from P2-66. Install a
jumper wire with a socket terminal into P2-66. S/N: CMC1107–Up
D. Connect the three jumper wires together. S/N: YBC1–Up
E. Turn the battery disconnect switch to the ON S/N: YBD1–Up

position. S/N: ZAD1–Up
The status for the Engine Control Switch is Run. The S/N: BLF166–Up
active 336-02 is gone. S/N: JCG1–Up
Results: S/N: SBG1–Up
• OK – The status for the Engine Control Switch is S/N: JCH1–Up

Run. The active 336-02 is gone. S/N: JDH1–Up
Repair: There may be an intermittent problem. S/N: LYH1–Up
If the problem is intermittent, perform the
diagnostic functional testTroubleshooting, S/N: YAH1–Up
“Inspecting Electrical Connectors”. S/N: ZAH1–Up
STOP. S/N: BPJ472–Up
S/N: JDJ1–Up
• Not OK – The status for the Engine Control Switch
is “Abnormal/Incorrect Data” . The 336-02 code is S/N: SBJ1–Up
active.
S/N: SFJ1–Up
RENR5059-14 303
S/N: ZAJ1–Up • 101-04 Crankcase Pressure short to ground

S/N: BRK287–Up • 110-03 Engine Coolant Temperature open/short to
+batt
S/N: SBK1–Up
S/N: SEK1–Up • 110-04 Engine Coolant Temperature short to
ground
S/N: YAL1–Up
• 105-03 Inlet Manifold Air Temperature open/short
S/N: YAM1–Up to +batt
S/N: FDN1515–Up
• 105-04 Inlet Manifold Air Temperature short to
S/N: JCN1–Up ground
S/N: YAN1–Up • 1175-03 Engine Oil Temperature open/short to
+batt
S/N: LYP1–Up
• 175-04 Engine Oil Temperature short to ground
S/N: YAP1–Up
S/N: ZAP1–Up • 273-03 Turbo Outlet Pressure open/short to +batt
S/N: ZBP1–Up • 273-04 Turbo Outlet Pressure short to ground

S/N: GAR1–Up • 274-03 Atmospheric Pressure open/short to +batt
S/N: PBR1–Up • 274-04 Atmospheric Pressure short to ground
S/N: PDR1–Up • 275-03 Right Turbo Inlet Pressure open/short to
S/N: YAR1–Up +batt
S/N: YBR1–Up • 275-04 Right Turbo Inlet Pressure short to ground
S/N: ZAR1–Up • 275-03 Left Turbo Inlet Pressure open/short to
+batt
S/N: ZBR1–Up
S/N: GZS1–Up • 275-04 Left Turbo Inlet Pressure short to ground
S/N: GZT1–Up • 279-03 Aftercooler Temperature open/short to

+batt
S/N: YAT1–Up
• 279-04 Aftercooler Temperature short to ground
S/N: YBT1–Up
S/N: YAW1–Up • 542-03 Unfiltered Engine Oil Pressure open/short
to +batt
S/N: YBW1–Up
• 542-04 Unfiltered Engine Oil Pressure short to
S/N: BGX120–Up ground
S/N: GZY1–Up • 543-03 Filtered Oil Pressure Sensor open/short to
S/N: JCY1–Up +batt
S/N: YAY1–Up • 543-04 Filtered Oil Pressure Sensor short to

ground
S/N: YAZ1–Up
• 827-08 Left Exhaust Temperature signal abnormal
• 828-08 Right Exhaust Temperature signal
Use this procedure to troubleshoot any suspect abnormal
problems with the following sensors:
Engine sensors provide various signals to the
• 94-03 Filtered Fuel Pressure open/short to +batt engine's Electronic Control Module (ECM). These
sensors receive a regulated voltage from the ECM.
• 94-04 Filtered Fuel Pressure short to ground Analog sensors receive 5.0 ± 0.2 VDC and digital
sensors receive 8.0 ± 0.4 VDC.
• 101-03 Crankcase Pressure open/short to +batt
304 RENR5059-14
The ECM performs an automatic calibration of these

sensors whenever the ECM is powered and the
engine is off for at least five seconds. During an
automatic calibration, the ECM calibrates pressure
sensors to the value of the atmospheric pressure
sensor and against an acceptable offset pressure
range.
Pull-up Voltage
The ECM continuously outputs a pull-up voltage on
the input terminal from an analog sensor. The ECM
uses this pull-up voltage in order to detect an open in
the signal circuit. When the ECM detects the
presence of a voltage that is above a threshold on
the signal circuit, the ECM will generate an open
circuit diagnostic code 0-3 for that sensor. The
presence of pull-up voltage at the sensor connector
indicates that the wires from the sensor connector to
the ECM are not open or shorted to ground.
Note: No pull-up voltage is present on the input from

a digital sensor.
RENR5059-14 305
306 RENR5059-14
C. Press the “Start” button. Wiggle the wiring harness

Test Step 1. Check for “ Active”” or for the suspect sensor in order to reproduce an
“ Logged”” Diagnostic Codes intermittent problem.
A. Connect Caterpillar Electronic Technician (ET) to If an intermittent problem exists, the status will be
highlighted and an audible beep will be heard.
B. Turn the engine control to the STOP mode. Expected Result:
C. Turn the engine battery disconnect switch to the No intermittent problems were indicated during the
ON position. “Wiggle Test” .
D. Monitor the diagnostic codes on Cat ET. Check Results:
and record any diagnostic codes.
• OK – No intermittent problems were found. The
Note: Wait at least 15 seconds in order for the harness and connectors appear to be OK. If a
diagnostic codes to become active. diagnostic code is still active, proceed to Test Step
1 and continue to troubleshoot the active
E. Determine if a diagnostic code has occurred diagnostic code.
several times.
• Not OK – At least one intermittent problem was
Note: A diagnostic code that is logged several times
indicated.
is an indication of an intermittent problem. Most
intermittent problems are the result of a bad
Repair: Repair the harness or the connector.
connection between a socket and a pin in a
connector or a bad connection between a wire and
terminal.
Connectors”. Verify that the repair eliminates
F. Determine if the problem is active and related to the problem.
one of the following diagnostic codes:
STOP.
• 03
Test Step 3. Check the Analog Supply
• 04 Voltage at the Sensor Connectors
• 08 A. Turn the engine control to the OFF/RESET mode.
Expected Result: B. Turn the engine battery disconnect switch to the

OFF position.
A diagnostic code has occurred several times.
C. Disconnect the suspect sensor(s) at the sensor
Results: connector:
D. Turn the engine control to the STOP mode.
• OK – A diagnostic code has occurred several
times.Proceed to Test Step 2. E. Turn the engine battery disconnect switch to the
ON position.
• Not OK - 0-3 – An active 0-3 diagnostic code is
present.Proceed to Test Step 3. F. Measure the voltage on the ECM side of the
sensor connector between pin A and pin B for the
• Not OK - 0-4 – An active 0-4 diagnostic code is suspect sensor(s).
present.Proceed to Test Step 5.
Expected Result:
• Not OK - 0-8 – An active 0-8 diagnostic code is
present.Proceed to Test Step 8. The supply voltage is 5.0 ± 0.2 VDC.
Results:
Test Step 2. Perform the “ Wiggle Test”” on
Caterpillar Electronic Technician (ET) • OK – The voltage is 5.0 ± 0.2 VDC.Proceed to
Test Step 6.
A. Select the “Wiggle Test” from the diagnostic tests
on Cat ET. • Not OK – The voltage is not 5.0 ± 0.2 VDC.
B. Choose the appropriate group of parameters to Proceed to Test Step 4.
monitor.
RENR5059-14 307
Test Step 4. Check the Analog Supply B. Turn the engine battery disconnect switch to the
Voltage at the ECM OFF position.
A. Turn the engine control to the OFF/RESET mode. C. Disconnect the sensor connector of the suspect
sensor(s) with the active 04 diagnostic code.
B. Turn the engine battery disconnect switch to the
OFF position. D. Turn the engine control to the STOP mode. Wait at
least 15 seconds for activation of the diagnostic
C. Check the supply voltage by removing the supply codes.
wires from P1-2 and P1-18.
E. Turn the engine battery disconnect switch to the
Note: The same 5 V supply provides power to both ON position.
pins on ECM connector P1.
F. Access the “Active Diagnostic Code” screen on
D. Install a 208-0059 Adapter Cable As (70-PIN Cat ET. Check for an active 0-3 diagnostic code.
BREAKOUT) at the J1/P1 ECM connector.
Expected Result:
The 03 diagnostic code is now active for the suspect
F. Turn the engine battery disconnect switch to the sensor(s).
ON position.
G. Measure the voltage between terminal P1-2 and Results:
terminal P1-3 of the breakout T.
• OK – The 04 diagnostic code was active before
H. Turn the engine control to the OFF/RESET mode. disconnecting the sensor. The 03 diagnostic code
became active after disconnecting the sensor.
I. Turn the engine battery disconnect switch to the
OFF position. Repair: Temporarily connect a new sensor to
the harness, but do not install the new sensor in
J. Remove the wire jumpers and replace all wires.
the engine. Verify that there are no active
Remove the breakout T. Reconnect ECM diagnostic codes for the sensor. If there are no
connector J1/P1. active diagnostic codes for the sensor,
permanently install the new sensor. Clear any
Expected Result: logged diagnostic codes.
The supply voltage is 5.0 ± 0.2 VDC.
STOP.
Results:
• Not OK – The 04 diagnostic code is still active for
the suspect sensor. There is a short circuit
• OK – The supply voltage is 5.0 ± 0.2 VDC. The
between the sensor harness connector and the
supply voltage at the ECM is correct. There is a
ECM. Leave the sensor disconnected.Proceed to
problem in the wiring between the ECM and the
Test Step 7.
suspect sensor.
Repair: Repair the connectors or wiring and/or Test Step 6. Check the Pull-up Voltage at
replace the connectors or wiring. the Sensor Connector
STOP. Repair Complete A. Turn the engine control to the STOP mode.
• Not OK – The supply voltage is not 5.0 ± 0.2 VDC.
ON position.
The voltage at the ECM is not correct.
C. Disconnect the suspect sensor.
Troubleshooting, “Replacing the ECM”. Verify D. Measure the voltage between terminal C (signal)
that the problem is resolved. and terminal B (sensor return) at the sensor
connector.
E. Turn the engine control to the OFF/RESET mode.
Test Step 5. Create an Open at the F. Turn the engine battery disconnect switch to the
Suspect Sensor Connector OFF position.
A. Turn the engine control to the OFF/RESET mode. Expected Result:

308 RENR5059-14

c. Remove the wire jumper. Reconnect all wires
Results: and connectors.
• OK – The voltage is 11 ± 2 VDC. The signal wire to Expected Result:
the ECM from the sensor connector is OK.
The 03 diagnostic code is active when the sensor
Repair: The open circuit is in the sensor or the signal wire is removed from the ECM connector. The
wire between the sensor and the sensor 04 diagnostic code is active when the signal wire is
connector. Replace the sensor. Do not install connected to the sensor return.
the sensor in the engine. Verify that no
diagnostic codes are active for the suspect Results:
sensor before permanently installing the
sensor. • OK – The ECM is operating properly. The problem
is in the wiring between the ECM and the sensor
STOP. connector.
• Not OK – The voltage is not 11 ± 2 VDC. There is Repair: If the code is active for more than one
an open or a short between the sensor and the sensor, the problem is most likely in the return
ECM.Proceed to Test Step 7. wire for the sensor. Repair the return wire for
the sensor or replace the harness.
Test Step 7. Check the Operation of the If the code is only active for one sensor, the
ECM problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor.
STOP.
OFF position. • Not OK – One of the following conditions exists:
C. Check the operation of the ECM by creating an The 03 diagnostic code is not active when the
open at the ECM. sensor signal wire is disconnected. The 04
diagnostic code is not active when the wire jumper
a. Disconnect the appropriate suspect sensor is installed.
signal wire from the P1 or P2 ECM connector.
Remove the signal wire for the suspect sensor Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”. Verify
from the ECM connector.
that the problem is resolved.
b. Install a jumper wire on each end into the socket
for the signal wire of the suspect sensor. STOP.
c. Reconnect the ECM connectors. Test Step 8. Check the Digital Supply
d. Turn the EMCP to the ON position. Monitor the Voltage at the Sensor Connector
“Active Diagnostic Code” screen on Cat ET. A. Turn the engine control to the OFF/RESET mode.
Wait at least 15 seconds for activation of the
code. B. Turn the engine battery disconnect switch to the
OFF position.
The 03 should be active for the suspect
sensor. C. Disconnect the suspect sensor(s) at the sensor
connector:
D. Check the operation of the ECM by creating a
short at the ECM. D. Turn the engine control to the STOP mode.
a. Install a wire jumper between the wire jumper E. Turn the engine battery disconnect switch to the
for the signal wire for the suspect sensor and ON position.
engine ground. F. Measure the voltage on the ECM side of the
sensor connector between pin A and pin B for the
b. Monitor the “Active Diagnostic Code” screen on
suspect sensor(s).
Cat ET. Wait at least 15 seconds for activation of
the code. Expected Result:
The 04 diagnostic code should be active when
the wire jumper is installed. The supply voltage is 8.0 ± 0.4 VDC.
RENR5059-14 309
Results: Test Step 10. Check the Digital Sensor's

Duty Cycle at the Sensor Connector
• OK – The voltage is 8.0 ± 0.4 VDC.Proceed to
Test Step 10. A. Turn the engine control to the OFF/RESET mode.
• Not OK – The voltage is not 8.0 ± 0.4 VDC. B. Turn the engine battery disconnect switch to the
Proceed to Test Step 9. OFF position.
C. Remove the sensor's signal wire from pin C of the
Test Step 9. Check the Digital Supply sensor connector.
Voltage at the ECM D. Turn the engine control to the STOP mode.
A. Turn the engine control to the OFF/RESET mode. E. Turn the engine battery disconnect switch to the
B. Turn the engine battery disconnect switch to the ON position.
OFF position. F. Measure the duty cycle between the sensor's
C. Check the supply voltage by removing the supply signal wire and pin B of the sensor connector.
wire from P1-4.
Note: Set the multimeter to “VDC” . Press the “Hz”
D. Install a 208-0059 Adapter Cable As (70-PIN button twice so that the % symbol is displayed.
H. Turn the engine battery disconnect switch to the
F. Turn the engine battery disconnect switch to the OFF position.
ON position.
I. Replace the sensor's signal wire and reconnect the
G. Measure the voltage between terminal P1-4 and sensor.
terminal P1-5 of the breakout T.
Expected Result:
H. Turn the engine control to the OFF/RESET mode.
I. Turn the engine battery disconnect switch to the When the temperature is below 49 °C (120 °F), the
duty cycle is below 22 percent.
OFF position.
J. Remove the wire jumpers and replace all wires. When the temperature is between 49 °C (120 °F)
and 851 °C (1564 °F), the duty cycle is between 22
Remove the breakout T. Reconnect ECM to 88 percent.
connector J1/P1.
Results:
Expected Result:
• OK – The duty cycle is correct.Proceed to Test
The supply voltage is 8.0 ± 0.4 VDC.
Step 11.
Results:
• Not OK – The duty cycle is incorrect.
• OK – The supply voltage is 8.0 ± 0.4 VDC. The
Repair: Replace the sensor. Verify that no
supply voltage at the ECM is correct. There is a
diagnostic codes are active for the suspect
problem in the wiring between the ECM and the
sensor before permanently installing the
suspect sensor.
sensor.
STOP.
STOP. Repair Complete Test Step 11. Check the Digital Sensor's
Duty Cycle at the ECM
• Not OK – The supply voltage is not 8.0 ± 0.4 VDC.
The voltage at the ECM is not correct. A. Install a 208-0059 Adapter Cable As (70-PIN
B. Turn the engine control to the STOP mode.
that the problem is resolved. C. Turn the engine battery disconnect switch to the
ON position.
310 RENR5059-14
D. Measure the duty cycle between the terminal for S/N: YBB1–Up
the sensor's signal wire and terminal P1-5 on the
S/N: CMC1107–Up
breakout T.
S/N: YBC1–Up
Note: Set the multimeter to “VDC” . Press the “Hz”
button twice so that the % symbol is displayed. S/N: YBD1–Up
E. Turn the engine control to the OFF/RESET mode. S/N: ZAD1–Up
F. Turn the engine battery disconnect switch to the S/N: JDE1–Up

OFF position. S/N: BLF166–Up
When the temperature is below 49 °C (120 °F), the S/N: SBG1–Up

duty cycle is below 22 percent. S/N: JCH1–Up
When the temperature is between 49 °C (120 °F) S/N: JDH1–Up
and 851 °C (1564 °F), the duty cycle is between 22
to 88 percent. S/N: LYH1–Up
Results: S/N: YAH1–Up

S/N: ZAH1–Up
• OK – The duty cycle is correct.
S/N: BPJ472–Up
Repair: Replace the ECM. Refer to the
diagnostic procedure Troubleshooting, S/N: JDJ1–Up
“Replacing the ECM”. S/N: SBJ1–Up
STOP. OK S/N: SFJ1–Up
S/N: ZAJ1–Up
• Not OK – The duty cycle is not correct.
S/N: BRK287–Up
Repair: Repair the connectors and/or wiring
between the ECM and the sensor. S/N: SBK1–Up
S/N: SEK1–Up
S/N: YAL1–Up
i02386454
S/N: YAM1–Up
Engine Speed/Timing Sensor S/N: FDN1515–Up
SMCS Code: 1912-038
S/N: JCN1–Up
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S/N: GZS1–Up Note: The generator set may need a jumper wire on
the engine control to provide power to the generator
S/N: GZT1–Up control when the battery disconnect switch is closed
S/N: YAT1–Up and the engine control is in the OFF/RESET position.
Unless a timer is installed in the circuit, this jumper
S/N: YBT1–Up wire also provides power to the key switch input of
the engine ECM when the battery disconnect switch
S/N: YAW1–Up
is closed and the engine control is in the OFF/RESET
S/N: YBW1–Up position. The timer interrupts power to the key switch
input of the engine ECM when the battery disconnect
S/N: BGX120–Up switch is closed and the engine control is in the OFF/
RESET position. Cycling power to the key switch
S/N: GZY1–Up
input of the ECM will reset the ECM and all active
S/N: JCY1–Up diagnostic codes. The bottom dial on the timer should
be set to 0.7. The middle dial on the timer should be
S/N: YAY1–Up set to 3 seconds. The top dial on the timer should be
S/N: YAZ1–Up set to E.

The Electronic Control Module (ECM) provides the
engine speed/timing sensor with 12.5 ± 1.0 VDC. The
engine speed/timing sensor provides a pulse signal
to the ECM. The signal is created as the timing
reference gear rotates past the pickup of the engine
speed/timing sensor. The timing reference gear is
mounted on the rear of the left camshaft. A unique
tooth pattern on the timing reference gear allows the
ECM to determine the crankshaft position, rotation,
and rpm.
The engine speed/timing sensor generates a pulse
signal to the ECM as each tooth passes the sensor.
The ECM counts the pulses in order to determine the
engine rpm. The ECM memorizes the pattern of the
pulses. The ECM compares that pattern to a
standard pattern in order to determine the crankshaft
position. The ECM uses this information to determine
the position of the No. 1 cylinder. The ECM then
triggers each unit injector to fire in the correct firing
order and at the correct time. The actual timing and
duration of each injection is determined by the ECM.
The ECM uses engine rpm and engine load to
determine the timing and duration of injection. The
loss of the signal from the engine speed/timing
sensor triggers the termination of the signals to the
fuel injectors by the ECM.
Note: If the engine timing gear is installed backward,

the diagnostic code 190-08 will be generated. If this
code is active, the ECM will not fire the injectors. You
may refer to the diagnostic procedure
Troubleshooting, “Engine Monitoring System” in
order to determine if there are any parameters that
are affecting engine operation.
312 RENR5059-14
Typical example
Expected Result:
Test Step 1. Inspect Electrical The connectors and wiring are free of the following
Connectors and Wiring problems: damage, corrosion, abrasion and incorrect
attachment.
Turn the engine battery disconnect switch to the Results:
OFF position.
• OK – The connectors and wiring are okay.Proceed
B. Thoroughly inspect the ECM connector J1/P1 and
to Test Step 2.
the machine connector J2/P2. Inspect all of the
other connectors. Refer to the diagnostic • Not OK – The connectors and/or wiring are not
functional test Troubleshooting, “Inspecting OK.
C. Perform a 45 N (10 lb) pull test on each of the
replace the connectors and/or wiring.
with the circuit. STOP.
D. Check the ECM connector (allen head screw) for
the proper torque. Refer to the diagnostic Test Step 2. Check for an “ ACTIVE””
functional test Troubleshooting, “Inspecting diagnostic Code
A. Connect Caterpillar Electronic Technician (ET) to
E. Check the engine connector (allen head screw) for the service tool connector. Start Cat ET.
functional test Troubleshooting, “Inspecting B. Turn the engine control to the STOP mode. Turn
Electrical Connectors” for details. the engine battery disconnect switch to the ON
position.
for pinch points. C. Access the logged diagnostic codes on Cat ET.
RENR5059-14 313
Expected Result: Repair: Replace the engine speed/timing

sensor. Calibrate the sensor. Perform the
The Cat ET screen indicates one of the following calibration procedure Troubleshooting, “Engine
diagnostic codes: CID-FMI 190-02, CID-FMI 190-03 Speed/Timing Sensor - Calibrate”.
and CID-FMI 190-08.
STOP.
Results:
• OK – A diagnostic code for the engine speed/ Test Step 4. Check the Engine RPM on
timing sensor is present.Proceed to Test Step 3. Cat ET
A. Turn the engine control to the STOP mode. Turn
Test Step 3. Check the Engine Speed/ the engine battery disconnect switch to the ON
Timing Sensor position. Start the engine.
NOTICE B. Observe the engine speed on Cat ET.
Be sure to extend the sliphead before you install the Expected Result:
Engine Speed/Timing Sensor. Also check that the
Timing Gear is in a position that will not allow the slip- Cat ET displays a steady engine speed between 100
head of the Engine Speed/Timing Sensor to protrude and 250 rpm while the engine is cranking.
into one of the slots of the Timing Gear. This is done
visually with a flashlight prior to the installation of the Results:
Engine Speed/Timing Sensor. Turn the crankshaft to
rotate the Timing Gear, if necessary, to position the • OK – The Cat ET screen displays a steady engine
gear in a place that will not allow the sliphead to pro- speed between 100 and 250 rpm while the engine
trude into a slot. If the sensor sliphead does protrude is cranking. The engine speed/timing sensor is
into one of the slots, the sliphead wll be BKoken off operating normally at this time.
as the gear begins to rotate.
Repair: There may be an intermittent problem.
A. Turn the engine control to the OFF/RESET mode. If the problem is intermittent, perform the
Turn the engine battery disconnect switch to the diagnostic functional test Troubleshooting,
OFF position. “Inspecting Electrical Connectors”.
B. Disconnect connector J20/P20 and remove the STOP.

engine speed/timing sensor.
• Not OK – The Cat ET screen does not display a
C. Inspect the plastic sliphead for damage. steady engine speed between 100 and 250 rpm
D. Check the tension. Gently extend the sliphead while the engine is cranking. The Cat ET screen
does not display the correct engine rpm signal.
3.5 mm (0.14 inch). Return the sliphead to the
original position.
E. Extend the sliphead. Test Step 5. Check the Supply Voltage to
F. Install the engine speed/timing sensor. the Sensor
A. Disconnect the engine speed/timing connector
Expected Result:
J20/P20.
The sliphead requires at least 22 N (5 lb) of force in B. Turn the engine control to the STOP mode. The
order to push in the sliphead from the extended
position. engine should be off.
C. Measure the voltage at the connector for the
Results: engine speed/timing sensor between J20-A and
J20-B.
• OK – The sensor and the sliphead are
undamaged. The tension on the sliphead is Expected Result:
normal. Reinstall the sensor.Proceed to Test Step
4. The supply voltage is 12.5 ± 1.0 VDC.
• Not OK – The engine speed/timing sensor or the Results:
sliphead is damaged and/or the sliphead has
insufficient tension.
314 RENR5059-14
• OK – The supply voltage is 12.5 ± 1.0 VDC. The A. Turn the engine control to the OFF/RESET mode.
sensor is receiving the correct supply voltage. Turn the engine battery disconnect switch to the
Proceed to Test Step 6. OFF position.
• Not OK – The supply voltage is not 12.5 ± 1.0 B. Remove the signal wire 999-WH(White) from ECM
VDC. The supply voltage is incorrect.Proceed to connector P1-33.
Test Step 8.
C. Turn the engine control to the STOP mode. Turn
the engine battery disconnect switch to the ON
Test Step 6. Check the Signal Voltage at position. The engine should be off.
the Sensor
D. Measure the voltage between the signal wire
A. Remove the signal wire 999-WH(White) from the 999-WH(White) from ECM connector P1-33 and
sensor connector P20-C. the engine ground.
B. Reconnect connector J20/P20. E. Crank the engine. Measure the voltage between
C. Turn the engine control to the STOP mode. Turn wire 999-WH(White) and the engine ground.
the engine battery disconnect switch to the ON F. Turn the engine control to the OFF/RESET mode.
position. The engine should be off. Turn the engine battery disconnect switch to the
D. Measure the voltage between the signal wire OFF position.
999-WH(White) from the sensor connector P20-C G. Reconnect all wires and connectors.
and the engine ground.
Expected Result:
E. Crank the engine. Measure the voltage between
the signal wire 999-WH(White) from the sensor The voltage measures less than 3 VDC or more than
connector P20-C and the engine ground. 9 VDC when the engine is not cranking. While the
engine is cranking, the voltage is between 2.0 VDC
F. Turn the engine control to the OFF/RESET mode. and 7.0 VDC.
Turn the engine battery disconnect switch to the
OFF position. Note: The voltage output is determined by the
presence or the absence of a tooth on the timing
G. Reinsert the sensor signal wire back into P20-C. gear.
Expected Result: Results:
The voltage measures less than 3 VDC or more than
• OK – A correct signal voltage appears at the ECM
9 VDC when the engine is not cranking. While the
engine is cranking, the voltage is between 2.0 VDC connector P1 but the ECM is not reading the
and 7.0 VDC. signal.
Note: The voltage output is determined by the Repair: Replace the ECM. Refer to the
presence or the absence of a tooth on the timing diagnostic procedure Troubleshooting,
gear. “Replacing the ECM”.
Results: STOP.
• OK – The engine speed/timing sensor is producing • Not OK – The correct signal voltage does not
the correct output signal.Proceed to Test Step 7. appear at the ECM. There is a problem in the
wiring between the ECM and the sensor.Proceed
• Not OK – The engine speed/timing sensor is not to Test Step 9.
producing the correct output signal.
Test Step 8. Check the Supply Voltage at
Repair: Replace the engine speed/timing
sensor. Calibrate the sensor. Perform the
the ECM
calibration procedure Troubleshooting, “Engine A. Turn the engine control to the OFF/RESET mode.
Speed/Timing Sensor - Calibrate”. Turn the engine battery disconnect switch to the
OFF position.
STOP.
B. Reconnect the connector for the engine speed/
Test Step 7. Check the Signal Voltage at timing sensor J20/P20.
the ECM C. Disconnect ECM connector J1/P1.
RENR5059-14 315
D. Remove wire 996-RD(Red) from the ECM E. Measure the resistance between wire
connector P1-43. Install a jumper wire into the 998-BK(Black) at connector J20-B and wire
socket for P1-43. 999-WH(White) at connector J20-C.
E. Remove wire 998-BK(Black) from the ECM F. Measure the resistance of the following wires to
connector P1-51. Install a jumper wire into the engine ground: J20-A, J20-B and J20-C.
socket for P1-51.
Expected Result:
Note: If you remove the sensor common from the
ECM, an open circuit diagnostic code will be The resistance is more than 20,000 Ohms.
generated for all sensors that use the sensor
common. Troubleshoot the original code. Delete the Results:
logged diagnostic codes when you are finished.
• OK – The resistance is greater than 20,000 Ohms.
F. Turn the engine control to the STOP mode. Turn Proceed to Test Step 10.
the engine battery disconnect switch to the ON
position. The engine should be off. • Not OK – The resistance is less than 20,000
Ohms. There is a short circuit in the harness or in
G. Measure the voltage between the jumper wire at the connectors.
ECM connector P1-43 and the jumper wire at ECM
connector P1-51. Repair: Repair the connectors and/or wiring or
replace the connectors and/or the wiring.
H. Turn the engine control to the OFF/RESET mode.
Turn the engine battery disconnect switch to the STOP.
OFF position.
I. Reconnect all wires and connectors. Test Step 10. Check for an Open Circuit in
the Harness
Expected Result:
A. Use a suitable piece of wire to short wire
The voltage is 12.5 ± 1.0 VDC. 996-RD(Red) at connector J20-A to wire
998-BK(Black) at connector J20-B.
Results:
B. Measure the resistance from wire 996-RD(Red)at
• OK – The voltage is 12.5 ± 1.0 VDC. There is a the ECM connector P1-43 and wire 998-BK(Black)
problem in the wiring between the ECM and the at the ECM connector P1-51.
sensor.Proceed to Test Step 9.
C. Use a suitable piece of wire to short wire
• Not OK – The voltage is not 12.5 ± 1.0 VDC. The 996-RD(Red) at connector J20-A to wire
voltage from the ECM is incorrect. 999-WH(White) at connector J20-C.
D. Measure the resistance between wire
Repair: Perform the diagnostic functional test
996-RD(Red) at connector P1-43 and wire
Troubleshooting, “Electrical Power Supply”.
999-WH(White) at the ECM connector P1-33.
STOP. E. Remove all shorts and reconnect J1/P1 and J20/
P20.
Test Step 9. Check for Shorts in the
Wiring Harness Expected Result:
A. Turn the engine control to the OFF/RESET mode. The resistance is less than 5 Ohms.
Turn the engine battery disconnect switch to the
OFF position. Results:
B. Disconnect the ECM connector J1/P1 and the • OK – The resistance is less than 5 Ohms. The
engine speed/timing connector J20/P20. wiring is OK.
C. Measure the resistance between wire Repair: There may be an intermittent problem.
996-RD(Red) at connector J20-A and wire If the problem is intermittent, perform the
998-BK(Black) at connector J20-B. diagnostic functional test Troubleshooting,
D. Measure the resistance between wire
996-RD(Red) at connector J20-A and wire STOP.
999-WH(White) at connector J20-C.
316 RENR5059-14
• Not OK – The resistance is greater than 5 Ohms. S/N: SFJ1–Up

There is an open circuit or excessive resistance in
the harness or in the connectors. S/N: ZAJ1–Up
S/N: BRK287–Up
replace the connectors and/or the wiring. S/N: SBK1–Up
S/N: SEK1–Up
STOP.
S/N: YAL1–Up
i02386467
S/N: YAM1–Up
Ether Injection System S/N: FDN1515–Up
SMCS Code: 1456-038
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up
Use this procedure to troubleshoot any suspect
S/N: ZAH1–Up problems with the ether system.
S/N: BPJ472–Up This procedure covers the following diagnostic
S/N: JDJ1–Up codes:
S/N: SBJ1–Up • 546-05 Ether Hold Relay open/short to ground

RENR5059-14 317
• 546-06 Ether Hold Relay short to +Battery

The ether injection system will improve cold weather
starting of the engine. The Electronic Control Module
(ECM) controls the ether injection system. The ECM
energizes the ether solenoid in a continuous flow for
a predetermined amount of time that is based on the
coolant temperature. The ether injection system is
disabled if there is an active engine shutdown.
The ether injection system can also be operated in
manual mode. The ether system is switched into
manual mode whenever the starting aid switch is
depressed.
An test on Caterpillar Electronic Technician (ET)
allows the technician to activate the ether system for
a ten second period. The test is functional when the
engine speed is 0 rpm. The test is accessed by
selecting the following menus on Cat ET:
• “Diagnostics”
• “Diagnostic Tests”
• “Override Parameters”
Schematic

Test Step 1. Inspect the Electrical position.
318 RENR5059-14
C. Thoroughly inspect the ECM connectors J1/P1 • OK – No active codes or logged codes are
and J2/P2. Inspect all of the other connectors. present. The ether injection system does not inject
Refer to the diagnostic functional test ether.Proceed to Test Step 3.
Connectors” for details. • Active Code – Active Diagnostics are displayed.
wires in the ECM connector that are associated • Logged Code – Logged Diagnostics are displayed.
with the circuit. Check for an intermittent short or for an open in
the wiring or in the connectors
the proper torque. Refer to the diagnostic Repair: Repair the connectors or wiring and/or
functional test Troubleshooting, “Inspecting replace the connectors or wiring.
for the proper torque. Refer to the diagnostic
Test Step 3. Check the Ether Canisters
Electrical Connectors” for details. A. Turn the engine control to the OFF/RESET mode.
G. Check the harness and the wiring for abrasion and B. Turn the battery disconnect switch to the OFF
Expected Result: C. Remove the ether canister(s) from the ether

solenoid(s). Determine if the canister(s) contains
All connectors, pins, and sockets are completely any ether.
coupled and/or inserted. The harness and wiringare
free of corrosion, of abrasion and of pinch points. Expected Result:
Results: The ether canister(s) is not empty.
• OK – The connectors and wiring are OK.Proceed Results:

to Test Step 2.
• OK – The ether canister(s) is not empty.Proceed to
• Not OK – The connectors and/or wiring are not Test Step 14.
OK.
• Not OK – The ether canister(s) is empty.
replace the connectors or wiring. Repair: Replace the empty ether canister with
a full ether canister. Retry the system.
Test Step 2. Check the Engine
Diagnostics on the Generator Set Control Test Step 4. Check the Voltage from the
Ether Start Relay
A. Turn the battery disconnect switch to the ON
position. A. Turn the engine control to the OFF/RESET mode.
B. Turn the engine control to the STOP mode. B. Turn the battery disconnect switch to the OFF
position.
C. Determine if 545-05 Ether Start Relay open/short
to+Battery, 545-06 Ether Start Relay short to C. Remove the ether canister(s) from the ether
ground, 546-05 Ether Hold Relay open/short to solenoid(s).
ground or 546-06 Ether Hold Relay short to D. Connect the Cat ET to the service tool connector
+Battery is active or logged. J60/P60.
Expected Result: E. Connect a voltmeter between terminal 30 of the
ether start relay and ground.
No active codes or logged codes are present.
F. Turn the battery disconnect switch to the ON
Results: position.
G. Turn the engine control to the STOP mode.
RENR5059-14 319
H. Select the “Diagnostic Tests” on the Cat ET. I. Activate the ether override and observe the
voltmeter while ether injection is ON. Disable the
I. Select the “Override Parameters” screen on the Cat
ether override.
ET.
J. Activate the ether override and observe the Note: Do not allow the ether to be ON for more than
two minutes. Damage to the solenoid may occur.
ether override. J. Measure the voltage at the ether solenoid
Note: Do not allow the ether to be ON for more than connector with the voltmeter.
two minutes. Damage to the solenoid may occur. K. Deactivate the ether override.
K. Measure the voltage at the ether start relay with L. Turn the engine control to the OFF/RESET mode.
the voltmeter.
M. Turn the battery disconnect switch to the OFF
L. Deactivate the ether override. position.
Expected Result: N. Reconnect all connectors.
The voltage at the ether start relay is 24 ± 3 VDC Expected Result:

during the first two seconds of injection. The voltage
then decreases to 3 ± 1 VDC for the remainder of the The voltage at the ether solenoid is 24 ± 3 VDC
injection duration. during the first two seconds of injection. The voltage
then decreases to 3 ± 1 VDC for the remainder of the
Results: injection duration.
• OK – The voltage at the ether start relay is 24 ± 3 Results:

VDC during the first two seconds of injection. The
voltage then decreases to approximately 3 ± 1 • OK – The voltage at the ether solenoid is 24 ± 3
VDC for the remainder of injection duration. VDC during the first two seconds of injection. The
Proceed to Test Step 5. voltage then decreases to approximately 3 ± 1
VDC for the remainder of injection duration.
• Not OK - 24 VDC – The voltage at the ether start
relay is not 24 ± 3 VDC during the first two Repair: If ether is not being injected,
seconds of injection.Proceed to Test Step 6. temporarily replace the ether solenoid. If the
problem is no longer present, reinstall the old
• Not OK - 3 VDC – The voltage did not decrease to solenoid. If the problem returns, replace the
approximately 3 ± 1 VDC for the remainder of the solenoid.
injection duration.Proceed to Test Step 9.
Test Step 5. Check the Voltage at the • Not OK - 24 VDC – The voltage at the ether
Ether Solenoids solenoid is not 24 ± 3 VDC during the first two
seconds of injection.
B. Turn the battery disconnect switch to the OFF Repair: Inspect the wiring and connectors
position. between the ether start relay and the
connectors at the ether solenoids. Repair the
C. Disconnect the ether solenoid connector at the connectors or wiring and/or replace the
solenoid. connectors or wiring.
D. Connect a voltmeter between pin 1 and pin 2 of STOP. Repair Complete
the ether solenoid connector.
E. Turn the battery disconnect switch to the ON • Not OK - 3 VDC – The voltage did not decrease to
3 ± 1 VDC for the remainder of the injection
position.
duration.Proceed to Test Step 9.
F. Turn the engine control to the STOP mode.
G. Select the “Diagnostic Tests” on the Cat ET.
Test Step 6. Check the ECM Voltage to
the Ether Start Relay
H. Select the “Override Parameters” screen on the
Cat ET. A. Turn the engine control to the OFF/RESET mode.
320 RENR5059-14
B. Turn the battery disconnect switch to the OFF • OK – The voltage is 24 ± 3 VDC.
position.
Repair: Disconnect the +Battery wire from the
C. Connect a voltmeter between terminal 85 of the +Battery terminal of the ether start relay. Check
ether start relay and ground. this wire for continuity to ground. If the wire is
OK, replace the ether start relay. If the wire is
D. Turn the battery disconnect switch to the ON
not OK, repair the wire. Verify that the system is
position.
operating correctly.
F. Select the “Diagnostic Tests” on the Cat ET.
• Not OK – The voltage is not 24 ± 3 VDC.
G. Select the “Override Parameters” screen on the
Cat ET.
Repair: Verify that the circuit breaker for the
H. Activate the ether override and observe the engine control is not tripped. Ensure that the
voltmeter while ether injection is ON. Disable the battery disconnect switch is operating properly.
ether override. Disconnect the +Battery wire from the +Battery
terminal of the ether start relay. Check the wire
Note: Do not allow the ether to be ON for more than from the +Battery terminal for continuity to the
two minutes. Damage to the solenoid may occur. +Battery terminal. If the wire is not OK, repair
the wire. Verify that the system is operating
I. Measure the voltage at the ether start relay with the correctly.
voltmeter.
J. Deactivate the ether override.
K. Turn the engine control to the OFF/RESET mode. Test Step 8. Check the Voltage to the
L. Turn the battery disconnect switch to the OFF
Ether Start Relay at the ECM Connector
position. A. Turn the engine control to the OFF/RESET mode.
Expected Result: B. Turn the battery disconnect switch to the OFF

position.
The voltage is 24 ± 3 VDC for two seconds.
C. Remove wire 382-RD from the ECM connector
Results: P2-10. Install a wire jumper into the socket for P2-
10.
• OK – The voltage was 24 ± 3 VDC.Proceed to Test
D. Connect a voltmeter between wire 382-RD and
Step 7.
the engine ground.
• Not OK – The voltage was not 24 ± 3 VDC. E. Turn the battery disconnect switch to the ON
Proceed to Test Step 8. position.
Test Step 7. Check the Battery Voltage to F. Turn the engine control to the STOP mode.
the Ether Start Relay G. Select the “Diagnostic Tests” on the Cat ET.
A. Turn the battery disconnect switch to the ON H. Select the “Override Parameters” screen on the
position. Cat ET.
B. Turn the engine control to the STOP mode. I. Activate the ether override and observe the
C. Measure the voltage between the +Battery
ether override.
terminal of the ether start relay and ground.
D. Turn the engine control to the OFF/RESET mode. Note: Do not allow the ether to be ON for more than
two minutes. Damage to the solenoid may occur.
E. Turn the battery disconnect switch to the OFF
position. J. Measure the voltage at wire 382-RD(Red).
K. Deactivate the ether override.
Expected Result:
L. Turn the engine control to the OFF/RESET mode.
M. Turn the battery disconnect switch to the OFF
Results: position.
RENR5059-14 321
N. Remove the wire jumper and reconnect ECM Expected Result:

connector J1/P1. Replace all wires.
The voltage is 24 ± 3 VDC after the ether injection
Expected Result: has been activated for two seconds.
The voltage at the ECM is 24 ± 3 VDC. Results:
Results: • OK – The voltage is 24 ± 3 VDC after the ether

injection has been activated for two seconds.
• OK – The voltage at the ECM is 24 ± 3 VDC. Proceed to Test Step 10.
Repair: The wire 382-RD and/or the connectors • Not OK – The voltage at terminal 30 is not 24 ± 3
between the ECM and the ether start relay need VDC after the ether injection has been activated
repair. Inspect the wiring and connectors for two seconds.Proceed to Test Step 12.
between the ether start relay and the connector
at the ECM. Repair the connectors or wiring Test Step 10. Check the Voltage at the
and/or replace the connectors or wiring.
Resistor and the Diode Assembly
STOP. Repair Complete A. Turn the engine control to the OFF/RESET mode.
• Not OK – The voltage at the ECM is not 24 ± 3 B. Turn the battery disconnect switch to the OFF
VDC. position.
C. Disconnect the connector for the resistor and
diagnostic procedure Troubleshooting, diode assembly.
“Replacing the ECM”. Note: This procedure must be performed on all of the
resistor and diode assemblies, if more than one
STOP. Repair Complete resistor and diode assembly is present.
Test Step 9. Check the Voltage from the D. Connect a voltmeter to the +Battery pin of the
Ether Hold Relay resistor and the diode assembly and the engine
ground.
E. Turn the battery disconnect switch to the ON
B. Turn the battery disconnect switch to the OFF position.
position.
F. Turn the engine control to the OFF/RESET mode.
C. Connect a voltmeter between the +Battery
terminal of the ether hold relay and ground. G. Select the “Diagnostic Tests” on the Cat ET.
D. Turn the battery disconnect switch to the ON H. Select the “Override Parameters” screen on the
position. Cat ET.
E. Turn the engine control to the STOP mode. I. Activate the ether override and observe the
F. Select the “Diagnostic Tests” on the Cat ET. ether override.
G. Select the “Override Parameters” screen on the
Note: Do not allow the ether to be ON for more than
Cat ET. two minutes. Damage to the solenoid may occur.
H. Activate the ether override and observe the
voltmeter while ether injection is ON. Disable the J. Measure the voltage at the diode assembly and
ether override. ground.
K. Deactivate the ether override.
two minutes. Damage to the solenoid may occur. L. Turn the engine control to the OFF/RESET mode.
I. Measure the voltage at the ether hold relay. M. Turn the battery disconnect switch to the OFF
position.
J. Deactivate the ether override.
K. Turn the engine control to the OFF/RESET mode. Expected Result:
L. Turn the battery disconnect switch to the OFF The voltage is 24 ± 3 VDC.
position.
322 RENR5059-14
Results: resistor and the diode assembly. If the problem

is no longer present, reinstall the resistor and
• OK – The voltage is 24 ± 3 VDC.Proceed to Test the diode assembly. If the problem returns,
Step 11. replace the resistor and the diode assembly.
• Not OK – The voltage is not 24 ± 3 VDC. STOP. Repair Complete
Repair: There is a problem in the harness Test Step 12. Check the Battery Voltage
between the ether hold relay and the resistor
and diode assembly. Repair the connectors or to the Ether Hold Relay
wiring and/or replace the connectors or wiring. A. Turn the engine control to the OFF/RESET mode.
STOP. Repair Complete B. Turn the battery disconnect switch to the OFF
position.
Test Step 11. Check the Resistor and C. Connect a voltmeter between the +Battery
Diode Assembly terminal of the ether hold relay and ground.
A. Disconnect the connector for the resistor and D. Turn the battery disconnect switch to the ON
diode assembly. position.
B. Set the multimeter to the “Check Diode” setting. E. Turn the engine control to the STOP mode.
C. Connect the positive lead of the multimeter to pin F. Measure the voltage at the ether hold relay.
2 and the negative lead to pin 1 of the resistor and
the diode assembly and observe the multimeter.
H. Turn the battery disconnect switch to the OFF
D. Connect the positive lead of the multimeter to pin
position.
1 and the negative lead to pin 2 of the resistor and
the diode assembly and observe the multimeter. Expected Result:
E. Repeat the measurements for all of the resistor
and the diode assemblies if more than one resistor
and diode assembly is present. Results:
Expected Result: • OK – The voltage is 24 ± 3 VDC.Proceed to Test
When the positive lead of the multimeter is Step 13.
connected to pin 2 and the negative lead of the
multimeter is connected to pin 1, the multimeter • Not OK – The voltage is not 24 ± 3 VDC.
displays an overload “(OL)” .
When the positive lead of the multimeter is engine control is not tripped. Ensure that the
connected to pin 1 and the negative lead of the battery disconnect switch is operating properly.
multimeter is connected to pin 2, the multimeter Disconnect the wire that is on terminal 87 of the
displays a number less than one. ether hold relay. Check the wire that is from
terminal 87 for continuity to the +Battery
Results: terminal. If the wire is not OK, repair the wire.
Verify that the system is operating correctly.
• OK – The resistor and the diode assembly is
operating correctly. STOP. Repair Complete
Repair: There is a problem in the harness
between the resistor and diode assembly and Test Step 13. Check the Coil of the Ether
the ether solenoids. Repair the connectors or Hold Relay
wiring and/or replace the connectors or wiring.
STOP. Repair Complete B. Turn the battery disconnect switch to the OFF
position.
• Not OK – The resistor and the diode assembly is
not operating correctly. C. Remove the wire from the +Battery terminal of the
ether hold relay.
Repair: The resistor and the diode assembly is
causing the problem. Temporarily replace the
RENR5059-14 323
D. Connect a voltmeter between the +Battery wire B. Turn the battery disconnect switch to the OFF
and the +Battery terminal of the ether hold relay. position.
E. Turn the battery disconnect switch to the ON C. Disconnect ECM connector J1/P1.
position.
D. Install a jumper wire between terminal 1 and
F. Turn the engine control to the STOP mode. terminal 2 of the starting aid switch.
G. Select the “Diagnostic Tests” on the Cat ET. E. Measure the resistance between P1-20 and P1-23
at the ECM connector P1.
H. Select the “Override Parameters” screen on the
Cat ET. F. Reconnect ECM connector J1/P1. Remove the
jumper wire from the starting aid switch.
I. Activate the ether override and observe the
voltmeter while ether injection is ON. Disable the Expected Result:
ether override.
The resistance is less than 10 Ohms.
two minutes. Damage to the solenoid may occur. Results:
J. Measure the voltage at the ether hold relay. • OK – The resistance is less than 10 Ohms. The
K. Deactivate the ether override. switch wiring is not the problem.Proceed to Test
Step 15.
L. Turn the engine control to the OFF/RESET mode.
• Not OK – The resistance is greater than 10 Ohms.
M. Turn the battery disconnect switch to the OFF There is a problem with the switch wiring in the
position. harness.
Expected Result: Repair: Repair the connectors or wiring and/or
The voltage measures 24 ± 3 VDC. replace the connectors or wiring.

Results:
• OK – The voltage measures 24 ± 3 VDC. Test Step 15. Check the Starting Aid
Switch
Repair: Temporarily replace the ether hold
relay. If the problem is no longer present, A. Remove the wires from terminal 1 and terminal 2
reinstall the ether hold relay. If the problem of the starting aid switch.
returns, replace the ether hold relay.
B. Toggle the starting aid switch.
STOP. Repair Complete C. Measure the resistance between pin 1 and pin 2 of
the starting aid switch.
• Not OK – The voltage does not measure 24 ± 3
VDC. The problem is the ether hold relay or the D. Release the starting aid switch and repeat the
+Battery wire to the ECM. previous measurement.
Repair: Temporarily replace the ether hold E. Replace all wires.

relay. If the problem is no longer present,
reinstall the ether hold relay. If the problem Expected Result:
returns, replace the ether hold relay. Check the The resistance is less than 10 Ohms with the switch
+Battery wire from the ether hold relay to the toggled. The resistance is greater than 20,000 Ohms
ECM for continuity. Replace the wire or repair when the switch is released.
the wire if the wire is damaged.
Results:
• OK – The resistance is less than 10 Ohms with the
Test Step 14. Check the Wires of the switch toggled. The resistance is greater than
20,000 Ohms when the switch is released.
Starting Aid Switch at the Harness Proceed to Test Step 4.
324 RENR5059-14
• Not OK – The resistance is greater than 10 Ohms S/N: JDJ1–Up

when the switch is toggled. The resistance is less
than 20,000 Ohms when the switch is released. S/N: SBJ1–Up
S/N: SFJ1–Up
Repair: There is a problem with the starting aid
switch. Temporarily replace the starting aid S/N: ZAJ1–Up
switch with a new switch. If the problem is no
S/N: BRK287–Up
longer present, reinstall the old switch. If the
problem returns, replace the switch. S/N: SBK1–Up
STOP. Repair Complete S/N: SEK1–Up
i02386484 S/N: YAL1–Up

S/N: YAM1–Up
Injector Solenoids
S/N: FDN1515–Up
SMCS Code: 1290-038-JV
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up
Use this procedure for the following conditions:
S/N: ZAH1–Up
S/N: BPJ472–Up • An injector solenoid may have a problem.
RENR5059-14 325
• You have been directed to this procedure from • 14-06 Cylinder #14 Injector Cyclinder 14 short
Troubleshooting, “Troubleshooting without a
Diagnostic Code”. • 15-05 Cylinder #15 Injector Cylinder 15 open
circuit
• There is an active diagnostic code for a unit
injector solenoid on the 3500 engine. • 15-06 Cylinder #15 Injector Cyclinder 15 short
Use this procedure for the following diagnostic codes: • 16-05 Cylinder #16 Injector Cylinder 16 open
circuit
• 1-05 Cylinder #1 Injector Cylinder 1 open circuit
• 16-06 Cylinder #16 Injector Cyclinder 16 short
Perform this procedure under conditions that are
• 2-05 Cylinder #2 Injector Cylinder 2 open circuit identical to the conditions that exist when the
problem occurs. Typically, problems with the injector
• 2-06 Cylinder #2 Injector Cyclinder 2 short solenoid occur when the engine is warmed up and/or
when the engine is under vibration (heavy loads).
• 3-05 Cylinder #3 Injector Cylinder 3 open circuit
These engines have Mechanical Electronic Unit
• 3-06 Cylinder #3 Injector Cyclinder 3 short Injectors (MEUI) that are mechanically actuated and
electronically controlled. The Engine Control Module
• 4-05 Cylinder #4 Injector Cylinder 4 open circuit (ECM) sends a 105 volt pulse to each injector
solenoid. The pulse is sent at the proper time and at
• 4-06 Cylinder #4 Injector Cyclinder 4 short the correct duration for a given engine load and
speed. The solenoid is mounted on top of the fuel
• 5-05 Cylinder #5 Injector Cylinder 5 open circuit injector body.
• 5-06 Cylinder #5 Injector Cyclinder 5 short If an open is detected in the solenoid circuit, a
diagnostic code is generated. The ECM continues to
• 6-05 Cylinder #6 Injector Cylinder 6 open circuit try to fire the injector. If a short is detected, a
diagnostic code is generated. The ECM will disable
• 6-06 Cylinder #6 Injector Cyclinder 6 short the solenoid circuit. The ECM will periodically try to
fire the injector. If the short circuit remains, this
• 7-05 Cylinder #7 Injector Cylinder 7 open circuit sequence of events will be repeated until the problem
is corrected.
When an injector is replaced, program the new
• 8-05 Cylinder #8 Injector Cylinder 8 open circuit injector code into the ECM. If the ECM is replaced, all
of the injector codes must be programmed into the
• 8-06 Cylinder #8 Injector Cyclinder 8 short new ECM. The injector codes are a four digit number.
• 9-05 Cylinder #9 Injector Cylinder 9 open circuit The Caterpillar Electronic Technician (ET) includes
the following tests that aid in troubleshooting the
• 9-06 Cylinder #9 Injector Cyclinder 9 short injector solenoids:
• 10-05 Cylinder #10 Injector Cylinder 10 open “ Cylinder Cutout Test””
circuit
All active diagnostic codes must be repaired before
• 10-06 Cylinder #10 Injector Cyclinder 10 short running the “Cylinder Cutout Test” . Use the “Cylinder
Cutout Test” to diagnose a malfunctioning injector
• 11-05 Cylinder #11 Injector Cylinder 11 open while the engine is running. When a good injector is
circuit cut out, the “Fuel Position” should change. The
change in the fuel position is caused by the other
• 11-06 Cylinder #11 Injector Cyclinder 11 short injectors that are compensating for the cut out
injector. If a malfunctioning injector is cut out, the
• 12-05 Cylinder #12 Injector Cylinder 12 open “Fuel Position” will not change. The “Cylinder Cutout
circuit Test” is used to isolate the malfunctioning injector in
order to avoid replacement of good injectors.
“ Injector Solenoid Test””
• 13-05 Cylinder #13 Injector Cylinder 13 open
circuit
• 14-05 Cylinder #14 Injector Cylinder 14 open

circuit
326 RENR5059-14
Use the “Injector Solenoid Test” to aid in diagnosing

an open circuit or a short circuit while the engine is
not running. The “Injector Solenoid Test” briefly
activates each solenoid. A good solenoid will create
an audible click when the solenoid is activated. Cat
ET will indicate the status of the solenoid as “OK” ,
“Open” , or “Short” .
RENR5059-14 327
Typical schematic for the 3500 engines
328 RENR5059-14
Test Step 1. Inspect the Electrical

A. Turn the engine battery disconnect switch to the
OFF position.
C. Thoroughly inspect the ECM connector J2/P2.
Inspect all of the connectors that are associated
with the circuit. Refer to the diagnostic functional
test Troubleshooting, “Inspecting Electrical
with the circuit.
E. Check the allen head screw on each ECM
connector for the proper torque. Refer to
Connectors” for the correct torque values.
for pinch points.
Expected Result:
Illustration 53 g01152207 coupled and/or inserted, and the harness and wiring
P2 terminals that are associated with the injector are free of corrosion, of abrasion and of pinch points.
solenoids
Results:
(P2-1) Injector cylinder #1 signal
(P2-2) Injector cylinder #1 return
(P2-3) Injector cylinder #2 signal • OK – The connectors and wiring are OK.Proceed
(P2-4) Injector cylinder #2 return to Test Step 2.
(P2-41) Injector cylinder #3 return • Not OK – There is a problem in the connectors
(P2-43) Injector cylinder #4 return and/or wiring.
(P2-15) Injector cylinder #5 return Repair: Repair the connectors or wiring and/or
(P2-16) Injector cylinder #6 signal replace the connectors or wiring. Ensure that all
(P2-48) Injector cylinder #7 signal of the seals are properly in place and ensure
(P2-49) Injector cylinder #7 return that the connectors are completely coupled.
(P2-51) Injector cylinder #8 return Verify that the repair eliminates the problem.
(P2-25) Injector cylinder #9 return STOP. STOP
(P2-58) Injector cylinder #11 signal Test Step 2. Check for Logged Diagnostic
(P2-52) Injector cylinder #12 signal Codes
(P2-32) Injector cylinder #13 signal A. Connect Cat ET to the service tool connector.
(P2-60) Injector cylinder #14 signal B. Turn the engine battery disconnect switch to the
(P2-61) Injector cylinder #14 return ON position.
(P2-18) Injector cylinder #15 return C. Turn the engine control to the STOP mode.
(P2-27) Injector cylinder #16 return D. Check for logged diagnostic codes for the injector
solenoids on Cat ET.
Expected Result:
RENR5059-14 329
No 1-05 to 16-05 or 1-06 to 16-06 are logged. STOP.
Results: • Not OK – The results indicated that the fuel usage

did not change for the remaining injectors.
• OK – No 1-05 to 16-05 or 1-06 to 16-06 are
logged.Proceed to Test Step 3. Repair: Verify that the engine valve lash for that
injector is set correctly. Rerun the “Cylinder
• Not OK – A 1-05 to 16-05 is logged.Proceed to Cutout Test” . If the problem is still present,
Test Step 4. replace the injector. If the new injector has a
trim code that is different from the old injector,
• Not OK – A 1-06 to 16-06 is logged.Proceed to change the trim code in the ECM.
Test Step 5.
STOP.
Test Step 3. Perform the “ Cylinder Cutout
Test”” Test Step 4. Check the Harness between
the ECM and the Injector Connectors for
NOTICE an Open Circuit
Engine power is reduced when a properly functioning
cylinder is cut out. Make sure that you will not dam-
age auxiliary or driven equipment if the engine power
is suddenly reduced.
This engine uses high voltage to control the fuel
injectors.
A. Turn the engine battery disconnect switch to the
OFF position. Disconnect electronic fuel injector enable circuit
connector to prevent personal injury.
Do not come in contact with the fuel injector ter-
C. Verify that the ECM connector J2/P2 and the minals while the engine is running.
injector connectors J301/P301 through J316/P316
are properly connected. A. Turn the engine battery disconnect switch to the
D. Turn the engine battery disconnect switch to the OFF position.
START position. B. Turn the engine control to the OFF/RESET mode.
E. Turn the engine control to the STOP mode. C. Disconnect the J301/P301 through J316/P316
F. Start the engine. connectors for the suspect injector(s).
G. Apply a load to the engine. D. Fabricate a jumper wire 100 mm (4 inch) long with
Deutsch pins on both ends of the wire.
H. Perform the following steps on all suspect
cylinders (solenoids). E. Insert one end of the jumper wire into the socket
for the suspect injector's supply wire. Insert the
I. Use the diagnostic tests on the Cat ET to initiate other end of the jumper wire into the socket for the
the “Cylinder Cutout Test” . suspect injector's return wire. This will replace the
J. Disconnect any suspect cylinders and run the injector solenoid with a short circuit.
“Cylinder Cutout Test” . F. Turn the engine battery disconnect switch to the
ON position. Turn the engine control to the STOP
Expected Result: mode.
The results indicated that the remaining injectors Note: This test will help the service technician verify
used more fuel when the “Cylinder Cutout Test”
that the ECM can fire the solenoids. do not try to
enabled the suspect injector(s).
manually crank the engine during this test. The ECM
will terminate the “Injector Solenoid Test” .
Results:
G. Perform the “Injector Solenoid Test” at least two
• OK – The results indicated that the remaining
times.
injectors used more fuel.
H. Repeat this procedure for each suspect injector.
Repair: The injectors are firing in all cylinders. Stop the “Injector Solenoid Test” before handling
Reset the system and check for diagnostic the jumper wire.
codes.
330 RENR5059-14
Expected Result: • OK – All of the suspect cylinders indicate “Open”

on Cat ET. The harness between the ECM and
Cat ET displays “Open” for the cylinder with the the injector connector does not have a short
jumper wire. circuit.Proceed to Test Step 7.
Results: • Not OK – One or more of the suspect cylinders
indicate “Short” on Cat ET. Note the cylinders that
• OK – Cat ET displays “Open” for the cylinder with indicate “Short” .Proceed to Test Step 6.
the jumper wire. There is a problem in the wiring
between the ECM and the injector connector.
Proceed to Test Step 6. Test Step 6. Check the ECM for Proper
Operation
• Not OK – Cat ET displays “Short” for the cylinder
with the jumper wire. The harness between the A. Turn the engine battery disconnect switch to the
ECM and the injector connector does not have an OFF position. A strong electrical shock hazard is
open circuit.Proceed to Test Step 7. present if the engine battery disconnect switch is
not turned off.
Test Step 5. Check the Harness between B. Turn the engine control to the OFF position.
the ECM and the Valve Cover Base for a C. Turn the engine control to the OFF/RESET mode.
Short Circuit
D. Check the operation of the ECM by creating an
open at the ECM.
a. Install a 208-0059 Adapter Cable As (70-PIN

This engine uses high voltage to control the fuel BREAKOUT) at the J2/P2 ECM connector.
injectors.
b. Disconnect the appropriate suspect injector wire
Disconnect electronic fuel injector enable circuit from the P2 ECM connector. Remove the signal
connector to prevent personal injury. wire for the suspect injector(s) from the ECM
Do not come in contact with the fuel injector ter- connector.
minals while the engine is running.
c. Install a jumper wire with Deutsch sockets on
A. Turn the engine battery disconnect switch to the each end into the socket for the signal wire of
OFF position. A strong electrical shock hazard is the suspect injector(s).
present if the engine battery disconnect switch is d. Reconnect the ECM connector.
not turned off.
e. Turn the engine battery disconnect switch to the
ON position. Turn the engine control to the
C. Disconnect the J301/P301 through J316/P316 STOP mode.
connectors for the suspect injector(s).
Note: This test will help the service technician
D. Turn the engine battery disconnect switch to the verify that the ECM can fire the solenoids. do not
ON position. try to manually crank the engine during this test.
The ECM will terminate the “Injector Solenoid Test”
Note: This test will help the service technician verify .
that the ECM can fire the solenoids. do not try to
manually crank the engine during this test. The ECM f. Perform the “Injector Solenoid Test” .
will terminate the “Injector Solenoid Test” .
g. Monitor the “Active Diagnostic Code” screen on
E. Turn the engine control to the STOP mode. Cat ET. Wait at least 15 seconds for activation of
F. Perform the “Injector Solenoid Test” at least two the code.
times. The 05 diagnostic code is active for the
suspect injector(s).
Expected Result:
h. Turn the engine battery disconnect switch to the
All of the suspect cylinders indicate “Open” on Cat OFF position.
ET.
i. Turn the engine control to the OFF/RESET
Results: mode.
RENR5059-14 331
E. Check the operation of the ECM by creating a STOP.

short at the ECM.
a. Install a wire jumper between the wire jumper
Test Step 7. Measure the Resistance at
for the signal wire for the suspect injector(s) and the Valve Cover Base
the terminal for the suspect injector(s) on the
breakout T.
b. Turn the engine battery disconnect switch to the
ON position. Turn the engine control to the Personal injury can result from high voltage.
STOP mode. The Electronic Control Module produces high
voltage.
Note: This test will help the service technician
verify that the ECM can fire the solenoids. do not Make sure the Electronic Control Module is not
try to manually crank the engine during this test. powered and the fuel injector solenoids are dis-
The ECM will terminate the “Injector Solenoid Test” connected before proceeding.
.
A. Measure the solenoid resistance between pin 1
c. Perform the “Injector Solenoid Test” . and pin 2 at the injector connectors J301/P301
through J316/P316.
d. Monitor the “Active Diagnostic Code” screen on
Cat ET. Wait at least 15 seconds for activation of B. Record the measured resistance for each
the code. solenoid.
The 06 diagnostic code is active when the wire Expected Result:
jumper is installed.
The resistance is 1.06 ± 0.05 Ohms.
e. Turn the engine battery disconnect switch to the
OFF position. Results:
f. Turn the engine control to the OFF/RESET • OK – The resistance is 1.06 ± 0.05 Ohms.
mode.
Repair: The problem may be intermittent. If the
g. Remove the wire jumper. Reconnect all wires problem is intermittent, refer to the diagnostic
and connectors. functional test Troubleshooting, “Inspecting
Electrical Connectors”. Verify that the repair
Expected Result: eliminates the problem.
Cat ET displays “Short” when the wire jumper is
shorted to engine ground. Cat ET displays “Open” STOP.
when the signal wire for the injector is removed from
the ECM connector. • Not OK – The resistance is not 1.06 ± 0.5 Ohms.
Results: Repair: Replace the injector. If the new injector

has a trim code that is different from the old
• OK – The ECM is operating properly. The problem injector, change the trim code in the ECM.
is in the wiring between the ECM and the injector
connector. STOP.
i02550953
Repair: Repair the harness or the connector.
Refer to the diagnostic functional test Inspecting Electrical
Connectors”. Verify that the repair eliminates Connectors
the problem.
SMCS Code: 1901-038
STOP. S/N: JM21–Up
• Not OK – The ECM did not detect the open or the S/N: GD31–Up
short.
S/N: JM31–Up
Repair: Replace the ECM. Refer to S/N: JM41–Up
that the problem is resolved. S/N: LD41–Up
332 RENR5059-14

S/N: YAH1–Up Most electrical problems are caused by poor
S/N: ZAH1–Up connections. The following procedure will assist in
detecting problems with connectors and with wiring. If
S/N: BPJ472–Up a problem is found, correct the condition and verify
S/N: JDJ1–Up
Intermittent electrical problems are sometimes
S/N: SBJ1–Up resolved by disconnecting and reconnecting
S/N: SFJ1–Up connectors. It is very important to check for
diagnostic codes immediately before disconnecting a
S/N: ZAJ1–Up connector. Also check for diagnostic codes after
reconnecting the connector. If the status of a
S/N: BRK287–Up diagnostic code is changed due to disconnecting and
reconnecting a connector, there are several possible
S/N: SBK1–Up reasons. The likely reasons are loose terminals,
S/N: SEK1–Up improperly crimped terminals, moisture, corrosion,
and inadequate mating of a connection.
S/N: YAL1–Up
Follow these guidelines:
S/N: YAM1–Up
• Always use a 1U-5804 Crimp Tool to service
S/N: FDN1515–Up Deutsch HD and DT connectors. Never solder the
S/N: JCN1–Up terminals onto the wires. Refer to “SEHS9615,
Servicing Deutsch HD and DT Style Connectors”.
S/N: YAN1–Up
• Always use a 147-6456 Wedge Removal Tool to
S/N: LYP1–Up remove wedges from DT connectors. Never use a
screwdriver to pry a wedge from a connector.
S/N: YAP1–Up
S/N: ZAP1–Up
S/N: ZBP1–Up
RENR5059-14 333
• Always use a breakout harness for a voltmeter

probe or a test light. Never break the insulation of
a wire in order to access to a circuit for
measurements.
• If a wire is cut, always install a new terminal for the
repair.
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 equip-
ment in an explosive atmosphere.
Test Step 1. Check Connectors for

Moisture and Corrosion
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 55 .
Leaky seal at the connector (typical example)
A. Inspect all wiring harnesses. Ensure that the

routing of the wiring harness allows the wires to
enter the face of each connector at a
perpendicular angle. Otherwise, the wire will Seal for a three-pin connector (typical example)
deform the seal bore. Refer to Illustration 54 . This
will create a path for the entrance of moisture.
Verify that the seals for the wires are sealing
correctly.
334 RENR5059-14
The harness wiring, connectors, and seals are in

good condition. There is no evidence of moisture in
the connectors.
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. Ensure that all of the seals are
properly in place. Ensure that the connectors
have been reattached.
If corrosion is evident on the pins, sockets or
the connector, use only denatured alcohol to
remove the corrosion. Use a cotton swab or a
soft brush to remove the corrosion.
If moisture was found in the connectors, run the
Illustration 57 g01131165 engine for several minutes and check again for
Seal for ECM connector (typical example) moisture. If moisture reappears, the moisture is
wicking into the connector. Even if the moisture
entry path is repaired, it may be necessary to
C. Disconnect the suspect connector and inspect the replace the wires.
connector seal. Ensure that the seals are in good
condition. If necessary, replace the connector. Verify that the repair eliminates the problem.
D. Thoroughly inspect the connectors for evidence of STOP.
moisture entry.
Note: It is normal to see some minor seal abrasion Test Step 2. Check the Wires for Damage
on connector seals. Minor seal abrasion will not allow to the Insulation
the entry of moisture.
A. Carefully inspect each wire for signs of abrasion,
If moisture or corrosion is evident in the connector, of nicks, and of cuts.
the source of the moisture entry must be found
and the source of the moisture entry must be Inspect the wires for the following conditions:
repaired. If the source of the moisture entry is not
repaired, the problem will recur. Simply drying the • Exposed insulation
connector will not fix the problem. Check the
following items for the possible moisture entry • Rubbing of a wire against the engine
path:
• Rubbing of a wire against a sharp point
• Missing seals
B. Check all of the wiring harness fasteners in order
• Improperly installed seals to verify that the harness is properly secured. Also
check all of the fasteners in order to verify that the
• Nicks in exposed insulation harness is not compressed. Pull back the harness
• Improperly mated connectors sleeves in order to check for a flattened portion of
wire. A fastener that has been overtightened
Moisture can also travel to a connector through flattens the harness. This damages the wires that
the inside of a wire. If moisture is found in a are inside the harness.
connector, thoroughly check the connector's
harness for damage. Also check other connectors Expected Result:
that share the harness for moisture.
The wires are free of abrasion, of nicks, and of cuts
Note: The ECM is a sealed unit. If moisture is found and the harness is properly clamped.
in an ECM connector, the ECM is not the source of
the moisture. Do not replace the ECM. Results:
Expected Result:
RENR5059-14 335
• OK – The harness is OK.Proceed to Test Step 3. A. Ensure that the locking wedge for the connector is
installed properly. Terminals cannot be retained
• Not OK – There is damage to the harness. inside the connector if the locking wedge is not
installed properly.
Repair: Repair the wires or replace the wires,
as required. Verify that the repair eliminates the B. Perform the 45 N (10 lb) pull test on each wire.
problem. Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire
STOP. should remain in the connector body. This test
checks whether the wire was properly crimped in
Test Step 3. Inspect the Connector the terminal and whether the terminal was properly
Terminals inserted into the connector.
A. Visually inspect each terminal in the connector. Expected Result:
Verify that the terminals are not damaged. Verify
that the terminals are properly aligned in the Each terminal and each connector easily withstands
connector and verify that the terminals are 45 N (10 lb) of pull and each wire remains in the
connector body.
properly located in the connector.
Results:
Expected Result:
The terminals are properly aligned and the terminals • OK – All terminals pass the pull test.Proceed to
appear undamaged. Test Step 5.
Results: • Not OK – A wire has been pulled from a terminal

or a terminal has been pulled from the connector.
• OK – The terminals are OK.Proceed to Test Step
4. Repair: Use the 1U-5804 Crimp Tool to
replace the terminal. Replace damaged
• Not OK – The terminals of the connector are connectors, as required. Verify that the repair
damaged. eliminates the problem.
Repair: Repair the terminals and/or replace the STOP.

terminals, as required.
Test Step 5. Check Individual Pin
Retention into the Socket
STOP.
Test Step 4. Perform a Pull Test on Each

Wire Terminal Connection
Diagram for testing pin retention (typical example)
A. Verify that the sockets provide good retention for

the pins. Insert a new pin into each socket one at a
time in order to check for a good grip on the pin by
Receptacle lock wedge (typical example) the socket.
336 RENR5059-14
Expected Result:
The sockets provide good retention for the new pin.
Results:
• OK – The terminals are OK.Proceed to Test Step

6.
• Not OK – Terminals are damaged.
Repair: Use the 1U-5804 Crimp Tool to

replace the damaged terminals. Verify that the
STOP. Illustration 60 g01132827

Allen head screw for the 120 pin ECM connector
Test Step 6. Check the Locking (typical example)
Mechanism of the Connectors
a. Torque the allen head bolt for the 120 pin ECM
A. Ensure that the connectors lock properly. After connector to 7.0 ± 0.5 N·m (60 ± 4 lb in).
locking the connectors, ensure that the two halves
cannot be pulled apart.
B. Verify that the latch tab of the connector is
properly latched. Also verify that the latch tab of
the connector returns to the locked position.
Expected Result:
The connector will securely lock. The connector and
the locking mechanism are without cracks or breaks.
Results:
• OK – The connectors are in good repair.Proceed

to Test Step 7.
• Not OK – The connector's locking mechanism is Allen head screw for the 70 pin ECM connector
damaged or missing. (typical example)
Repair: Repair the connector or replace the b. Torque the allen head screw for the 70 pin ECM
connector, as required. Verify that the repair connector to 6.0 + 1.5 - 0.5 N·m
eliminates the problem. (55 + 13 - 4 lb in).
STOP.
Test Step 7. Check the Allen Head Screws

on the Connectors
Visually inspect the allen head screws for the ECM
connectors. Ensure that the threads on each allen
head screw are not damaged.
A. Connect the ECM connectors.
RENR5059-14 337
Repair: Repair the connector or replace the

connector, as required. Verify that the repair
STOP.
Test Step 8. Perform the “ Wiggle Test”” on

Caterpillar Electronic Technician (ET)
A. Select the “Wiggle Test” from the diagnostic tests
on Cat ET.
B. Choose the appropriate group of parameters to
monitor.
Illustration 62 g01132863 C. Press the “Start” button. Wiggle the wiring harness
Allen head screw for the 40 pin ECM connector in order to reproduce intermittent problems.
(typical example)
If an intermittent problem exists, the status will be
highlighted and an audible beep will be heard.
c. Torque the allen head screw for the 40 pin ECM
connector to 2.25 ± 0.25 N·m (20 ± 2 lb in). 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.
Allen head screw for the 40 pin customer connector Repair: Repair the harness or the connector.
and the 70 pin customer connector (typical example) Verify that the repair eliminates the problem.
B. Connect the customer connector. STOP.

Torque the allen head screw for the 40 pin i02386529
customer connector and the 70 pin customer
connector to 2.25 ± 0.25 N·m (20 ± 2 lb in). Prelubrication System
Expected Result: SMCS Code: 1319-038
The ECM connector is secure and the allen head S/N: JM21–Up
screws are properly torqued.
S/N: GD31–Up
Results: S/N: JM31–Up
• OK – The ECM connectors and the customer S/N: JM41–Up
connector is properly connected.Proceed to Test
Step 8. S/N: LD41–Up
S/N: LY71–Up
• Not OK – The allen head screws for the ECM
connector or the customer connector is damaged. S/N: LY81–Up
S/N: LD91–Up
338 RENR5059-14

S/N: YAH1–Up Use this procedure to troubleshoot any suspect
S/N: ZAH1–Up problems with the prelubrication system.
S/N: BPJ472–Up This procedure covers the following open circuit

diagnostic codes and short circuit diagnostic codes:
S/N: JDJ1–Up
• 338-05 Pre-Lube Relay open circuit
S/N: SBJ1–Up
• 338-06 Pre-Lube Relay short to ground
S/N: SFJ1–Up
S/N: ZAJ1–Up The Electronic Control Module (ECM) has the ability
to automatically lubricate the engine before cranking.
S/N: BRK287–Up This may increase the life of certain engine parts by
lubricating the parts before the starting motor is
S/N: SBK1–Up engaged.
S/N: SEK1–Up The prelubrication system is activated when the
engine control is placed in the RUN or in the AUTO
S/N: YAL1–Up
mode. The system prevents the starting motor from
S/N: YAM1–Up engaging while the pump builds pressure in the
engine oil system. After a short period of time, the
S/N: FDN1515–Up starting motor is allowed to engage. The keyswitch
must be left in the START mode for the duration of
S/N: JCN1–Up the prelube cycle in order to start the engine.
S/N: YAN1–Up A test on Caterpillar Electronic Technician (ET)
allows the technician to activate the prelube system.
S/N: LYP1–Up
The test is functional when the engine speed is 0
S/N: YAP1–Up rpm. The test is accessed by selecting the following
menus on Cat ET:
S/N: ZAP1–Up
• Diagnostics
S/N: ZBP1–Up
• Diagnostic Tests
S/N: GAR1–Up
S/N: PBR1–Up • Override Parameters
S/N: PDR1–Up
RENR5059-14 339
Schematic
340 RENR5059-14

coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
Results:

to Test Step 2.
• Not OK – There is a problem in the connectors

and/or wiring.

of the seals are properly in place and ensure
that the connectors are completely coupled.
STOP.

Codes
A. Connect Cat ET to the service tool connector.
position.
Illustration 65 g01166619 C. Turn the engine control to the STOP mode.
P2 ECM connector
D. Monitor the active diagnostic code screen on Cat
(P1-66) Prelube relay
(P1-35) Digital return ET. Check and record any active diagnostic codes.
(P1-12) Prelube pump
Note: Wait at least 15 seconds in order for the
Test Step 1. Inspect Electrical Expected Result:
No diagnostic codes are active.
position. Results:
• OK – No diagnostic codes are active, but a
C. Thoroughly inspect the ECM connector J1/P1. problem is suspected in the prelube system.
Inspect all of the other connectors for the circuit. Proceed to Test Step 6.
Connectors” for details. • Not OK – The 06 diagnostic code is active at this
time.Proceed to Test Step 3.
wires in the ECM connector that are associated • Not OK – The 05 diagnostic code is active at this
with the circuit. time.Proceed to Test Step 4.
E. Check the ECM connector (allen head screw) for Test Step 3. Create an Open at the
the proper torque. Refer to Troubleshooting,
“Inspecting Electrical Connectors” for details. Connector for the Prelube Relay
F. Check the harness and the wiring for abrasion and A. Turn the battery disconnect switch to the OFF
Expected Result:
C. Disconnect the connector for the prelube relay.
RENR5059-14 341
D. Turn the battery disconnect switch to the ON D. Turn the battery disconnect switch to the ON
position. position. Turn the engine control to the STOP
mode.
F. Proceed to the “Diagnostic Overrides” screen on Note: Monitor the “Active Diagnostic Codes” screen
on Cat ET after installing the jumper wire.
Cat ET.
G. Activate the prelube system. E. Proceed to the “Diagnostic Overrides” screen on
Cat ET.
Note: Monitor the “Active Diagnostic Codes” screen
on Cat ET. F. Activate the prelube system.
H. Check for a 05 diagnostic code for the prelube Note: Monitor the “Active Diagnostic Codes” screen
on Cat ET.
relay.
Note: Wait at least 15 seconds in order for the G. Wait at least 15 seconds for activation of the 06
diagnostic codes to become active. diagnostic code.
H. Turn the battery disconnect switch to the OFF
I. Turn the engine control to the OFF position.
position. Remove the wire jumper. Turn the engine
J. Turn the engine control to the OFF/RESET mode. control to the OFF/RESET mode.
Expected Result: Expected Result:

A 05 diagnostic code is now active for the prelube A 06 diagnostic code is active when the jumper wire
relay. is installed. A 05 diagnostic code is active when the
jumper wire is removed.
Results:
Results:
• OK – A 06 diagnostic code was active before
disconnecting the connector. A 05 diagnostic code • OK – The engine harness and the ECM are OK.
became active after disconnecting the connector.
Repair: Temporarily connect a new prelube
Repair: Temporarily connect a new prelube relay to the harness, but do not install the new
relay to the harness, but do not install the new prelube relay. Verify that there are no active
prelube relay. Verify that there are no active diagnostic codes for the prelube relay. If there
diagnostic codes for the prelube relay. If there are no active diagnostic codes for the prelube
are no active diagnostic codes for the prelube relay, permanently install the new prelube relay.
relay, permanently install the new prelube relay. Clear any logged diagnostic codes.
Clear any logged diagnostic codes.
STOP.
STOP.
• Not OK – The 05 diagnostic code remains active
• Not OK – A 06 diagnostic code remains active. with the jumper in place. The open circuit is
There is a short between the connector for the between the ECM and the connector for the
prelube relay and the ECM. Leave the connector prelube relay.Proceed to Test Step 5.
for the prelube relay disconnected.Proceed to Test
Step 5. Test Step 5. Check the Operation of the
ECM
Test Step 4. Create a Short at the
Connector for the Prelube Relay A. Check the operation of the ECM by creating an
open at the ECM.
position. a. Disconnect the J1/P1 ECM connector.
B. Turn the engine control to the OFF/RESET mode. b. Remove the wire for the prelube relay from P1-
66.
C. Install a jumper wire between the +Battery
terminal and the −Battery terminal of the c. Install a 208-0059 Adapter Cable As (70-PIN
connector for the prelube relay. BREAKOUT) between J1 and P1.
d. Reconnect the ECM connector.

342 RENR5059-14
e. Turn the battery disconnect switch to the ON for the prelube relay is disconnected. The 06
position. Turn the engine control to the STOP diagnostic code is not active when the wire jumper
mode. is installed.
f. Proceed to the “Diagnostic Overrides” screen Repair: Replace the ECM. Refer to
on Cat ET. Troubleshooting, “Replacing the ECM”. Verify
g. Activate the prelube system.
STOP.
Note: Monitor the “Active Diagnostic Codes”
screen on Cat ET.
Test Step 6. Check the Voltage to the Coil
h. Wait at least 15 seconds for activation of the 05 of the Prelube Switch
diagnostic code.
A. Disconnect wire F718-BK(Black) from the coil of
B. Check the operation of the ECM by creating a the prelube switch.
short at the ECM.
B. Connect a voltmeter between wire
a. Install a wire jumper between the terminal for F718-BK(Black) and engine ground.
the prelube relay on the breakout T and engine
ground.
position.
b. Turn the keyswitch to the ON position. Turn the D. Turn the engine control to the STOP mode.
engine control to the STOP mode.
E. Proceed to the “Diagnostic Overrides” screen on
c. Proceed to the “Diagnostic Overrides” screen Cat ET.
on Cat ET.
F. Activate the prelube system.
d. Activate the prelube system. G. Measure the voltage between wire
Note: Monitor the “Active Diagnostic Codes” F718-BK(Black) and engine ground.
screen on Cat ET. H. Turn the battery disconnect switch to the OFF
position.
e. Wait at least 15 seconds for activation of the 06
diagnostic code. I. Turn the engine control to the OFF/RESET mode.
C. Turn the battery disconnect switch to the OFF J. Replace all wires to the original configuration.
position. Turn the engine control to the OFF/
RESET mode. Reconnect all wires to the original Expected Result:
configuration. The voltage measures 24 ± 3 VDC.
Expected Result: Results:
A 05 diagnostic code is active when the wire from the
prelube relay is removed from the ECM connector. A • OK – The voltage is 24 ± 3 VDC.Proceed to Test
06 diagnostic code is active when the ECM terminal Step 7.
for the prelube relay is connected to engine ground.
• Not OK – The voltage is not 24 ± 3 VDC.
Results:
Repair: Perform the following steps.
• OK – The ECM is operating properly. The problem A. Check wire F718-BK(Black) for a short to
is in the wiring between the ECM and the ground. If a short to ground is present
connector for the prelube relay. replace the wire.
Repair: Repair the connectors or wiring and/or B. Measure the resistance of wire
replace the connectors or wiring. F718-BK(Black) between the connector for
the prelube relay and the prelube switch. If
STOP. the resistance indicates an open, replace the
wire.
• Not OK – One of the following conditions exists:
The 05 diagnostic code is not active when the wire
RENR5059-14 343
C. If wire F718-BK(Black) is OK, measure the C. If the +Battery wire is OK, measure the
voltage to the prelube relay. If 24 ± 3 VDC is voltage to the prelube switch . If 24 ± 3 VDC
present for the prelube relay, replace the is present on the +Battery wire , verify that
prelube relay and retest the prelube system. the −Battery wire on the coil of the prelube
switch has continuity to the −Battery. If the
D. If 24 ± 3 VDC is not present at the prelube +Battery wire is OK, replace the prelube
relay, verify that the 15A breaker between
switch and retest the prelube system.
the battery and the prelube relay is not
tripped. Verify that the wiring between the D. If 24 ± 3 VDC is not present on the +Battery
battery and the prelube relay is OK. wire verify that the 15A breaker between the
battery and the prelube switch is not tripped.
STOP. Verify that the wiring between the battery and
the prelube switch is OK.
Test Step 7. Check the Voltage at the
STOP.
Prelube Motor
A. Disconnect the +Battery wire from the prelube Test Step 8. Check the Operation of the
motor. Prelubrication Motor
B. Connect a voltmeter between the +Battery wire A. Turn the battery disconnect switch to the OFF
and engine ground. position.
C. Turn the battery disconnect switch to the ON B. Turn the engine control to the OFF/RESET mode.
position.
C. Connect one side of a suitable piece of 10 AWG
D. Turn the engine control to the STOP mode. wire to the +Battery terminal.
E. Proceed to the “Diagnostic Overrides” screen on D. For one second, connect the other end of the wire
Cat ET. to the positive terminal of the prelubrication motor.
F. Activate the prelube system.
Expected Result:
G. Measure the voltage between the +Battery wire
and engine ground. The prelubrication motor starts while the wire is
connected to the positive terminal of the
H. Turn the battery disconnect switch to the OFF prelubrication motor.
position.
Results:
I. Turn the engine control to the OFF/RESET mode.
• OK – The prelubrication motor starts. There is a
J. Replace all wires to the original configuration.
problem in the wiring harness at the prelubrication
motor.
Expected Result:
The voltage is 24 ± 3 VDC. Repair: Repair the connectors or wiring and/or
Results:
• OK – The voltage is 24 ± 3 VDC.Proceed to Test
Step 8. • Not OK – The prelubrication motor did not start.
• Not OK – The voltage is not 24 ± 3 VDC. Repair: Verify that the wire to ground at the
prelubrication relay has continuity to engine
Repair: Perform the following steps. ground. If the wire to ground is OK, the problem
is in the prelubrication motor. Install a new
A. Check the +Battery wire for a short to prelubrication motor. Verify that the problem is
ground. If a short to ground is present no longer present.
replace the wire.
B. Measure the resistance of the +Battery wire STOP. Repair Complete
between the prelube switch and the prelube
motor. If the resistance indicates an open,
replace the wire.
344 RENR5059-14
i02386543 S/N: YAL1–Up

S/N: YAM1–Up
Speed Control
S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up System Operation Description:
S/N: ZAH1–Up The speed control provides a throttle signal and a

droop signal to the engine's Electronic Control
S/N: BPJ472–Up Module (ECM). The output for rated speed is a pulse
width modulated signal (PWM) at a constant
S/N: JDJ1–Up frequency. The speed signal varies with the position
S/N: SBJ1–Up of the speed adjust potentiometer. The output for
droop is a PWM signal at a constant frequency. The
S/N: SFJ1–Up droop signal varies with the position of the droop
adjust potentiometer. The output signal is referred to
S/N: ZAJ1–Up as a duty cycle or as a PWM signal. The output signal
is expressed as a percentage between 0 and 100
S/N: BRK287–Up percent for the speed adjust and a percentage
S/N: SBK1–Up between 0 and 10 percent for the droop adjust.
S/N: SEK1–Up
RENR5059-14 345
The ECM calculates the desired engine rpm from the

rated speed signal and the droop signal. The rated
speed signal is valid when the duty cycle is in the
range of 5 to 95 percent. If the ECM determines that
the rated speed signal is invalid, the engine rpm will
be set to the programmed low idle.
Note: Desired speed can be adjusted from 1369 to
1945 rpm for a 60 Hz system and from 1141 to 1621
rpm for a 50 Hz system.
The droop signal is valid when the duty cycle is in the
range of 15 to 85 percent. If the ECM determines that
the droop signal is invalid, the engine will run with no
droop which is referred to as isochronous mode.
Some applications may choose not to use the speed
control. Some applications may use a load sharing
module. The load sharing module is configured to
provide the engine control with a rated speed signal.
The signal has the same characteristics as the above
defined signal. Some of these load sharing modules
cannot provide a signal until the engine is running. In
these cases, perform troubleshooting while the
engine is running.
Typical circuit with engine control
C. Thoroughly inspect the ECM connectors J1/P1

Test Step 1. Inspect Electrical and J2/P2. Inspect all of the other connectors.
Connectors and Wiring Refer to the diagnostic functional test
A. Place the engine control in the OFF/RESET mode. Connectors” for details.
B. Turn the battery disconnect switch to the OFF D. Perform a 45 N (10 lb) pull test on each of the
position. wires in the ECM connector that are associated
with the circuit.
346 RENR5059-14
E. Check the ECM connector (allen head screw) for STOP. Repair Complete
functional test Troubleshooting, “Inspecting Test Step 3. Determine the Component
Electrical Connectors” for details. that has Failed
F. Check the customer connector (allen head screw) A. Determine if the problem is with the input for the
for the proper torque. Refer to the diagnostic throttle or the droop.
Electrical Connectors” for details. B. Place the engine control in the STOP mode. Turn
the battery disconnect switch to the ON position.
G. Check the harness and the wiring for abrasion and
for pinch points. C. Observe the position of the throttle on the
Caterpillar Electronic Technician (ET) as you turn
Expected Result: the speed adjust potentiometer.
All connectors, pins, and sockets are completely D. Observe the droop on Cat ET as you turn the
coupled and/or inserted, and the harness and wiring droop adjust potentiometer.
Expected Result:
Results:
The throttle position on Cat ET varies with the turning
• OK – The connectors and wiring are OK.Proceed of the speed adjust potentiometer. The droop on Cat
to Test Step 2. ET varies with the turning of the droop adjust
potentiometer.
• Not OK – The connectors and/or wiring are not
OK. Results:
Repair: Repair the connectors or wiring and/or • RATED SPEED – The throttle position on Cat ET
replace the connectors or wiring. does not vary with the turning of the speed adjust
potentiometer.Proceed to Test Step 4.
• DROOP SPEED – The droop on Cat ET does not
vary with the turning of the droop adjust
Test Step 2. Check the Supply Voltage to potentiometer.Proceed to Test Step 5.
the Speed Control
• Unsure – The problem is not apparent.Proceed to
A. Turn the battery disconnect switch to the ON Test Step 4.
position.
B. Place the engine control in the STOP mode. Test Step 4. Check the Throttle Position
C. Connect one probe of a voltmeter to the +Battery A. Place the engine control in the STOP mode. Turn
terminal of the speed control. Connect one probe the battery disconnect switch to the ON position.
of the voltmeter to the −Battery terminal of the
B. Observe the position of the throttle on Cat ET.
speed control.
C. Turn the speed adjust potentiometer to the lowest
Expected Result: setting.
The voltage is 24 ± 3 VDC. • 60 Hz equals 1369 rpm.
Results: • 50 Hz equals 1141 rpm.
• OK – The voltage is 24 ± 3 VDC. The voltage D. Start at the low idle position. Slowly turn the speed
supply to the speed control is correct.Proceed to adjust potentiometer in the other direction. Monitor
Test Step 3. the position of the throttle on Cat ET.
• Not OK – The voltage is not 24 ± 3 VDC. Expected Result:
Repair: Check wire 998-BK(Black) for The throttle position on Cat ET reads 0 percent at the
continuity to the ECM connector P1-66. Check lowest setting and 0 to 100 percent as the speed
the wires for continuity to the “relay breaker” . adjust potentiometer is adjusted.
Check the breakers.
Results:
RENR5059-14 347
• OK – The speed control is operating correctly. C. Place one probe of the multimeter on the S
terminal of the speed control. Place the other
Repair: The problem may be intermittent. If the probe on the −Battery terminal of the speed
problem is intermittent, perform the diagnostic control.
Electrical Connectors”. D. Monitor the output of the percent duty cycle from
the speed control on the multimeter. Turn the
STOP. speed adjust potentiometer from the low setting to
the high setting.
• Not OK – The throttle position on Cat ET does not
vary as the speed adjust potentiometer is Note: The throttle position on Cat ET will not match
adjusted.Proceed to Test Step 6. the percent duty cycle on the multimeter.
Test Step 5. Check the Droop Signal on Expected Result:

Cat ET The duty cycle is between 4 and 10 percent at the
low setting and between 90 and 95 percent at the
A. Place the engine control in the STOP mode. Turn high setting.
the battery disconnect switch to the ON position.
B. Observe the droop on Cat ET. Results:
C. Turn the droop adjust potentiometer in a • OK – The speed control is supplying the correct
counterclockwise direction. duty cycle.Proceed to Test Step 8.
D. Slowly turn the droop adjust potentiometer in a • Not OK – The duty cycle is not correct on the
clockwise direction. Monitor the droop on Cat ET. multimeter.
Note: Do not overturn the droop adjust potentiometer Repair: Temporarily install another speed
in the clockwise direction. The signal will become control. Verify that the problem is no longer
erratic. present. Reinstall the old speed control. If the
problem returns, replace the speed control.
Expected Result:
The droop on Cat ET reads 0 percent at the lowest STOP. Repair Complete
setting and 0 to 10 percent as the droop adjust
potentiometer is adjusted. Test Step 7. Check the Droop Signal at
the Speed Control
Results:
A. Remove the wire from the D terminal of the speed
• OK – The droop is operating correctly. control.
Repair: The problem may be intermittent. If the B. Set the multimeter to “VDC” . Press the “Hz”
problem is intermittent, perform the diagnostic button twice in order to display the “%” symbol.
C. Place one probe of the multimeter on the D
Electrical Connectors”.
terminal of the speed control. Place the other
STOP. probe on the −Battery terminal of the speed
control.
• Not OK – The droop on Cat ET does not vary as D. Monitor the output of the percent duty cycle from
the droop adjust potentiometer is adjusted.
the speed control on the multimeter. Turn the
droop adjust potentiometer from the low setting to
the high setting.
Test Step 6. Check the Speed Control
Note: The droop on Cat ET will not match the percent
A. Remove the wire from the S terminal at the speed
duty cycle on the multimeter.
control.
B. Set the multimeter to “VDC” . Press the “Hz” Expected Result:
button twice in order to display the “%” symbol. The duty cycle is between 15 and 85 percent. This
range should be attainable.
Results:
348 RENR5059-14
• OK – The speed control is providing the correct Test Step 9. Check the Droop Signal at
droop signal.Proceed to Test Step 9. the ECM Input
• Not OK – The problem appears to be in the speed A. Place the engine control in the STOP mode. Turn
control. the battery disconnect switch to the ON position.
Repair: Temporarily install another speed B. Measure the voltage between the pins P2-69 and
control. Verify that the problem is no longer P2-66 at the ECM connector.
present. Reinstall the old speed control. If the C. Set the multimeter to “VDC” . Press the “Hz”
problem returns, replace the speed control.
button twice in order to display the % symbol.
STOP. Repair Complete D. Monitor the output of the percent duty cycle of the
droop signal at the speed control with the
Test Step 8. Check the Speed Signal at multimeter. Monitor the droop on Cat ET. Turn the
the ECM Input droop adjust potentiometer from the low setting to
the high setting.
A. Place the engine control in the STOP mode. Turn
the battery disconnect switch to the ON position. Note: Do not overturn the droop adjust potentiometer
in the clockwise direction. The signal will become
B. Set the multimeter to “VDC” . Press the “Hz” erratic.
button twice so that the “%” symbol is displayed.
C. Measure the voltage between pins P1-10 and P2- Expected Result:
66 on the ECM connectors. The duty cycle is between 1 and 15 percent at the
D. Monitor the output of the percent duty cycle from clockwise setting and between 85 and 99 percent at
the counterclockwise setting. The droop is between 0
the speed control on the multimeter. Monitor the and 100 percent for the above settings of the droop
percent throttle position on Cat ET. Turn the speed adjust potentiometer.
adjust potentiometer from the low setting to the
high setting. Results:
Expected Result: • OK – The duty cycle is correct.

The duty cycle is between 4 and 10 percent at the Repair:
low setting and between 90 and 95 percent at the
high setting. The percent throttle position is between STOP. OK
0 and 100 percent for the above settings of the speed
adjust potentiometer.
Results:
between P2-69 and the D terminal of the speed
• OK – The duty cycle is correct.Proceed to Test
control.
Step 5.
• Not OK – The duty cycle is correct but the droop is
not correct. The ECM is not processing the correct
between P1-10 and the S terminal of the speed
signal.
control. Verify that the low idle switch is
functioning properly.
• Not OK – The duty cycle is correct but the throttle
position is not correct. The ECM is not processing
the correct signal. i02386544

Starting Motor System
“Replacing the ECM”. SMCS Code: 1901-038
STOP. Repair Complete S/N: JM21–Up

RENR5059-14 349

S/N: YAH1–Up The engine control has the ability to crank the engine
S/N: ZAH1–Up when the engine control is placed in the RUN mode
or the engine control is placed in the AUTO mode.
S/N: BPJ472–Up When the engine control begins a cranking
sequence, the Electronic Control Module (ECM) will
S/N: JDJ1–Up activate the prelube system. Refer to the diagnostic
functional test Troubleshooting, “Prelubrication
S/N: SBJ1–Up System”. The engine control will start the first crank
S/N: SFJ1–Up cycle, when the prelube is completed. The crank
cycle continues for the programmed time or the
S/N: ZAJ1–Up engine speed reaches the crank terminate speed. If
crank terminate speed is not reached before reaching
S/N: BRK287–Up the cycle crank time, the starting motor will deactivate
for a time that is equal to the cycle crank time.
S/N: SBK1–Up
S/N: SEK1–Up This process will repeat for a programmed amount of
times (Total Number of Crank Cycles). If the engine
S/N: YAL1–Up does not start, Caterpillar Electronic Technician (ET)
will display “OVERCRANK” . The engine control will
S/N: YAM1–Up be in an idle state. The crank cycle can be restarted
by turning the engine control to the OFF/RESET or to
S/N: FDN1515–Up the STOP mode and then turning the engine control
S/N: JCN1–Up to the START mode.
S/N: YAN1–Up
350 RENR5059-14
Note: When the starting motor fails to engage the

flywheel due to a butt engagement, that crank cycle
will still be counted in the total number of crank
cycles.
Typical schematic

Test Step 1. Check for Connector the proper torque. Refer to the diagnostic
Damage functional test Troubleshooting, “Inspecting
B. Turn the battery disconnect switch to the OFF for the proper torque. Refer to the diagnostic
position. functional test Troubleshooting, “Inspecting
C. Thoroughly inspect the ECM connectors J1/P1 Electrical Connectors” for details.
and J2/P2. Inspect all of the other connectors. G. Check the harness and the wiring for abrasion and
Refer to the diagnostic functional test for pinch points.
Connectors” for details. Expected Result:
D. Perform a 45 N (10 lb) pull test on each of the All connectors, pins, and sockets are completely
wires in the ECM connector that are associated coupled and/or inserted. The harness and wiringare
with the circuit. free of corrosion, of abrasion and of pinch points.
RENR5059-14 351
Results: • Not OK - Status Screen – The “startup mode”

parameter on the status screen on the Cat ET
• OK – The connectors and wiring are OK.Proceed does not display “CRANK” .
to Test Step 2.
Repair: The problem is in the engine control
• Not OK – The connectors and/or wiring need (generator) and/or the associated wiring. Repair
repair. the engine control and/or the wiring.
Repair: Repair the connectors or wiring and/or STOP. Repair Complete

Test Step 3. Manually Crank the Engine
Test Step 2. Attempt to Start the Engine position. Turn the engine control to the OFF/
RESET mode.
A. Connect Cat ET to the service tool connector J60/
P60. B. Open the power distribution box that is located on
the left side of the engine, close to the starter
B. Turn the battery disconnect switch to the ON motors.
position.
C. Connect one probe of a digital voltmeter to the
C. Turn the engine control to the STOP mode. −Battery terminal. Connect the other probe of the
D. Observe the “startup mode” parameters on the digital voltmeter to wire 314-PU(Purple) on
Cat ET status screen. terminal 2 of the magnetic switch.
E. Turn the engine control to the RUN or to the AUTO D. Turn the battery disconnect switch to the ON
mode. Continue monitoring engine parameters as position.
the engine cranks. E. Turn the engine control to the STOP mode.
F. The crank cycle will continue for the time that is F. Monitor the voltage on the digital voltmeter.
equal to the cycle crank time that has been
programmed or the crank cycle will continue until G. Turn the engine control to the OFF/RESET mode.
the engine speed reaches the crank terminate
speed. Expected Result:
G. Turn the engine control to the OFF/RESET mode. The voltage measures 24 ± 3 VDC.
H. Turn the battery disconnect switch to the OFF Results:

position.
• OK – The voltage measures 24 ± 3 VDC.Proceed
Expected Result: to Test Step 7.
The status screen for the “startup mode” parameter • Not OK – The voltage does not measure 24 ± 3
displays “CRANK” . The engine cranks. VDC.Proceed to Test Step 4.
Results:
Test Step 4. Check the Coil on the
• OK – The “startup mode” parameter on the status Magnetic Switch
screen on the Cat ET displays “CRANK” .
Repair: The engine cranks. The starting system position.
is working properly. B. Connect one probe of the digital voltmeter to
terminal 3 of the magnetic switch. Connect the
STOP. Repair Complete other probe of the digital voltmeter to wire 102-BK
on terminal 4 of the magnetic switch.
• Not OK - Engine Doesn't Crank – The “startup
mode” parameter on the status screen on the Cat C. Turn the battery disconnect switch to the ON
ET displays “CRANK” . The engine will not crank. position.
D. Turn the engine control to the STOP mode.
E. Monitor the voltage on the digital voltmeter.
352 RENR5059-14
F. Turn the engine control to the OFF/RESET mode. • Not OK – The voltage does not measure 24 ± 3
VDC.Proceed to Test Step 6.
G. Turn the battery disconnect switch to the OFF
position.
Test Step 6. Check the Voltage from the
H. Remove the digital voltmeter and replace all wires. Engine Control to the Connector of the
Expected Result: Generator and Engine
The voltage measures 24 ± 3 VDC.
position.
Results: B. Turn the engine control to the OFF/RESET mode.
• OK – The voltage measures 24 ± 3 VDC. C. Disconnect the generator and the engine harness
connector J3/P3.
Repair: The problem appears to be with the
D. Remove the wires J3-24 and J3-39 from the
magnetic switch. Temporarily install a new
magnetic switch. Verify that the problem is no generator and engine connector J3/P3. Remove
longer present. Reinstall the old magnetic the wires from the side of the connector that is
switch. If the problem returns, replace the going to the generator.
magnetic switch. E. Reconnect the generator and engine connector
J3/P3.
F. Connect one probe of a digital voltmeter to the wire
• Not OK – The voltage does not measure 24 ± 3 from J3-24. Connect the other probe of the digital
VDC.Proceed to Test Step 5. voltmeter to the wire from J3-39.
Test Step 5. Check the Voltage to the G. Turn the battery disconnect switch to the ON
position.
Magnetic Switch
H. Turn the engine control to the STOP mode.
A. Connect one probe of a digital voltmeter to
−Battery terminal. Connect the other probe of the I. Monitor the voltage on the digital voltmeter.
digital voltmeter to wire F701-BR on terminal 3 of
J. Turn the engine control to the OFF/RESET mode.
the magnetic switch.
K. Turn the battery disconnect switch to the OFF
position.
position.
C. Turn the engine control to the STOP mode. Expected Result:
D. Monitor the voltage on the digital voltmeter. The voltage measures 24 ± 3 VDC.
E. Turn the engine control to the OFF/RESET mode. Results:
F. Turn the battery disconnect switch to the OFF
position. • OK – The voltage measures 24 ± 3 VDC.
Expected Result: Repair: The problem is most likely in the wiring

between the generator and engine harness
The voltage measures 24 ± 3 VDC. connector J3/P3 and the magnetic switch.
Results: STOP. Repair Complete
• OK – The voltage measures 24 ± 3 VDC. • Not OK – The voltage does not measure 24 ± 3
VDC.
Repair: The coil of the magnetic switch is open.
Temporarily install a new magnetic switch. Repair: The problem is in the generator set
Verify that the problem is no longer present. control and/or the wiring from the generator set
Reinstall the old magnetic switch. If the problem control to J3/P3. Repair the generator set
returns, replace the magnetic switch. control and/or the wiring.
STOP. Repair Complete STOP. Repair Complete

RENR5059-14 353
Test Step 7. Check the Solenoid.

position.
C. Connect one end of a suitable piece of 10 AWG
wire to +Battery terminal. Connect the other end to
the S terminal of the starting solenoid for one
second.
Expected Result:
The starting solenoid activates while the wire is
connected to the S terminal.
Results:
• OK – The starting solenoid activated. The problem

appears to be in the system wiring.

magnetic switch has not tripped. Check and
repair the wiring between the S terminal of the
starting solenoid and terminal 2 of the magnetic
switch. Verify repairs by checking starting
solenoid operation.
• Not OK – The starting solenoid did not activate.

The problem appears to be in the starting
solenoid.
Repair: Temporarily install a new starting

solenoid. Verify that the problem is no longer
present. Reinstall the old starting solenoid. If
the problem returns, replace the starting
solenoid.

354 RENR5059-14
Calibration Procedures S/N: BRK287–Up

S/N: SBK1–Up
S/N: SEK1–Up
i02386551 S/N: YAL1–Up
Analog Sensor - Calibrate S/N: YAM1–Up

S/N: JCN1–Up
S/N: JM21–Up
S/N: YAN1–Up
S/N: GD31–Up
S/N: LYP1–Up
S/N: JM31–Up
S/N: YAP1–Up
S/N: JM41–Up
S/N: ZAP1–Up
S/N: LD41–Up
S/N: ZBP1–Up
S/N: LY71–Up
S/N: GAR1–Up
S/N: LY81–Up
S/N: PBR1–Up
S/N: LD91–Up
S/N: PDR1–Up
S/N: LY91–Up
S/N: YAR1–Up
S/N: CPA182–Up
S/N: YBR1–Up
S/N: BMB132–Up
S/N: ZAR1–Up
S/N: CNB1100–Up
S/N: ZBR1–Up
S/N: YBB1–Up
S/N: GZS1–Up
S/N: CMC1107–Up
S/N: GZT1–Up
S/N: YBC1–Up
S/N: YAT1–Up
S/N: YBD1–Up
S/N: YBT1–Up
S/N: ZAD1–Up
S/N: YAW1–Up
S/N: JDE1–Up
S/N: YBW1–Up
S/N: BLF166–Up
S/N: BGX120–Up
S/N: JCG1–Up
S/N: GZY1–Up
S/N: SBG1–Up
S/N: JCY1–Up
S/N: JCH1–Up
S/N: YAY1–Up
S/N: JDH1–Up
S/N: YAZ1–Up
S/N: LYH1–Up
S/N: YAH1–Up System Operation Description:
S/N: ZAH1–Up The Electronic Control Module (ECM) attempts to

perform an automatic calibration of all pressure
S/N: BPJ472–Up sensors whenever the ECM is powered and the
engine has been off for at least ten seconds.
S/N: JDJ1–Up Cranking the engine during the first ten seconds
S/N: SBJ1–Up causes the ECM to abort the calibration attempt.
S/N: SFJ1–Up
S/N: ZAJ1–Up
RENR5059-14 355
During an automatic pressure sensor calibration, the Expected Result:

ECM checks all pressure sensors against an
acceptable range. If any pressure sensor reading is Cat ET indicates that the calibration was completed.
outside the acceptable range, the previous
calibration value is used. The ECM then calibrates all Results:
pressure sensors against the atmospheric pressure
sensor. • OK – Cat ET indicates that the calibration was
A pressure sensor calibration will not be successful if completed.
there are active sensor diagnostic codes with an FMI
of 03 and/or 04. A pressure sensor calibration will not Repair: Reset the system and check for active
be successful if one of the following conditions exist: diagnostic codes.
• The pressure reading is outside of an acceptable STOP.

range.
• Not OK – All pressure sensors could not be
• The pressure reading varies significantly during calibrated.Proceed to Test Step 3.
calibration.
Test Step 3. Determine the Cause of
Test Step 1. Check for “ ACTIVE”” Failed Calibration
Diagnostic Codes A. Check if any pressure sensors have an active
diagnostic code. A pressure sensor calibration will
not be successful if there are active diagnostic
position. Place the engine control in the OFF/
codes with an FMI of 03 and/or 04.
RESET mode.
B. Verify that the correct sensor has been installed.
B. Connect Caterpillar Electronic Technician (ET).
C. Check the display status screen on Cat ET for the
pressure sensor reading.
position. Place the engine control in the STOP
mode. Note: The valid range for atmospheric pressure must
D. Start Cat ET. be between 45 kPa (6.5 psi) and 111 kPa (16 psi) for
a successful calibration.
E. Check for active diagnostics.
Expected Result:
Expected Result:
Cat ET displays the following pressures:
There are no active diagnostics.
• Crankcase pressure is atmospheric pressure ±
Results: 8 kPa (1.2 psi).
• OK – There are no active diagnostics.Proceed to • Turbocharger compressor inlet pressure is

Test Step 2. atmospheric pressure ± 8 kPa (1.2 psi).
• Turbocharger compressor outlet pressure is
• Not OK – A pressure sensor with an active atmospheric pressure ± 15 kPa (2.2 psi).
diagnostic code cannot be calibrated.
• Fuel pressure is atmospheric pressure ± 27 kPa
Repair: Perform the appropriate (3.9 psi).
troubleshooting procedure.
• Engine oil pressure is atmospheric pressure ±
STOP. 27 kPa (3.9 psi).
Test Step 2. Perform a Calibration of the Results:

Sensors • OK – Repeat calibration of the sensors.
A. Select “Calibrations” from the “Service” menu on
Cat ET. Select the “Pressure Sensor Calibration” Repair: Repeat the calibration. Verify that no
from the “Calibrations” menu. The ECM will active diagnostic codes are present.
perform a pressure sensor calibration when this
STOP.
screen is entered.
356 RENR5059-14
• Not OK – There is a problem with the wiring S/N: JDJ1–Up

harness and/or the sensor. Inspect the
components for damage, for corrosion or for S/N: SBJ1–Up
abrasion. Repair the components and/or replace S/N: SFJ1–Up
the components.
S/N: ZAJ1–Up
Repair: Perform the appropriate
S/N: BRK287–Up
troubleshooting procedure.
S/N: SBK1–Up
STOP.
S/N: SEK1–Up
i02343375
S/N: YAL1–Up
Engine Speed/Timing Sensor - S/N: YAM1–Up
Calibrate S/N: FDN1515–Up
SMCS Code: 1912-524
S/N: JCN1–Up
S/N: LYH1–Up
S/N: YAH1–Up
S/N: ZAH1–Up
S/N: BPJ472–Up
RENR5059-14 357

The engine speed/timing sensor provides engine
information to the Electronic Control Module (ECM).
The sensor generates a pulse signal. A loss of the
engine speed/timing signal causes the ECM to stop
sending power to the fuel injectors.
The ECM provides the engine speed/timing sensor
with 12.5 ± 1.0 VDC. A unique tooth on the timing
reference gear generates a unique duty cycle. The
signal provides the ECM with information on the
engine position.
Schematic
G. Insert the 6V-2197 Magnetic Transducer through

Test Step 1. Check for “ ACTIVE”” the 6V-3093 Transducer Adapter. Insert the
Diagnostic Codes transducer until contact is made with the surface
of the flywheel. Move the transducer 0.9 mm
A. Turn the engine control to the OFF/RESET mode. (0.04 inch) away from the flywheel.
NOTICE
position.
Do not install the timing calibration probe over the
C. Connect the Caterpillar Electronic Technician (ET) timing pin hole at the flywheel or damage will result.
at the service tool connector J60/P60. Start the
Cat ET.
H. Tighten the nut on the 6V-3093 Transducer
D. Remove the timing calibration plug from the Adapter.
flywheel housing.
I. Connect the 7X-1695 cable from the engine
E. Examine the flywheel through the timing timing calibration probe to the connector P26.
calibration hole. Ensure that the probe is not
inserted into the timing pin hole. If necessary, turn J. Turn the battery disconnect switch to the ON
the engine. position.
F. Install the 6V-3093 Transducer Adapter into the K. Turn the engine control to the STOP mode.
hole for the timing calibration at the flywheel.
Expected Result:
Only CID-FMI 261-13 is active.
358 RENR5059-14
Results:
• OK – CID-FMI 261-13 is the only active code at

this time.Proceed to test step 2.
• Not OK – CID-FMI 261-13 is not the only active

code at this time.
Repair: Repair any active diagnostic codes.
Test Step 2. Calibration

A. Select “Service” from the main menu on the Cat
ET. Select “Calibrations” from the drop-down
menu. Select “Timing Calibration” .
B. Press the “Continue” button on the Cat ET.
Note: Engine speed will be set to 800 rpm by the
ECM during the calibration.
Note: If the Cat ET screen shows “CALIBRATION

UNSUCCESSFUL” , the electronic injection timing
has not been set.
Expected Result:
The timing calibration is successful.
Results:
• OK – The timing calibration was successful.

Disconnect the timing calibration probe before you
exit the “Timing Calibration” screen on the Cat ET.
Reset the system and check for any diagnostic
codes.
STOP.
• Not OK – The timing did not calibrate.
Repair: Verify that the engine speed was stable

during the testing (± 50 rpm). If the engine
speed was unstable or the engine speed could
not be controlled within ± 50 rpm because of
mechanical factors or of electrical factors, refer
to the diagnostic procedure Troubleshooting,
“Engine Misfires, Runs Rough or Is Unstable”.
If all of the problems have been corrected but
the timing cannot be calibrated, check the cable
of the 6V-2197 Timing Calibration Probe and
check the 6V-2197 Timing Calibration Probe
in order to verify that the probe is not bent.
Verify that the probe is installed correctly before
restarting this procedure.
STOP.
RENR5059-14 359
Index Section
Index
A E255 Diagnostic Reset ...................................... 244
E264 Emergency Stop Activated ........................ 245
Air Shutoff System ............................................ 256 E272 Inlet Air Restriction Warning ...................... 247
Alternator (Charging Problem and/or Noisy E279 High Aftercooler Temperature Warning....... 248
Operation) ........................................................41 E552 Low Aftercooler Coolant Level ................... 250
Probable Causes .............................................42 ECM Will Not Accept Factory Passwords ..............47
Recommended Actions ....................................42 Probable Causes .............................................48
Analog Sensor - Calibrate .................................. 354 Recommended Actions ....................................49
Analog Sensor Supply ....................................... 261 ECM Will Not Communicate with Other
Systems or Display Modules ..............................49
C Probable Causes .............................................50
Recommended Actions ....................................50
Calibration Procedures ...................................... 354 Electrical Connectors and Functions.....................19
CAN Data Link .................................................. 268 Electrical Power Supply ..................................... 291
Can Not Reach Top Engine RPM..........................44 Electronic Service Tool Will Not Communicate
Probable Causes .............................................44 with ECM ..........................................................50
Recommended Actions ....................................45 Probable Causes .............................................51
Cat Data Link .................................................... 271 Recommended Actions ....................................51
Coolant Level Sensor ........................................ 274 Electronic Service Tools.......................................21
Coolant Temperature Is Too High .........................45 Cat Electronic Technician (ET) .........................23
Probable Causes .............................................46 Optional Service Tools......................................23
Recommended Actions ....................................46 PL1000E Communication ECM (If so
Customer Parameters Worksheet.........................36 equipped) ......................................................27
Service Tools...................................................22
Electronic Troubleshooting.....................................6
D Emergency Stop Switch..................................... 295
Diagnostic Codes.............................................. 109 Engine Control Switch (ECS) ............................. 299
Diagnostic Codes........................................... 109 Engine Cranks but Will Not Start...........................52
Diagnostic Functional Tests ............................... 256 Probable Causes .............................................53
Digital Sensor Supply ........................................ 281 Recommended Actions ....................................53
Direct Fuel Control Mode ................................... 287 Engine Has Early Wear.................................. 54, 56
Probable Causes ....................................... 54, 57
Recommended Actions .............................. 54, 57
E Engine Misfires, Runs Rough or Is Unstable..........59
Probable Causes .............................................60
E004 Engine Overspeed Shutdown .................... 211 Recommended Actions ....................................60
E007 High Aftercooler Temperature Derate ......... 212 Engine Oil in Cooling System ...............................62
E008 High Aftercooler Temperature Shutdown .... 213 Probable Causes .............................................63
E009 High Altitude Derate.................................. 215 Recommended Actions ....................................64
E012 High Crankcase Pressure Derate............... 216 Engine Sensor Open/Short Test ......................... 302
E013 High Crankcase Pressure Shutdown.......... 217 Engine Speed/Timing Sensor............................. 310
E015 High Engine Coolant Temperature Derate .. 219 Engine Speed/Timing Sensor - Calibrate............. 356
E016 High Engine Coolant Temperature Engine Stalls at Low RPM.............................. 64, 66
Shutdown ....................................................... 221 Probable Causes ....................................... 65–66
E017 High Engine Coolant Temperature Recommended Actions .............................. 65–66
Warning .......................................................... 223 Engine Will Not Crank..........................................68
E021 High Exhaust Temperature Derate ............. 225 Probable Causes .............................................69
E031 Air Inlet Restriction Derate......................... 227 Recommended Actions ....................................69
E038 Low Engine Coolant Temperature Ether Injection System....................................... 316
Warning .......................................................... 228 Event Codes ..................................................... 207
E040 Low Engine Oil Pressure Shutdown ........... 230 Active Event Codes........................................ 207
E043 Low System Voltage Warning .................... 231 Clearing Event Codes .................................... 208
E095 Fuel Filter Restriction Warning................... 233 Logged Event Codes...................................... 208
E099 Engine Oil Filter Restriction Warning .......... 235 Trip Points for the Monitoring System .............. 209
E100 Low Engine Oil Pressure Warning.............. 236 Troubleshooting............................................. 208
E101 High Crankcase Pressure Warning ............ 238 Excessive Black Smoke.......................................71
E162 High Boost Pressure ................................. 239 Probable Causes .............................................72
E173 High Exhaust Temperature Warning........... 241 Recommended Actions ....................................72
E190 Engine Overspeed Warning....................... 242 Excessive Engine Oil Consumption ......................70
E198 Low Fuel Pressure.................................... 243 Probable Causes .............................................71
E2087 Air Intake Shutoff Closed ......................... 251 Recommended Actions ....................................71
E2088 Air Intake Shutoff Detection Circuit Excessive White Smoke ......................................73
Detected but Not Installed ................................ 252 Probable Causes .............................................74
E2143 Low Engine Coolant Level ....................... 254 Recommended Actions ....................................74
360 RENR5059-14
Index Section
Exhaust Temperature Is Too High .........................75 MID 036 - CID 0006 - FMI 05 Injector Cylinder 6
Probable Causes .............................................76 open circuit ..................................................... 123
Recommended Actions ....................................77 MID 036 - CID 0006 - FMI 06 Injector Cylinder 6
short............................................................... 124
F open circuit ..................................................... 125
Factory Passwords..............................................29 MID 036 - CID 0007 - FMI 06 Injector Cylinder 7
Customer Passwords .......................................30 short............................................................... 126
Factory Passwords ..........................................30 MID 036 - CID 0008 - FMI 05 Injector Cylinder 8
Passwords ......................................................29 open circuit ..................................................... 127
Flash Programming .............................................30 MID 036 - CID 0008 - FMI 06 Injector Cylinder 8
Programming a Flash File.................................31 short............................................................... 128
Fuel Dilution of Engine Oil....................................77 MID 036 - CID 0009 - FMI 05 Injector Cylinder 9
Probable Causes .............................................78 open circuit ..................................................... 129
Recommended Actions ....................................79 MID 036 - CID 0009 - FMI 06 Injector Cylinder 9
Fuel in Cooling System ........................................79 short............................................................... 130
Probable Causes .............................................80 MID 036 - CID 0010 - FMI 05 Injector Cylinder
Recommended Actions ....................................81 10 open circuit................................................. 132
MID 036 - CID 0010 - FMI 06 Injector Cylinder
10 short .......................................................... 133
I MID 036 - CID 0011 - FMI 05 Injector Cylinder
11 open circuit ................................................. 134
Important Safety Information ..................................2 MID 036 - CID 0011 - FMI 06 Injector Cylinder
Injector Solenoids ............................................. 324 11 short .......................................................... 135
Inspecting Electrical Connectors ........................ 331 MID 036 - CID 0012 - FMI 05 Injector Cylinder
Intermittent Engine Shutdown ..............................81 12 open circuit................................................. 136
Recommended Actions ....................................82 12 short .......................................................... 137
Intermittent Low Power or Power Cutout ...............83 MID 036 - CID 0013 - FMI 05 Injector Cylinder
Probable Causes .............................................84 13 open circuit................................................. 138
Recommended Actions ....................................84 MID 036 - CID 0013 - FMI 06 Injector Cylinder
13 short .......................................................... 139
L 14 open circuit................................................. 140
Low Engine Oil Pressure .....................................85 MID 036 - CID 0014 - FMI 06 Injector Cylinder
Probable Causes .............................................86 14 short .......................................................... 141
Recommended Actions ....................................86 MID 036 - CID 0015 - FMI 05 Injector Cylinder
Low Power/Poor or No Response to Throttle .........86 15 open circuit................................................. 142
Recommended Actions ....................................87 15 short .......................................................... 143
16 open circuit................................................. 144
M MID 036 - CID 0016 - FMI 06 Injector Cylinder
16 short .......................................................... 145
Mechanical Noise (Knock) in Engine.....................89 MID 036 - CID 0091 - FMI 08 Throttle Position
Probable Causes .............................................89 signal abnormal............................................... 146
Recommended Actions ....................................90 MID 036 - CID 0094 - FMI 03 Fuel Pressure
MID 036 - CID 0001 - FMI 05 Injector Cylinder 1 open/short to +batt .......................................... 147
open circuit ..................................................... 113 MID 036 - CID 0094 - FMI 04 Fuel Pressure
MID 036 - CID 0001 - FMI 06 Injector Cylinder 1 short to ground ................................................ 148
short............................................................... 114 MID 036 - CID 0100 - FMI 03 Engine Oil
MID 036 - CID 0002 - FMI 05 Injector Cylinder 2 Pressure open/short to +batt ............................ 149
open circuit ..................................................... 115 MID 036 - CID 0100 - FMI 04 Engine Oil
MID 036 - CID 0002 - FMI 06 Injector Cylinder 2 Pressure short to ground.................................. 150
short............................................................... 116 MID 036 - CID 0101 - FMI 03 Crankcase
MID 036 - CID 0003 - FMI 05 Injector Cylinder 3 Pressure open/short to +batt ............................ 151
open circuit ..................................................... 117 MID 036 - CID 0101 - FMI 04 Crankcase
MID 036 - CID 0003 - FMI 06 Injector Cylinder 3 Pressure short to ground.................................. 152
short............................................................... 118 MID 036 - CID 0105 - FMI 03 Inlet Manifold
MID 036 - CID 0004 - FMI 05 Injector Cylinder 4 Temp Sensor open/short to +batt ...................... 153
open circuit ..................................................... 119 MID 036 - CID 0105 - FMI 04 Inlet Manifold
MID 036 - CID 0004 - FMI 06 Injector Cylinder 4 Temp Sensor short to ground............................ 155
short............................................................... 120 MID 036 - CID 0110 - FMI 03 Engine Coolant
MID 036 - CID 0005 - FMI 05 Injector Cylinder 5 Temperature open/short to +batt ....................... 156
open circuit ..................................................... 121 MID 036 - CID 0110 - FMI 04 Engine Coolant
MID 036 - CID 0005 - FMI 06 Injector Cylinder 5 Temperature short to ground ............................ 157
short............................................................... 122
RENR5059-14 361
Index Section
MID 036 - CID 0168 - FMI 00 System Voltage MID 036 - CID 0338 - FMI 06 Pre-Lube Relay
High ............................................................... 158 short to ground ................................................ 193
Low ................................................................ 159 open............................................................... 194
intermittent/erratic............................................ 160 short............................................................... 195
MID 036 - CID 0175 - FMI 03 Engine Oil MID 036 - CID 0542 - FMI 02 Unfiltered Engine
Temperature open/short to +batt ....................... 161 Oil Pressure misinstalled.................................. 196
MID 036 - CID 0175 - FMI 04 Engine Oil MID 036 - CID 0542 - FMI 03 Unfiltered Engine
Temperature short to ground ............................ 162 Oil Pressure open/short to +batt ....................... 197
MID 036 - CID 0190 - FMI 02 Loss of Engine MID 036 - CID 0542 - FMI 04 Unfiltered Engine
Speed signal ................................................... 163 Oil Pressure short to ground ............................. 198
MID 036 - CID 0190 - FMI 03 Engine Speed MID 036 - CID 0546 - FMI 05 Ether Hold Relay
open/short to +batt .......................................... 164 open/short to ground........................................ 199
MID 036 - CID 0248 - FMI 09 Cat Data Link not MID 036 - CID 0546 - FMI 06 Ether Hold Relay
communicating................................................ 165 short to +batt................................................... 200
MID 036 - CID 0253 - FMI 02 Personality MID 036 - CID 0799 - FMI 12 Need Service tool
Module mismatch ............................................ 166 update ............................................................ 201
MID 036 - CID 0254 - FMI 12 Electronic Control MID 036 - CID 0827 - FMI 08 Left Exhaust
Module Error ................................................... 168 Temperature signal abnormal ........................... 203
MID 036 - CID 0261 - FMI 13 Engine Timing MID 036 - CID 0828 - FMI 08 Right Exhaust
calibration required .......................................... 169 Temperature signal abnormal ........................... 204
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC MID 036 - CID 1495 - FMI 02 Injector Trim
Power Supply short to +batt.............................. 170 Codes Not Programmed .................................. 205
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC
Power Supply short to ground........................... 171
MID 036 - CID 0263 - FMI 03 Digital Sensor N
Supply short to +batt........................................ 172 Noise Coming from Cylinder ................................90
MID 036 - CID 0263 - FMI 04 Digital Sensor Probable Causes .............................................91
Supply short to ground ..................................... 173 Recommended Actions ....................................91
MID 036 - CID 0268 - FMI 02 Check
Programmable Parameters .............................. 174
MID 036 - CID 0273 - FMI 00 Turbo Outlet O
Pressure above normal .................................... 175
MID 036 - CID 0273 - FMI 03 Turbo Outlet Oil Contains Coolant ...........................................91
Pressure open/short to +batt ............................ 176 Oil Analysis Results and Probable Causes.........93
MID 036 - CID 0273 - FMI 04 Turbo Outlet Recommended Actions ....................................95
Pressure short to ground.................................. 177
MID 036 - CID 0274 - FMI 03 Atmospheric
Pressure open/short to +batt ............................ 178 P
MID 036 - CID 0274 - FMI 04 Atmospheric Poor Fuel Consumption ..................................... 103
Pressure short to ground.................................. 179 Probable Causes ........................................... 103
MID 036 - CID 0275 - FMI 03 Right Turbo Inlet Recommended Actions .................................. 104
Pressure open/short to +batt ............................ 180 Prelubrication System........................................ 337
MID 036 - CID 0275 - FMI 04 Right Turbo Inlet Programming Parameters....................................28
Pressure short to ground.................................. 181
MID 036 - CID 0276 - FMI 03 Left Turbo Inlet
Pressure open/short to +batt ............................ 182 R
MID 036 - CID 0276 - FMI 04 Left Turbo Inlet
Pressure short to ground.................................. 184 Replacing the ECM .............................................37
MID 036 - CID 0279 - FMI 03 Aftercooler
Temperature open/short to +batt ....................... 185 S
MID 036 - CID 0279 - FMI 04 Aftercooler
Temperature short to ground ............................ 186 Self-Diagnostics..................................................17
MID 036 - CID 0289 - FMI 02 Unfiltered Fuel Speed Control................................................... 344
Pressure misinstalled....................................... 187 Starting Motor System ....................................... 348
MID 036 - CID 0289 - FMI 03 Unfiltered Fuel Symptoms ..........................................................40
Pressure open/short to +batt ............................ 188 System Configuration Parameters ........................32
MID 036 - CID 0289 - FMI 04 Unfiltered Fuel Parameter Descriptions....................................34
Pressure short to ground.................................. 189 Parameter Table ..............................................33
MID 036 - CID 0336 - FMI 02 Incorrect ECS System Overview ..................................................6
Switch inputs................................................... 190 Electronic Controls.............................................7
MID 036 - CID 0337 - FMI 02 Incorrect Remote Engine Starting and Stopping Procedures............7
E-Stop Switch inputs........................................ 191
MID 036 - CID 0338 - FMI 05 Pre-Lube Relay
open circuit ..................................................... 192 T
Table of Contents ..................................................3
362 RENR5059-14
Index Section
Too Much Valve Lash ........................................ 104

Probable Causes ........................................... 105
Recommended Actions .................................. 105
Too Much Vibration............................................ 106
Probable Causes ........................................... 107
Troubleshooting Section ........................................6
Troubleshooting with a Diagnostic Code ............. 109
Troubleshooting with an Event Code................... 207
Troubleshooting without a Diagnostic Code...........40
V
Valve Rotocoil or Spring Lock Is Free.................. 107
Probable Causes ........................................... 108
RENR5059 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2017 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.
364 February 2017

Renr5059!14!00 Manuals Service Modules Troubleshooting Ceterpilar

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Renr5059!14!00 Manuals Service Modules Troubleshooting Ceterpilar

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RENR5059-14 (en-us)

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents MID 036 - CID 0002 - FMI 06 Injector Cylinder 2

E173 High Exhaust Temperature Warning........... 241

Diagnostic Functional Tests

Troubleshooting Section S/N: SFJ1–Up

S/N: JM21–Up S/N: YAN1–Up

S/N: GD31–Up S/N: LYP1–Up

S/N: JM31–Up S/N: YAP1–Up

S/N: JM41–Up S/N: ZAP1–Up

S/N: LD41–Up S/N: ZBP1–Up

S/N: LY71–Up S/N: GAR1–Up

S/N: LY81–Up S/N: PBR1–Up

S/N: LD91–Up S/N: PDR1–Up

S/N: LY91–Up S/N: YAR1–Up

S/N: CPA182–Up S/N: YBR1–Up

S/N: BMB132–Up S/N: ZAR1–Up

S/N: CNB1100–Up S/N: ZBR1–Up

S/N: YBB1–Up S/N: GZS1–Up

S/N: CMC1107–Up S/N: GZT1–Up

S/N: YBC1–Up S/N: YAT1–Up

S/N: YBD1–Up S/N: YBT1–Up

S/N: ZAD1–Up S/N: YAW1–Up

S/N: JDE1–Up S/N: YBW1–Up

S/N: BLF166–Up S/N: BGX120–Up

S/N: JCG1–Up S/N: GZY1–Up

S/N: SBG1–Up S/N: JCY1–Up

S/N: JCH1–Up S/N: YAY1–Up

S/N: JDH1–Up S/N: YAZ1–Up

Engine Governor 5) The generator control module deactivates the

Block Diagram for the 3500B Engine

Location Of The 3512B and 3516B Engine Sensors

Location Of The 3512B and 3516B Engine Sensors

Location Of The 3512B and 3516B Engine Sensors

Location Of The 3508B Engine Sensors

Location Of The 3508B Engine Sensors

Location Of The 3508B Engine Sensors

i01977688 S/N: LY81–Up

S/N: ZAD1–Up S/N: YAW1–Up

i02385530 S/N: SEK1–Up

i06844639 S/N: CNB1100–Up

S/N: ZAH1–Up Service Tools

S/N: ZAJ1–Up Service Tools

S/N: BRK287–Up Part Description

S/N: YAL1–Up 431-7087 Tool Gp (REFRACTOMETER (DEF))

S/N: YAM1–Up N/A 4 mm Allen Wrench

S/N: FDN1515–Up 1U-5805 Wire Removal Tool (14-GA, GREEN)

S/N: JCN1–Up Magnetic Transducer As (TIMING

S/N: PBR1–Up 7X-1695 Cable As

S/N: PDR1–Up 146-4080 Digital Multimeter Gp (RS232)

S/N: YAR1–Up 7X-1710 Multimeter Probes

S/N: GZS1–Up 208-0059 Adapter Cable As (70-PIN BREAKOUT)

S/N: BGX120–Up N/A Torque Wrench (capable of applying 1.5 N·m

(Table 1, contd) (Table 2, contd)

8T-5319 Connector Tool Group

Note: For more information regarding the use of Cat

Connecting the Communication Adapter

Part Number Description

N/A Personal Computer (PC)

466-6258 Communication Adapter Gp

317-7485 Communication Adapter (3)