C15 Troubleshooting

SENR9698-01July 2003

TroubleshootingC11, C13 and C15 On-highway EnginesKCA1-Up (Engine)KCB1-Up (Engine)BXS1-Up (Engine)

i01658146

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure toobserve basic safety rules or precautions. An accident can often be avoided by recognizing potentiallyhazardous situations before an accident occurs. A person must be alert to potential hazards. Thisperson 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 andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazardwarnings 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 asDANGER, 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 orpictorially presented.

Operations that may cause product damage are identified by NOTICE labels on the product and inthis publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Thewarnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,work method or operating technique that is not specifically recommended by Caterpillar is used,you must satisfy yourself that it is safe for you and for others. You should also ensure that theproduct will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information beforeyou start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

3Table of Contents

Table of Contents

Troubleshooting SectionElectronic TroubleshootingSystem Overview .................................................... 6Glossary ............................................................... 14Electronic Service Tools ........................................ 22Replacing the ECM ............................................... 23Sensors and Electrical Connectors ....................... 25Engine Wiring Harness Diagram .......................... 32

Programming ParametersProgramming Parameters ..................................... 34Dyno Mode ........................................................... 34Test ECM Mode .................................................... 34Customer Passwords ............................................ 35ECM Date/Time Stamped Information .................. 35ECM Snapshot ...................................................... 36Factory Passwords ................................................ 38Factory Passwords Worksheet ............................. 38Flash Programming .............................................. 39Service Information Report ................................... 40

Customer Specified ParametersCustomer Specified Parameters ........................... 41Customer Specified Parameters Table ................. 42Customer Specified Parameters Worksheet ......... 48Cruise Control Parameters ................................... 51Data Link Parameters ........................................... 54Dedicated PTO Parameters .................................. 54Driver Reward ....................................................... 58ECM Identification Parameters ............................. 58Engine/Gear Parameters ...................................... 58Engine Monitoring Parameters ............................. 61Idle Parameters ..................................................... 62Input Selections .................................................... 63Maintenance Parameters ...................................... 67Output Selections ................................................. 67Security Access Parameters ................................. 69Selected Engine Rating ........................................ 69Smart Idle Parameters .......................................... 70Timer Parameters ................................................. 70Trip Parameters ..................................................... 72Vehicle Activity Report Parameters ....................... 74Vehicle Speed Parameters ................................... 74

System Configuration ParametersSystem Configuration Parameters ........................ 77

Troubleshooting without a Diagnostic CodeCan Not Reach Top Engine RPM ......................... 79Can Not Reach Vehicle Speed Limit ..................... 80Check Engine Lamp or Warning Lamp IsMalfunctioning ..................................................... 82

Cooling Fan Is Always ON .................................... 83Cruise Control, Idle, or PTO Can Not Be Set ........ 85Driver Questionnaire ............................................. 87Driver Questionnaire Response ............................ 88ECM Will Not Accept Factory Passwords ............. 89

Electronic Service Tool Will Not Communicate withECM .................................................................... 90

Engine Cranks but Will Not Start .......................... 91Engine Misfires, Runs Rough or Is Unstable ........ 93Engine Retarder (Compression Brake) Will Not TurnON ....................................................................... 94

Engine Vibration ................................................... 96Engine Will Not Crank ........................................... 98Excessive Black Smoke ........................................ 98Excessive Fuel Consumption ............................. 100Excessive White Smoke ..................................... 101Intermittent Cruise Control, Idle, or PTOKickout .............................................................. 102

Intermittent Low Power or Power Cutout ............. 103Low Power/Poor or No Response to Throttle ...... 105Poor Acceleration or Response .......................... 107

Troubleshooting with a Diagnostic CodeDiagnostic Codes ................................................ 109No Diagnostic Code Detected (55) ..................... 1120001-05 Cylinder #1 Injector current low (72) ..... 1120001-06 Cylinder #1 Injector current high (72) ... 1130002-05 Cylinder #2 Injector current low (72) ..... 1130002-06 Cylinder #2 Injector current high (72) ... 1130003-05 Cylinder #3 Injector current low (73) ..... 1140003-06 Cylinder #3 Injector current high (73) ... 1140004-05 Cylinder #4 Injector current low (73) ..... 1150004-06 Cylinder #4 Injector current high (73) ... 1150005-05 Cylinder #5 Injector current low (74) ..... 1150005-06 Cylinder #5 Injector current high (74) ... 1160006-05 Cylinder #6 Injector current low (74) ..... 1160006-06 Cylinder #6 Injector current high (74) ... 1160022-11 Primary to Secondary Engine Speed SignalCalibration (42) ................................................. 117

0022-13 Engine Speed Signal Calibration NotPerformed (42) .................................................. 118

0030-08 PTO Throttle signal invalid (29) ............ 1190030-13 PTO Throttle out of calibration (29) ...... 1190041-03 8 Volt Supply voltage high (21) ............. 1190041-04 8 Volt Supply voltage low (21) .............. 1200043-02 Key Switch Fault (71) ............................ 1200052-11 Air Inlet Shutoff Shutdown (00) ............. 1210054-05 Auxiliary Output #06 current low (66) ... 1210054-06 Auxiliary Output #06 current high (66) .. 1210055-05 Auxiliary Output #07 current low (67) ... 1220055-06 Auxiliary Output #07 current high (67) .. 1220064-08 Secondary Engine Speed loss of signal(34) .................................................................... 122

0071-00 Idle Shutdown Override (01) ................. 1230071-01 Idle Shutdown (47) ............................... 1230071-14 PTO Shutdown (47) .............................. 1240084-00 Vehicle Overspeed Warning (41) .......... 1240084-01 Vehicle Speed loss of signal (31) ......... 1240084-02 Vehicle Speed signal invalid (36) .......... 1250084-08 Vehicle Speed signal out of range (36) .. 1250084-10 Vehicle Speed signal rate of change(36) .................................................................... 126

0084-14 Quick Stop Occurrence ........................ 1260091-08 Throttle Position Invalid (32) ................. 1260091-13 Throttle Position out of calibration (32) .. 1270100-01 Low Oil Pressure Warning (46) ............. 1270100-03 Oil Pressure voltage high (24) .............. 1300100-04 Oil Pressure voltage low (24) ................ 131

4Table of Contents

0100-11 Very Low Oil Pressure (46) ................... 1310102-03 Boost Pressure voltage high (25) ......... 1350102-04 Boost Pressure voltage low (25) ........... 1350105-00 High Intake Manifold Air TemperatureWarning (64) ..................................................... 135

0105-03 Intake Manifold Air Temperature voltagehigh (38) ............................................................ 136

0105-04 Intake Manifold Air Temperature voltage low(38) .................................................................... 137

0105-11 Very High Intake Manifold Air Temperature(64) .................................................................... 137

0108-03 Barometric Pressure voltage high (26) .. 1380108-04 Barometric Pressure voltage low (26) ... 1380110-00 High Coolant Temperature Warning(61) .................................................................... 138

0110-03 Coolant Temperature voltage high(27) .................................................................... 139

0110-04 Coolant Temperature voltage low (27) .. 1390110-11 Very High Coolant Temperature (61) .... 1400111-01 Low Coolant Level Warning (62) ........... 1400111-02 Coolant Level signal invalid (12) ........... 1410111-03 Coolant Level voltage high (12) ............ 1410111-04 Coolant Level voltage low (12) .............. 1420111-11 Very Low Coolant Level (62) ................. 1420111-14 Low Coolant Level Warning .................. 1430121-05 Low/High Retarder current low (14) ...... 1440121-06 Low/High Retarder current high (14) .... 1440122-05 Med/High Retarder current low (14) ..... 1440122-06 Med/High Retarder current high (14) .... 1450166-14 Rated Engine Power SpecialInstructions ........................................................ 145

0168-01 Low ECM Battery Power (17) ............... 1460168-02 ECM Battery Power Intermittent (51) .... 1460171-03 Ambient Air Temperature voltage high .. 1470171-04 Ambient Air Temperature voltage low ... 1470171-11 Ambient Air Temperature Data Lost ..... 1470174-00 High Fuel Temperature Warning (65) ... 1480174-03 Fuel Temperature voltage high (13) ...... 1480174-04 Fuel Temperature voltage low (13) ....... 1480190-00 Engine Overspeed Warning (35) .......... 1490190-08 Primary Engine Speed Loss of Signal(34) .................................................................... 149

0191-07 Transmission Not Responding (68) ...... 1490224-11 Theft Deterrent Active (00) ................... 1500224-14 Theft Deterrent Active with Engine Cranking(00) .................................................................... 150

0231-02 J1939 Data Incorrect (58) ..................... 1510231-12 J1939 Device Not Responding ............. 1510232-03 5 Volt Supply voltage high (21) ............. 1510232-04 5 Volt Supply voltage low (21) .............. 1520246-11 Brake Pedal Switch #1 Fault ................. 1520247-11 Brake Pedal Switch #2 Fault ................. 1530252-11 Engine Software Incorrect (59) ............. 1530253-02 Check Customer or System Parameters(56) .................................................................... 153

0253-11 Check Transmission Customer Parameters(56) .................................................................... 154

0283-05 Intake Valve Actuation System Oil PressureSolenoid current low (97) .................................. 154

0283-06 Intake Valve Actuation System Oil PressureSolenoid current high (97) ................................. 154

0283-07 Intake Valve Actuation Oil Pressure notresponding (91) ................................................. 155

0284-05 Engine Coolant Diverter current low(98) .................................................................... 155

0284-06 Engine Coolant Diverter current high(98) .................................................................... 155

0285-05 Intake Valve Actuator #1 current low(92) .................................................................... 156

0285-06 Intake Valve Actuator #1 current high(92) .................................................................... 156

0285-07 Intake Valve Actuator #1 not responding(92) .................................................................... 157
















0385-01 Low Intake Valve Actuation System OilPressure ............................................................ 163

0385-03 Intake Valve Actuation System Oil Pressurevoltage high (95) ............................................... 163

0385-04 Intake Valve Actuation System Oil Pressurevoltage low (95) ................................................. 164

Diagnostic Functional Tests5 Volt Engine Pressure Sensor Supply Circuit -Test ................................................................... 165

Accelerator Pedal (Throttle) Position Sensor Circuit -Test ................................................................... 169

Air Inlet Shutoff Circuit - Test .............................. 176ATA (SAE J1587 / J1708) Data Link Circuit -Test ................................................................... 182

Auxiliary Brake Circuit - Test ............................... 190Check Engine Lamp Circuit - Test ....................... 195Clutch Pedal Position Switch Circuit - Test ......... 199Coolant Level Sensor Circuit - Test ..................... 204

5Table of Contents

Cooling Fan Circuit and A/C High Pressure SwitchCircuit - Test ...................................................... 214

Cruise Control Switch Circuit - Test .................... 227Diagnostic Enable Switch Circuit - Test .............. 235Eaton Top 2 Transmission Circuit - Test .............. 239ECM Memory - Test ............................................ 246Electrical Connectors - Inspect ........................... 248Engine Coolant Diverter Circuit - Test ................. 255Engine Pressure Sensor Open or Short Circuit -Test ................................................................... 260

Engine Running Output Circuit - Test ................. 265Engine Shutdown Output Circuit - Test ............... 268Engine Speed/Timing Sensor Circuit - Test ........ 271Engine Temperature Sensor Open or Short Circuit -Test ................................................................... 277

Fan Override Switch Circuit - Test ...................... 281Idle Shutdown Timer - Test ................................. 286Ignition Key Switch Circuit and Battery Supply Circuit- Test ................................................................. 289

Ignore Brake/Clutch Switch Circuit - Test ............ 295Injector Solenoid Circuit - Test ............................ 298Intake Valve Actuation System Oil Pressure Circuit -Test ................................................................... 307

Intake Valve Actuator Circuit - Test ..................... 312Intake Valve Actuator Response - Test ............... 317Multi-Torque - Test .............................................. 322Neutral Switch Circuit - Test ................................ 323Powertrain Data Link Circuit - Test ...................... 330PTO Engine RPM Set Speed (Input A and Input B)Circuit - Test ...................................................... 335

PTO Shutdown Timer - Test ................................ 340PTO Shutdown Timer - Test ................................ 342PTO Switch Circuit - Test .................................... 344PTO Switch Circuit - Test .................................... 352PTO Switch ON Lamp Circuit - Test .................... 362PTO Switch ON Lamp Circuit - Test .................... 367Remote PTO Accelerator Position Sensor Circuit -Test ................................................................... 372

Remote PTO Accelerator Position Sensor Circuit -Test ................................................................... 380

Retarder (Compression Brake) Solenoid Circuit -Test ................................................................... 388

Service Brake Pedal Position (Switch 1) Circuit -Test ................................................................... 399

Service Brake Pedal Position (Switch 2) Circuit -Test ................................................................... 404

Starting Aid Output Circuit - Test ........................ 409Starting Aid Switch Circuit - Test ........................ 412Tachometer Circuit - Test .................................... 416Torque Limit Switch Circuit - Test ........................ 421Two Speed Axle Switch Circuit - Test .................. 425Vehicle Speed and Speedometer Circuit - Test .. 429Warning Lamp Circuit - Test ............................... 438

Calibration ProceduresEngine Speed/Timing Sensor - Calibrate ........... 443Injector Code - Calibrate ..................................... 447Vehicle Speed Circuit - Calibrate ........................ 448

Index SectionIndex ................................................................... 452

6Troubleshooting Section

Troubleshooting Section

Electronic Troubleshootingi01939963

System OverviewSMCS Code: 1900

System OperationThese truck engines were designed for electroniccontrol. A solenoid on each injector controls theamount of fuel that is delivered by the injector. AnEngine Control Module (ECM) sends a signal toeach injector solenoid in order to provide completecontrol of the engine.

Electronic ControlsThe electronic system consists of the EngineControl Module (ECM), the engine sensors and thevehicle interface. The ECM is the computer. Thepersonality module is the software for the computer.The personality module contains the operatingmaps. The operating maps define the followingcharacteristics of the engine:

Horsepower

Torque curves

RPM

Other characteristics

Engine GovernorThe electronic controls that are on the engine serveas the engine governor.

The electronic controls determine the timing andthe amount of fuel that is delivered to the cylinders.These decisions are based on the actual conditionsand the desired conditions at any given time.

The governor uses the accelerator pedal positionsensor to determine the desired engine speed.The governor compares the desired engine speedto the actual engine speed. The actual enginespeed is determined through the primary enginespeed/timing sensor. If the desired engine speed isgreater than the actual engine speed, the governorinjects more fuel in order to increase engine speed.

The desired engine speed is typically determinedby one of the following conditions:

The position of the accelerator pedal

The desired vehicle speed in cruise control

The desired engine rpm in PTO control

Timing ConsiderationsOnce the governor has determined the amount offuel that is required, the governor must determinethe timing of the fuel injection. Fuel injection timingis determined by the ECM after considering inputfrom the following components:

Coolant temperature sensor

Intake manifold air temperature sensor

Atmospheric pressure sensor

Boost pressure sensor

At start-up, the ECM determines the top centerposition of the number 1 cylinder from the signalfor the secondary engine speed/timing sensor.After start-up, the ECM determines the top centerposition of the number 1 cylinder from the primaryengine speed/timing sensor. The ECM decideswhen fuel injection should occur relative to the topcenter position and the ECM provides the signal tothe injector at the desired time. The ECM adjuststiming for the best engine performance, the bestfuel economy and the best control of white smoke.Actual timing cannot be viewed with the electronicservice tool, and Desired Timing cannot be viewedwith the electronic service tool.

Fuel InjectionThe ECM controls the amount of fuel that is injectedby varying the signals to the injectors. The injectorswill pump fuel only if the injector solenoid isenergized. The ECM sends a high voltage signalto the solenoid. This high voltage signal energizesthe solenoid. By controlling the timing and theduration of the high voltage signal, the ECM cancontrol injection timing and the ECM can control theamount of fuel that is injected.


The personality module inside the ECM sets certainlimits on the amount of fuel that can be injected.The FRC Fuel Limit is a limit that is based on theboost pressure. The FRC Fuel Limit is used tocontrol the air/fuel ratio for control of emissions.When the ECM senses a higher boost pressure,the ECM increases the FRC Fuel Limit. A higherboost pressure indicates that there is more air in thecylinder. When the ECM increases the FRC FuelLimit, the ECM allows more fuel into the cylinder.

The Rated Fuel Limit is a limit that is based on thepower rating of the engine and engine rpm. TheRated Fuel Limit is similar to the rack stops and thetorque spring on a mechanically governed engine.The Rated Fuel Limit provides the power curvesand the torque curves for a specific engine familyand a specific engine rating. All of these limitsare determined at the factory. These limits are inthe personality module and these limits cannot bechanged.

g00628178Illustration 1(1) TC reference(2) Speed-timing signal(3) Electrical current to injector solenoid(4) Injection pressure curve

Note: The signals and the timing of Illustration 1 arenot to scale.

Customer Parameters And Engine SpeedGoverningA unique feature with electronic engines is customerspecified parameters. These parameters allow thevehicle owner to fine tune the ECM for engineoperation. Fine tuning the ECM for engine operationallows the vehicle owner to accommodate thetypical usage of the vehicle and the power train ofthe vehicle.

Many of the customer parameters provide additionalrestrictions on the actions that will be performedby the ECM in response to the drivers input. Forexample, the PTO Top Engine Limit is an enginerpm limit. The PTO Top Engine Limit is an enginerpm limit that is used by the ECM as a cutoff forthe fuel. The ECM will not fuel the injectors abovethis rpm.

Some parameters are intended to notify the driverof potential engine damage (Engine MonitoringParameters). Some parameters enhance fueleconomy (Vehicle Speed, Cruise Control,Engine/Gear Speed Limit Parameter and IdleShutdown Parameters). Other parameters are usedto enhance the engine installation into the vehicle.Other parameters are also used to provide engineoperating information to the truck engine owner.

Engine MonitoringCaterpillar provides a factory installed enginemonitoring system. The Caterpillar engine monitoringsystem monitors engine oil pressure, coolanttemperature, intake manifold air temperature, andcoolant level (optional device). Optional devices areOEM installed.

The oil pressure, intake manifold air temperature,and coolant temperature sensors are standard onall engines. The vehicle OEM installs the coolantlevel sensor and the associated harness. Thecoolant level sensor is the only optional componentof Caterpillar engine monitoring. Coolant levelis selected through a customer programmableparameter.

Caterpillar engine monitoring can be programmedto three different modes. These three modes ofprogramming are the following modes: WARNING,DERATE, and SHUTDOWN. The coolant temperaturesensor, the oil pressure sensor and the coolant levelsensor (optional device) will operate in the enginemonitoring mode that is selected.

For example, if DERATE mode was selected, theengine will derate engine power and vehicle speed.The engine will derate engine power and vehiclespeed if the coolant temperature sensor, the oilpressure sensor or the coolant level sensor detectsconditions that exceed acceptable limits.

An excessive intake manifold air temperature willnot derate the engine. Also, an excessive intakemanifold air temperature will not shut down theengine.


Caterpillar Engine MonitoringWARNING Operation

If the system is programmed to WARNING, theECM causes the warning lamp to turn on. This willalso cause the check engine lamp to flash becauseof the active diagnostic code. The flashing checkengine lamp indicates that a problem has beendetected by the engine monitoring system. Nofurther action by the ECM or action by the engineoccurs if the ECM is programmed to WARNING.

If the problem is due to one of the followingconditions, the ECM will cause the Warning lamp toturn ON and the ECM will cause the check enginelamp to flash:

Low coolant level

High coolant temperature

High intake manifold air temperature

Low oil pressure

DERATE Operation

If the system is programmed to DERATE, the ECMcauses the warning lamp to turn ON. The warninglamp does not flash. Also, the ECM begins flashingthe check engine lamp. The flashing check enginelamp indicates that a problem has been detectedby the engine monitoring system.

This response is identical to the response when thesystem is in the WARNING mode.

The DERATE mode alters the engine performancewhen any of the following conditions exist:

Oil pressure becomes very low oil pressure.

Coolant level becomes very low coolant level.

Coolant temperature becomes high coolanttemperature.

Coolant temperature becomes very high coolanttemperature.

Whenever the warning lamp is flashing, the ECM islimiting or derating the engine.

The ECM limits the maximum vehicle speed and theECM reduces the available power when any of thefollowing conditions exist:

High coolant temperature

Very high coolant temperature

Very low coolant level

If the ECM detects very low oil pressure, the ECMlimits the following parameters:

Maximum vehicle speed

Available power

Engine rpm

This derating of engine performance is provided inorder to get the drivers attention so the driver cantake action in order to avoid engine damage.

SHUTDOWN Operation

If the system is programmed to SHUTDOWN, theECM takes all the action that is indicated for theDERATE mode and the ECM will eventually shutdown the engine under some conditions.

The SHUTDOWN mode will shut down the enginewhen any of the following conditions exist:

Oil pressure becomes very Low oil pressure.

Coolant level becomes very Low coolant level.

Coolant temperature becomes very high coolanttemperature.

Monitoring Fuel TemperatureThe fuel temperature sensor monitors the fueltemperature. The fuel rate that is calculated bythe ECM is adjusted in order to compensate forchanges in fuel temperature. The fuel rate isalso adjusted for constant power. The sensor isalso used to warn the operator of excessive fueltemperature with a diagnostic event code becauseexcessive fuel temperatures can adversely affectengine performance. The electronic service toolcan be used to temporarily disable the adjustmentof fuel temperature. This could be necessary fortesting a vehicle on a dynamometer with fueltemperature compensation.

Other ECM Functions OfPerformanceThe ECM also provides enhanced control of theengine for vehicle functions such as retardingthe engine and controlling the cooling fan. Referto Troubleshooting, Component Diagram forsupplemental information about the systems thatcan be monitored by the ECM in order to provideenhanced vehicle performance, fuel economy andconvenience for the driver.


Self-DiagnosticsThe electronic system has the ability to diagnoseproblems. When a problem is detected, a diagnosticcode is generated and the check engine/diagnosticlamp may be turned ON. In most cases, the code isalso stored in permanent memory or logged in theEngine Control Module (ECM).

When diagnostic codes occur, the diagnosticcodes are called active diagnostic codes. Activediagnostic codes indicate that a problem of somekind currently exists. Active diagnostic codesshould always be serviced before any other work isperformed. If a truck is brought in with an activecode, find the code in this manual and proceed todiagnose the cause.

Diagnostic codes that are stored in memory arecalled logged diagnostic codes. Logged diagnosticcodes do not necessarily indicate that somethingneeds to be repaired. The problem may have beentemporary, or the problem may have been repairedsince the problem was logged. Logged diagnosticcodes are instead meant to be an indication ofprobable causes for intermittent problems.

Diagnostic codes that identify operating conditionsoutside the normal operating range are calledevents. Event codes are not typically an indicationof an electronic system problem.

Some of the diagnostic codes require passwords tobe cleared from memory. Diagnostic codes that donot require passwords to be cleared from memoryare automatically deleted after 100 hours of engineoperation.

Engine Snapshot DataWhenever most diagnostic codes occur, the ECMrecords the time in engine hours of the occurrence.Also, the ECM records the operating parameters ofthe engine for 9.6 seconds before the diagnosticcode and 3.4 seconds after the diagnostic code.The operating parameters of the engine that arerecorded are similar to the operating parameters ofthe engine that are displayed in the status screensof the electronic service tool. Not all of the statusscreens or parameters are recorded. The enginesnapshot can also be triggered from the cruisecontrol Set/Resume switch. In order to trigger theengine snapshot from the cruise control Set/Resumeswitch, quickly toggle the switch to the Set position.Then, quickly toggle the switch to the Resumeposition. You can also toggle the cruise controlSet/Resume switch from the Resume position tothe Set position. The engine snapshot can also betriggered from the electronic service tool.

Effect Of Diagnostic Codes OnEngine PerformanceThe discussion on engine monitoring mentions thatthe check engine lamp flashes when a specificcondition exists. When the ECM detects the engineproblem, the ECM generates an active diagnosticcode. Also, the ECM logs the diagnostic codein order to indicate the time of the problemsoccurrence. The ECM also logs the number ofoccurrences of the problem. There are two types ofdiagnostic codes. There are fault codes and eventcodes.

Diagnostic Fault CodesDiagnostic fault codes are provided in order toindicate that an electrical problem or an electronicproblem has been detected by the ECM. In somecases, the engine performance can be affectedwhen the condition that is causing the code exists.More frequently, the driver cannot detect anydifference in the engine performance.

If the check engine lamp is flashing and the driverindicates that a performance problem occurs, thediagnostic code may indicate the cause of theproblem. The problem should be corrected.

If the driver does not indicate a problem withthe engine performance and a diagnostic codeis logged by the ECM, the situation indicatesthat the ECM detected an abnormal condition,but the abnormal condition did not affect engineperformance.

In this situation, the system has no faults exceptwhen either of the following conditions exist:

There are several occurrences of the diagnosticcode in a very short period of time.

The ECM is indicating an active code at thepresent time.

Diagnostic Event CodesDiagnostic event codes are used to indicate thatsome operational problem has been detected inthe engine or in the truck by the ECM. Usually, thisdoes not indicate an electronic malfunction.

The ECM also provides an ECM date/time clockthat is used to time stamp the following diagnosticevent codes:

84-00 Vehicle Overspeed Warning

84-14 Quick Stop Occurrence

100-11 Very Low Oil Pressure


105-11 Very High Intake Manifold Air Temperature

110-11 Very High Coolant Temperature

111-11 Very Low Coolant Level

190-00 Engine Overspeed Warning

Refer to Troubleshooting, Diagnostic Codes for alisting of all of the diagnostic codes.

ECM Lifetime TotalsThe ECM maintains total data of the engine for thefollowing parameters:

Total Time (Engine Hours)

Total Distance

PTO Time and PTO Fuel

Idle Time and Idle Fuel

Average Load Factor (Engine)

Total Fuel

Total Max Fuel

The total time is the engines operating hours.The engine hours do not include operating timewhen the ECM is powered ON but the engine isnot running.

Total Distance data requires a vehicle speedsensor or an electronic vehicle speed source to beconnected to the ECM. The same sensor is used forECM vehicle speed. Distance can be displayed inmiles or kilometers.

PTO Time and PTO Fuel are logged if the engineRPM is set with the cruise switch and when theengine is operating under a load. Also, the PTOTime and the PTO Fuel are logged when the PTOOn/Off switch is in the ON position and vehiclespeed is within the range of the PTO Vehicle SpeedLimit parameter.

Idle Time and Idle Fuel can include operatingtime when all of the following conditions are met:

When engine speed is set by using the cruiseswitches and the vehicle speed is within therange of the Idle Vehicle Speed Limit parameter.

The engine is not operating under a load.

Fuel information can be displayed in US Gallonsor liters.

Total Fuel is the total amount of fuel that isconsumed by the engine during operation.

Total Max Fuel is the maximum amount of fuel thatcould have been consumed by the engine duringoperation.

Average Load Factor provides relative engineoperating information. Average Load Factorcompares actual engine operation information tothe maximum engine operation that is available.Average Load Factor is determined by using TotalMax Fuel, Idle Fuel, and Total Fuel. All of theseparameters are available by using the electronicservice tool. These parameters are available withinthe menu for Current Totals.

Trip Data That Is Stored In The ECMThe trip data allows the tracking of engine operationby the vehicle owner over intervals that are definedby the vehicle owner. Two types of trip data arestored in the ECM, Driver Trip Data and Fleet TripData. All of the trip data is stored in memory andthe trip data is maintained through the unswitchedbattery lines when the key switch is OFF. An internalbattery will maintain this information while theunswitched battery lines are disconnected.

Driver Trip DataDriver trip data is known as the driver trip segment.The driver trip segment includes data for thefollowing parameters:

Total Time

Driving Time

Distance

Fuel

Overall Fuel Economy

Driving Fuel Economy

Idle Time

Idle Fuel

Percent Idle Time

PTO Time

PTO Fuel

Percent PTO Time

Average Load Factor


Average Vehicle Speed

Average Driving Speed

Maximum Vehicle Speed

Maximum Engine Speed

Start Time

End Time

Start Odometer

End Odometer

A driver trip segment can be reset by using theelectronic service tool or a Caterpillar MessengerDriver Information Display.

When the data is reset, the ECM stores the currenttotals at the time of the reset. This data is usedas the starting point for the driver trip data. Theelectronic service tool or the Messenger accessesthis starting point and the current totals from theECM in order to calculate the data for the driver tripsegment. Resetting the driver trip segment doesnot require passwords.

Fleet Trip DataFleet trip data includes a fleet trip segment,histograms, and custom data. The fleet trip segmentrecords the same parameters as the driver tripsegment except that the fleet trip segment can bereset independently of the driver trip segment.

Three histograms are available. One histogramrecords engine hours versus the engine speed. Thesecond histogram records engine hours versusvehicle speed. The third histogram records enginehours versus engine speed and vehicle speed.

The electronic service tool calculates thepercentage of time that is spent in each of theengine rpm or vehicle speed ranges. Custom datais available. Custom data allows the recording ofengine parameters that are specified by the vehicleowner. The ECM records the custom data.

A reset of the fleet trip data which includes the fleettrip segment, the histograms, and the custom datacan be done in several ways. The following toolscan be used to reset the fleet trip data:

Caterpillar Electronic Technician (Cat ET)

Caterpillar Fleet Information Software (FIS)

Caterpillar Messenger Driver Information Display

When the data is reset, the ECM records the currenttotals at the time of the reset. These totals are usedas the starting point for the fleet trip. The followingtools access the recorded starting point:

Cat ET

Caterpillar Fleet Information Software (FIS)

Messenger

The tool then subtracts the recorded starting pointfrom the current totals in the ECM in order tocalculate the fleet trip data. Resetting the fleet tripdata requires customer passwords if the passwordsare programmed.

Fleet Trip Custom DataFleet trip custom data is part of the fleet tripsegment. Fleet trip custom data allows the ownerof the vehicle to set five customized methods ofrecording data for the vehicle. Refer to Illustration2 for the basic program.

g00628194Illustration 2Basic Program

The following list defines the options for variable1 of the basic program:

Engine Hours

Distance Traveled

Fuel Burned

Occurrences

Refer to the following list for information regardingthe options that are available for variable 2 andvariable 5.

Variables 3, 4, 6, and 7 define the minimum rangeand the maximum range of variables 2 and 5.

Engine RPM

Vehicle Speed


Fuel Rate

Load Factor

Coolant Temperature

Oil Pressure

Fuel Temperature

Intake Manifold Air Temperature

Cruise

PTO

Engine Retarder

Throttle Position

Brake

Refer to the example of a custom data program, asshown below.

Fuel Burned when Fuel Temperature is between7 and 67 C (45 and 120 F) and Vehicle Speedis between 87 and 137 km/h (55 and 85 mph)The custom data programs are protected bycustomer passwords. The programs are stored inpermanent memory. The programs are not resetwhen the fleet trip segment is reset, but the datathat is recorded for the trip is reset.

Fuel Correction FactorA Fuel Correction Factor is available for finetuning the calculations for fuel consumption. TheFuel Correction Factor is protected by customerpasswords. The Fuel Correction Factor enhancesthe accuracy of the calculation for fuel consumption.Altering the Fuel Correction Factor does not affectdata that is already stored in the ECM. Alteringthe Fuel Correction Factor only affects data that isstored in the ECM after the Fuel Correction Factoris entered.

Note: The Fuel Correction Factor should be adjustedfrom data that has been recorded for a long time,data from the fuel tank and recorded data in theECM.

Quick Stop RateA customer parameter is available in order torecord the quick stop occurrences. The parameterdetermines the rate of change in vehicle speed thatis used by the ECM in order to record a quick stopevent code and a quick stop snapshot. Refer toTroubleshooting, ECM Snapshot.

Maintenance Indicator Data

The ECM records the current totals when a resetoccurs for the following three levels of maintenance:

PM1

PM2

Cooling System Clean/Flush

The ECM uses the previous point of maintenance inorder to calculate the timing of the next scheduledmaintenance work.

The maintenance indicator mode is programmableto hours or distance. The PM1 maintenance isprogrammable to the Off, Automatic Distance,Automatic Hours, Manual Distance, or ManualHours setting.

If the PM1 is programmed to the automatic mode,the ECM calculates the next point of maintenanceby considering the history of the vehicles operationfrom the previous maintenance interval. If thevehicle has a history of poor fuel economy themaintenance indicator parameter will occur soonerthan a vehicle with better fuel economy.

The ECM also uses the engine oil capacity. Alarger engine oil capacity provides a longermaintenance interval. The engine oil capacity isprogrammed into the ECM in liters or quarts. Ifthe PM1 is programmed to the manual mode, theowner can program the ECM in the owners specificmaintenance interval. The maintenance interval canbe programmed to the owners specific intervalthat is based on mileage or time. The interval forthe PM2 and the interval for the cooling systemClean/Flush are established by the factory.

MessengerThe Caterpillar Messenger Driver InformationDisplay is available to provide engine operatinginformation to the driver. The Driver Trip Segment,the Fleet Trip Segment, and the MaintenanceIndicator data can be viewed. However, the FleetTrip Histograms and the Custom Data cannot beviewed from the display.


Messenger provides the ability to enter an ID codefor a driver in order to divide the fleet trip segmentfor two drivers. If the driver enters the informationregarding the state of travel, the fleet trip segmentcan be tagged by the state of travel.

Messenger can be used in order to tag portions ofthe fleet trip segment into two ID codes. Messengercan also be used in order to tag portions of thefleet trip segment into the state of travel. The IDcode and the information regarding the state oftravel cannot be viewed from the display. Only theCaterpillar Fleet Information Software (FIS) can viewthis information. The ability to reset any of theseparameters is dependent on customer parametersin the ECM.

Messenger will also display engine operatingparameters such as engine rpm, coolanttemperature, boost pressure and many otherparameters.

Messenger will also display engine diagnosticcodes. Messenger will also display a brief textdescription of the diagnostic codes.

An available feature on Messenger is the theftdeterrent. The theft deterrent allows the driver toinput a password prior to shutdown. The theftdeterrent will prevent the engine from restarting untilthe password is successfully entered. Messengermust have the version of software that is capable ofsupporting this feature.

An Auto-Enable option is available as a TheftDeterrent. If this option is selected, the theftdeterrent will automatically be activated when theengine is shut down. The driver must input thecorrect password in order to start the engine.

Secure Idle is another Theft Deterrent. This allowsthe driver to bring the engine to an idle condition.The driver then enters the password. The engine willremain at low idle until the password is re-entered. Ifthe engine is shutdown, a password will be requiredto go above low idle after start-up.

Fleet Information Software (FIS)The Caterpillar Fleet Information Software (FIS) isanother method that can be used to review the tripinformation. The entire fleet trip segment, whichincludes the following elements of data can beaccessed with the Caterpillar FIS:

Histograms

Custom Data

Information that is tagged by the ID code

Information that is tagged by the state of travel

Maintenance Indicator information can be retrievedwith the Caterpillar FIS.

When the Caterpillar FIS downloads the information,the Caterpillar FIS also resets the ECM in order toprepare the ECM for the next trip. The informationcan be downloaded to a computer with theCaterpillar FIS program, or the information can bedownloaded to an Argo Mobile Data Tool (MDT).The Argo Mobile Data Tool (MDT) is then connectedto a computer in order to download the information.

Driver Reward Feature

The driver reward feature automatically adjusts theVSL as a reward to the driver for operating a truckin a manner that meets the truck engine ownersspecifications. Several parameters are monitored inorder to evaluate a drivers operating technique.Weighting factors are applied to the parameters thatreflect the operating techniques that are desiredand the operating techniques that are expected.If the operating techniques meet the ownersspecifications or the operating techniques exceedthe owners specifications, the VSL is automaticallyincreased as a reward. The VSL will decrease whenthe operating techniques do not meet the ownersspecifications.

Messenger can be used to monitor parameters thataffect the driver reward, which allows the driver toadjust the operating techniques, as required.

Wireless Communication EnableThe Wireless Communication Enable parameter inthe ECM allows the ECM to communicate throughthe SAE J1587 Data Link with certain systemsof communication. Programming this parameterrequires factory passwords.

With this system, the customer can remotely changethe following parameters with the Caterpillar FIS:

Fuel Correction Factor

Custom Data

Maintenance Indicator Data

With this system, the customer can remotely extractthe following information from the ECM:

Current Totals

Reports on Custom Data

Fleet Trip Data

Economy Model

Maintenance Information


Settings for Customer Parameters

The reports are processed for the owner of thefleet with the Caterpillar FIS. The frequency andthe timing of the downloading of the informationcan be at set intervals or the downloading of theinformation can be done manually.

i01909059

GlossarySMCS Code: 1900

Note: This glossary contains definitions ofterminology for all of Caterpillar On-Highway TruckEngines. Some of the terms are only applicable tocertain engines.

A/C High Pressure Switch The A/C high pressureswitch senses refrigerant pressure in the airconditioning system. The A/C high pressure switchopens the electrical contacts and the A/C highpressure switch closes the electrical contacts. Theopening and closing of the electrical contactsdepends on the pressure in the system. Theelectrical contacts control the cooling fan. Thisswitch may be connected to the ECM in someapplications.

Accelerator Pedal Position The accelerator pedalposition is the interpretation by the ECM of thesignal from the accelerator pedal position sensor.

Accelerator Pedal Position Sensor The acceleratorpedal position sensor is an electronic sensorthat is connected to the accelerator pedal. Theaccelerator pedal position sensor sends a PulseWidth Modulated signal to the ECM.

ACERT Advanced Combustion EmissionsReduction Technology

Active Diagnostic Code An active diagnostic codedescribes a condition that is currently present inorder to alert the driver or the service technician ofan abnormal parameter of engine operation. Referto a Diagnostic Fault Code.

Aftermarket Device An aftermarket device is adevice or an accessory that is installed by thecustomer after the vehicle is delivered.

Air-To-Air Aftercooler An air-to-air aftercooler isa device that is used on turbocharged enginesin order to cool inlet air that has undergonecompression. The inlet air is cooled after the inletair passes through the turbocharger. The inlet airis passed through an aftercooler (heat exchanger)that uses ambient air for cooling. The inlet air thathas been cooled advances to the inlet manifold.

Alternating Current (AC) Alternating current is anelectric current that reverses direction at a regularinterval that is reoccurring.

American Wire Gauge (AWG) AWG is a measureof the diameter of electrical wire. AWG is alsoa measure of the current carrying capacity ofelectrical wire. When the AWG number is smaller,the diameter of the wire is larger. When the AWGnumber is larger, the diameter of the wire is smaller.

Analog Sensors Analog sensors produce a DCoutput signal. The sensors detect changes intemperature or pressure. The change is convertedby the sensor to an electrical signal.

Analog Sensor Return The common line (ground)for the analog sensor from the ECM is used as aground for the analog sensors.

Analog Sensor Supply The +5 volt supply fromthe ECM provides power to the analog sensors.

Anti-Lock Brake System (ABS) An anti-lock brakesystem is a brake system that attempts to reduce askid during brake operation. A power train electroniccontrol can turn off the engine retarder, if necessary.Also, a power train electronic control can signal theengine ECM to deactivate the engine retarder.

ATA Data Link (American Trucking Association) The ATA data link is a two wire electrical connectionfor communication with other microprocessorbased devices. These devices are compatible withStandards for the American Trucking Associationand Standards for the SAE (J1587 and J1708) suchas trip recorders, electronic dashboards, powertrain controls, and maintenance systems. Thedata link is also the serial communication mediumthat is used for programming and troubleshootingCaterpillar truck engines.

Atmospheric Pressure Sensor The atmosphericpressure sensor measures barometric pressure.The sensor sends a signal to the Engine ControlModule (ECM). The signal is used in engine controland in engine operation.

Auxiliary Pressure Sensor This sensor is anadditional pressure sensor that is installed by theengine owner.


Auxiliary Retarder Relay The brakes solenoidsare driven by an OEM installed relay, which is drivenby the ECM.

Auxiliary Temperature Sensor This sensor is anadditional temperature sensor that is installed bythe engine owner.

Before Top Center (BTC) BTC is the 180 degreesof crankshaft rotation before the piston reachesthe top center position in the normal direction ofrotation.

Boost The difference between the turbochargeroutlet pressure and the atmospheric pressure iscommonly referred to as boost.

Boost Pressure Sensor The boost pressure sensormeasures inlet manifold air pressure. The boostpressure sensor sends a signal to the ECM.

Bypass Circuit A bypass circuit is a circuit that isused as a substitute circuit for an existing circuit. Abypass circuit is typically used as a test circuit.

Calibration Calibration is an electronic adjustmentof a sensor signal.

Camshaft Position Sensor Refer to SecondaryEngine Speed/Timing Sensor.

Caterpillar Driver Information Display (CAT ID) The Caterpillar Driver Information Display is adigital readout of the performance parameters ofthe vehicle and performance parameters that aremonitored by the ECM.

Caterpillar Electronic Technician (Cat ET) Cat ETis an electronic service tool that uses a softwareprogram to run on a personal computer (PC). CatET is used to service Caterpillar products. Thisprogram has replaced the ECAP tool.

Caterpillar Engine Monitoring Caterpillar EngineMonitoring is the part of the Caterpillar electronicengine control that monitors coolant temperature,oil pressure, intake manifold air temperature andcoolant level. The monitoring alerts the operator ofdetected problems. Coolant temperature, intakemanifold air temperature, and oil pressure sensorsare supplied by Caterpillar and monitored by theECM. The coolant level sensor is installed bythe vehicle OEM but still monitored by the ECM.Aftermarket engine monitoring systems do notinterface with the Caterpillar electronic enginecontrol.

Check Engine Lamp The check engine lamp issometimes referred to as the diagnostic lamp. Thecheck engine lamp is used to alert the operator ofthe presence of an active event. The lamp thenflashes a diagnostic code.

Clutch Pedal Position Switch The switch istypically supplied and installed by the OEM. Thisswitch is typically a limit switch that is mounted nearthe clutch pedal. The switch is usually adjustable.This switch is in the normally closed position whenthe clutch pedal is released. Depressing the clutchpedal will open the circuit.

Code Refer to the Diagnostic Fault Code and theDiagnostic Event Code.

Cold Mode Cold mode is a mode for cold startingand for cold engine operation that includes timingthat is retarded and low idle that is raised. Thismode is used for engine protection, reduced smokeemissions and faster warm up time.

Communication Adapter Tool The communicationadapter provides a communication link between theECM and Cat ET.

Control Area Network (CAN) Data Link The CANData Link is a serial communications port that isused for communication with other microprocessorbased devices. This is also referred to as the J1939Data Link.

Coolant Level Sensor This OEM installed sensordetects the absence or presence of coolant at theprobe. The sensor then sends a signal to the ECM.

Coolant Temperature Sensor This sensor detectsthe engine coolant temperature for Cold Modeoperation and the Caterpillar Engine Monitoring.The Caterpillar Engine Monitoring must be enabledfor the coolant temperature sensor to be used formonitoring purposes.

Cooling Fan Override Switch This switch overridescontrol of the cooling fan relay so the cooling fanoperates continuously. This switch is supplied andinstalled by the OEM.

Cooling Fan Relay This relay is controlled bythe ECM which uses information from the coolanttemperature sensor, the engine retarder and theair conditioning high pressure switch. The airconditioning high pressure switch is not alwaysinstalled. The relay and the air conditioning highpressure switch is supplied and installed by theOEM.

Crankshaft Position Sensor Refer to PrimaryEngine Speed/Timing Sensor.

Cruise Control Range The cruise control rangeis the speed range that is monitored by the cruisecontrol. This speed range is typically the anticipatedspeed range on the open road. The cruise controlrange can be programmed with the low cruise limitand the high cruise limit.


Custom Data Custom data is part of the fleet tripdata that is stored in the ECM. This capability allowsthe vehicle owner to specify operating parametersfor monitoring purposes while the engine is inservice.

Customer Specified Parameter A CustomerSpecified Parameter is a value that can be set andchanged by the customer. The parameters can beprotected by Customer Passwords.

Desired Engine Speed The desired engine speedis input to the electronic governor within the ECM.The electronic governor uses the signal from theaccelerator pedal position sensor, the enginespeed sensor, the cruise control, and the CustomerParameters in order to determine desired speed.

Desired RPM The desired rpm is input to theelectronic governor within the ECM. The electronicgovernor uses the signal from the accelerator pedalposition sensor, the engine speed sensor, the cruisecontrol, and the Customer Parameters in order todetermine desired rpm.

Diagnostic Event Code These codes indicate anevent that describes an abnormal engine conditionsuch as a high coolant temperature. These codesare not necessarily an indication of problems withinthe electronic system.

Diagnostic Fault Code A diagnostic fault codeis sometimes referred to as a fault code. Thesecodes indicate an electronic system malfunction orabnormal operating conditions.

Diagnostic Flash Code The diagnostic flash codesare flashed on the check engine lamp. These flashcodes indicate a malfunction in the electronicsystem or an event that is detected by the ECM.

Diagnostic Lamp A diagnostic lamp is sometimescalled the check engine lamp. The diagnostic lampis used to warn the operator of the presence of anactive diagnostic code.

Digital Sensors Digital sensors produce an ONor OFF type of signal. Some sensors vary the ONor OFF time which is referred to as Pulse WidthModulation (PWM).

Digital Sensor Return The common line (ground)from the ECM is used as a ground for the digitalsensors.

Digital Sensor Supply The supply from the ECM isused in order to power the digital sensors.

Direct Current (DC) Direct current is the type ofcurrent that flows consistently in only one direction.

DT, DT Connector, or Deutsch DT This is a type ofconnector that is used on Caterpillar truck engines.The connectors are manufactured by Deutsch.

Dual Coil Vehicle Speed Sensor The dual coilvehicle speed sensor is a magnetic pickup thatsenses movement of the teeth on the output shaftof the transmission. The sensor contains two coils.This sensor provides two differential output signals.

Duty Cycle Refer to Pulse Width Modulation.

Electronic Engine Control The electronic enginecontrol is a complete electronic system. Theelectronic engine control monitors the engineoperation under all conditions. The electronicengine control also controls the engine operationunder all conditions.

Electronic Service Tool Refer to CaterpillarElectronic Technician (Cat ET).

Electronically Controlled Unit Injector Theelectronically controlled unit injector is aninjection pump which is a mechanically actuated,electronically controlled unit injector. This unitcombines the pumping, electronic fuel meteringand injecting elements in a single unit.

Engine Control Module (ECM) The ECM is theengines control computer. The ECM provides powerto the electronics. The ECM monitors data that isinput from the engines sensors. The ECM acts as agovernor in order to control engine rpm.

Engine Coolant Diverter The engine coolantdiverter is a normally open valve that allows coolantto flow through a radiator that cools the intake air.The radiator is located after the turbochargersand before the air-to-air aftercooler. Energizingthe solenoid prevents the flow of coolant throughthe radiator in order to prevent overcooling of theengine when cold ambient air temperatures exist.

Engine Monitoring System The Engine MonitoringSystem is a programmable system that allows theECM to take actions if an engine parameter is out ofa certain range. The actions are Warning, Derate,and Shutdown.

Engine Oil Pressure Sensor This sensor measuresengine oil pressure and the sensor sends a signalto the ECM.

Engine Retarder Solenoids The engine retardersolenoids are installed by Caterpillar and thesolenoids are driven by the ECM. These solenoidsare used in place of relays such as the auxiliarybrake that is installed by the OEM.


Engine Speed/Timing Sensor This sensor providesa variable amplitude and Pulse Width Modulatedsignal to the ECM. The ECM interprets this signal asthe crankshaft position and the engine speed.

Erasable Programmable Read Only Memory(EPROM) An EPROM is a type of computermemory chip.

Estimated Dynamic Timing The estimated dynamictiming is the estimate that is provided by the ECMof the actual injection timing.

ET Refer to Caterpillar Electronic Technician(Cat ET).

Ether Relay The ether relay is used in order toactuate the ether injection system. The relay iscontrolled by the ECM.

Event Events indicate an event that describes anabnormal engine condition. These codes are notnecessarily an indication of problems within theelectronic system.

Exhaust Brake Relay The brake solenoids aredriven by an OEM installed relay, which is drivenby the ECM.

Failure Mode Identifier (FMI) This Identifierindicates the type of failure that has beenexperienced by the component. The FMI hasbeen adopted from the SAE practice of J1587diagnostics. The FMI follows the PID in thedescriptions of the fault code. The descriptions forthe FMIs are shown in the following list:

0 The data is valid but the data is above thenormal operational range

1 The data is valid but the data is below thenormal operational range

2 The data is erratic, intermittent, or incorrect.

3 The voltage is above normal or the voltage isshorted high

4 The voltage is below normal or the voltage isshorted low

5 The current is below normal or the circuit isopen

6 The current is above normal or the circuit isgrounded

7 The mechanical system is not respondingproperly

8 Abnormal frequency, pulse width, or period

9 Abnormal update

10 Abnormal rate of change

11 The failure mode is not identifiable

12 Damaged device or component

13 The device or the component is not calibrated

14 and 15 These locations are reserved for afuture assignment

Flash Code (FC) The flash codes are proprietaryCaterpillar code numbers that are flashed on thediagnostic lamp. The flash codes are flashed on thecheck engine lamp. These flash codes indicate amalfunction in the electronic system or an event thatis detected by the ECM.

Flash Programming Flash programming is themethod of programming or updating an ECM withCat ET over the data link instead of replacingcomponents. Flash programming installs thespecific Personality Module that is used to controlthe engine. The Personality Module containsspecific performance maps and features for aselected rating.

Fleet Information Software (FIS) FIS is a softwareprogram that operates on a personal computer(PC). This program allows the user to review thetrip information. The program also allows the userto reset the trip information which includes theMaintenance Indicator information.

Fuel Position This is an internal signal withinthe ECM. The signal comes from the electronicgovernor and the signal then goes to the fuelinjection control. The information that is gatheredis based on the Desired RPM, the FRC Limit, theRated Fuel Limit, and the actual engine rpm.

Fuel Ratio Control (FRC) The FRC is a limit thatis based on the control of the fuel to air ratio. TheFRC is used for purposes of emission control. Whenthe ECM senses a higher boost pressure (more airinto the cylinder), the FRC increases the FRC Limit(more fuel into the cylinder).

Fuel Temperature Sensor This sensor detectsthe fuel temperature. The ECM monitors the fueltemperature and the ECM adjusts the calculatedfuel rate accordingly.

Full Load Setting (FLS) The FLS is the numberthat represents the fuel system adjustment. Thisadjustment is made at the factory in order to helpensure the maximum fuel delivery of the fuel system.The correct value for this parameter is stamped onthe engine information ratings plate. This parametermust be programmed. If the parameters are notprogrammed, the diagnostic code that is 253-02Check Customer or System Parameters will beactive.


Full Torque Setting (FTS) The FTS is similar tothe Full Load Setting. This parameter must beprogrammed. If the parameters are not programmedthe diagnostic code that is 253-02 Check Customeror System Parameters will be active.

Gear Down Protection This feature consists of theHigh Gear Limits that are programmable. High GearLimits are used in order to promote driving in highergears for increased fuel economy.

Harness The harness is the bundle of wiring(loom) that connects all components of theelectronic system.

Hertz (Hz) Hertz is the measure of electricalfrequency in cycles per second.

High Pressure Oil Manifold The high pressureoil manifold is an oil gallery that is added to thecylinder head in order to supply the unit injectorswith high pressure oil.

High Pressure Oil Pump The high pressure oilpump is an axial piston pump that is driven bygears. The high pressure oil pump is used to raisethe engine oil pressure in order to activate the unitinjectors. The amount of oil pressure that is requiredto activate the unit injectors is called the actuationpressure.

Histogram The histogram is a bar graph whichmay indicate the relative frequency of vehicleoperation in specific operating ranges. A histogramcan be used to show many relationships.

Hydraulically Actuated Electronically Controlled UnitInjector (HEUI) The HEUI is an injection pumpwhich is a hydraulically actuated, electronicallycontrolled unit injector. This injector uses hydraulicforces to produce the high injection pressure.This unit combines the pumping, electronic fuelmetering, and injecting elements in a single unit.

Idle rpm Limit This is a programmable parameterwhich indicates the maximum allowable engine rpmthat is allowed when the engine rpm is set with thecruise set/resume switch.

Idle Shutdown Time This programmableparameter indicates a designated idle time inminutes that is allowed before shutdown.

Idle/PTO Bump rpm This programmable parameterindicates the amount of change to the engine rpmthat will occur when the switch for acceleration istoggled or the switch for deceleration is toggled.

Injection Actuation Pressure Control Valve This is adump valve that is controlled by an electrical signalthat maintains high pressure for the high pressureoil manifold. The ECM controls the pressure inthe high pressure oil manifold by inputs from theother sensors. The control valve regulates the highpressure oil to the hydraulic electronic unit injectorthrough the high pressure oil manifold. Proper fuelinjection pressure is necessary for desired engineoperation.

Injection Actuation Pressure Sensor An electricalsensor on the high pressure oil manifold convertsoil pressure into an electrical signal for the ECM.

Injector Codes The injector codes or injector trimcodes are numeric codes or alphanumeric codesthat are etched or stamped on individual injectors.These codes are used to fine tune the fuel delivery.

Injector Trim Files Injector trim files aredownloaded from a disk to the ECM. The trim filescompensate for variances in manufacturing of theinjector. The engine serial number must be know inorder to obtain the correct trim file.

Intake Manifold Air Temperature Sensor Thissensor detects the air inlet temperature. TheECM monitors the inlet air temperature and otherdata in order to adjust injection timing and otherperformance functions.

Intake Valve Actuation System Oil Pressure Sensor Monitors the pressure within the oil rail for the intakevalve actuator. The sensor can detect mechanicalproblems with the intake valve actuation systemsuch as leaking face seals.

Intake Valve Actuation System Oil PressureSolenoid Solenoid mounted at the end of the oilrail for the intake valve actuator. The solenoid isnormally closed to allow pressure to build up inthe rail.

Intake Valve Actuator An actuator that allows theECM to control the amount of time that the intakevalve is open. The actuator traps engine oil in orderto hold the intake valve open. The ECM can varythe time that the intake valve is open in order tooptimize engine performance.

Integrated Electronic Controls The engine isdesigned with the electronic controls as a necessarypart of the system. The engine will not operatewithout the electronic controls.


J1922 Data Link This data link is an SAEdiagnostic communications data link that is used tocommunicate between the electronic engine andthe power train components. Examples of powertrain components are the ABS/traction controlsystem and the transmissions. This allows thepower train component to control the engine duringreduced traction or transmission shifts.

J1939 Data Link This data link is an SAEdiagnostic communications data link that is used tocommunicate between the electronic engine, thetransmission, instrument clusters, and/or the powertrain controls.

Key Switch Input When the input is energized, theECM is powered up.

Kickout Switch This term refers to the servicebrake switch and the clutch switch. These switchesare used as an exit or a kickout for the cruisecontrol set speed, the idle speed setting, or thePTO/Idle set speed.

Latch Mode This is a programmable parameterfor control of the exhaust brake. The exhaustbrake engages when the service brake pedal isdepressed. The exhaust brake remains engageduntil the control detects a change in a control input.

Logged Diagnostic Codes Logged diagnosticcodes are codes which are stored in memory.These codes are meant to be an indicator ofpossible causes for intermittent problems. Refer tothe Diagnostic Fault Code for more information.

Maintenance Clear Switch The maintenanceclear switch is required to reset the PM1 Intervaldiagnostic after maintenance on the engineis performed. This reset is necessary for themaintenance indicator to function.

Maintenance Overdue Lamp This lamp will turn onwhen the Preventive Maintenance Interval occurssuch as PM1 Interval.

Mechanically Actuated Electronically Controlled UnitInjector (MEUI) The MEUI is an injection pumpwhich is a mechanically actuated, electronicallycontrolled unit injector. Mechanical forces that areproduced from the camshaft are used to producethe high injection pressures. This unit combines thepumping, electronic fuel metering, and injectingelements in a single unit.

Messenger Messenger is a digital display thatcan display the operating conditions for the engine.

Oil Pressure Sensor This sensor measures engineoil pressure and the sensor signals the ECM.

Open Circuit An open circuit is a condition that iscaused by an open switch, or an electrical wire ora connection is broken. When this condition exists,the signal or the supply voltage can no longer reachthe intended destination.

Original Equipment Manufacturer (OEM) TheOEM is the manufacturer of a vehicle that uses aCaterpillar engine for the power source.

Overspeed Verify This feature is used to test theOverspeed Shutoff Circuit. The shutoff circuit istripped at 75% of the Overspeed Shutoff Limit.

Parameter A parameter is a value or a limit thatis programmable. This helps determine specificcharacteristics or behaviors of the engine and/orvehicle.

Parameter Identifier (PID) The PID is a two digitcode or a three digit code which is assigned toeach component in order to identify data via thedata link to the ECM.

Passive Magnetic Speed Sensor This sensor is aspeed sensor that does not require a power and aground connection. The sensor produces a signalthat is based on the change in magnetic flux of aferrous metal gear near the sensing tip.

Password A password is a group of numericcharacters or a group of alphanumeric charactersthat is designed to restrict access to parameters.The electronic system requires correct passwordsin order to change Customer Specified Parameters(Customer Passwords) or certain enginespecifications (Factory Passwords). Passwords arealso required to clear certain diagnostic codes.

Personality Module or Ratings Personality Module This module is attached to the inside of theECM. The module contains all the instructions(software) for the ECM and the module contains theperformance maps for a specific horsepower family.

Power Cycled Power cycled happens whenpower to the ECM is cycled: on, off, and on. Powercycled refers to the action of cycling the keyswitchfrom any position to the OFF position, and to theSTART/RUN position.

Power Take-Off (PTO) The PTO operates withthe cruise control switches and the dedicatedPTO On/Off switch. This mode permits the settingof constant engine speeds or the mode permitsvarying the speed with either the accelerator pedalin the cab or a remote accelerator.

Power Train Data Link Refer to J1922 Data Linkor J1939 Data Link.


Powered Down Powered down occurs whenpower is removed from the ECM. Powered downrefers to the action of cycling the keyswitch fromany position to the OFF/RESET position.

Powered Up Powered up occurs when poweris applied to the ECM. Powered up refers to theaction of cycling the keyswitch from the OFF/RESETposition to the START position.

Primary Engine Speed/Timing Sensor Determinesthe position of the crankshaft for injection timing andengine speed. The primary engine speed/timingsensor is primarily used after the engine has started.

Pro-Link Pro-Link is an electronic service tool thatis hand-held. The tool is manufactured by MicroProcessor Systems, Inc. (MPSI). This tool is suppliedwith a Caterpillar cartridge in order to service aCaterpillar engine that is electronically controlled.

Progressive Shifting This is a method of quicklyupshifting through the lower gears without excessiveengine rpm in each gear. Shifts are made abovepeak torque but below rated rpm. If the engine isdriven to an excessively high engine rpm beforeshifting to the next gear, fuel is wasted. When theexcessively high engine rpm ranges are used, thetorque rise of the engine is not fully utilized. Thetwo steps LoGr 1 and LoGr 2 give the opportunityfor progressive shifting. LoGr 1 is typically set atno lower than peak torque plus 200 rpm. LoGr 2 istypically set at a point that is midway between theLoGr 1 rpm limit and the Top Engine Limit.

PTO Configuration This is a programmableparameter that determines the best use of the ECMinput and the ECM output for PTO applications.

Pulse Width Modulation (PWM) The PWM is asignal that consists of pulses that are of variablewidth. These pulses occur at fixed intervals. Theratio of TIME ON versus total TIME OFF can bevaried. This ratio is also referred to as a duty cycle.

g00284479Illustration 3

Rated Fuel Limit This term indicates the maximumallowable fuel position (longest injection pulse). Thisposition will produce rated power for this engineconfiguration.

Reference Voltage The Reference Voltage is aregulated voltage and a steady voltage that issupplied by the ECM to a sensor. The referencevoltage is used by the sensor to generate a signalvoltage.

Remote Shutdown The ECM disables the fuelinjection signal when the Remote Shutdown Switchis closed. This causes the ECM to shut down theengine. However, the ECM remains active. The airshutoff solenoid is not activated when the remoteshutdown switch is activated.

Remote Station Operation This is a location thatis outside of the vehicle cab. The functions suchas the engine speed control are typically used forsome type of PTO operation that is for pumpingor for some other application that uses the enginepower. These functions are controlled from theremote station.

Retarder Enable Signal The retarder enable signalinterfaces the ECM to the engine retarder. Thiswill restrict operation of the engine brake duringundesirable engine operating conditions. Oneoperating condition is at a time when the engineis being fueled.

Retarder Solenoids This refers to the engineretarder that is installed by Caterpillar. The solenoidsare driven directly by the Caterpillar ECM. Thesolenoids are not driven through an OEM installedrelay such as the auxiliary retarder.

Secondary Engine Speed/Timing Sensor Determines the position of the camshaft duringstart-up. The secondary engine speed/timing sensorwill be used if the signal from the primary enginespeed/timing sensor is lost.

Sensor The sensor is a device that is usedto detect a change in pressure, temperature, ormechanical movement. The information that isdetected is converted into an electrical signal.

Service Brake Pedal Position Switch This switchis typically a pressure switch that is supplied andinstalled by the OEM. This switch is normally closedwhen the brake pedal is in the released position.Depressing the brake will open the circuit.

Service Program Module (SPM) The serviceprogram module is a software program that is usedto adapt the electronic service tool to a specificengine application.


Short Circuit A short circuit is a condition that hasan electrical circuit that is inadvertently connectedto an undesirable point. An example of a shortcircuit is a wire which rubs against a vehicle frameand this rubbing eventually wears off the wireinsulation. Electrical contact with the frame is madeand a short circuit results.

Signal The signal is a voltage or a waveform thatis used in order to transmit information typicallyfrom a sensor to the ECM.

Speed Burp A Speed Burp is a sudden, brief,unwanted change in the engine rpm.

Standard SAE Diagnostic Communications DataLink Refer to the ATA Data Link.

Starting Aid Switch This switch is used for injectionof a starting aid in cold weather. An example of astarting aid is ether.

Static Timing Static timing is the basis for correctfuel timing and valve mechanism operation. Statictiming is determined by the timing ring and thealignment of the rear gear group.

Subsystem A Subsystem that is used in thisapplication is a part of the electronic system thatrelates to a particular function. An example of asubsystem is the throttle subsystem.

Supply Voltage The supply voltage is a constantvoltage that is supplied to a component in orderto provide electrical power that is required forthe component to operate. The power may begenerated by the ECM or the power may be batteryvoltage that is supplied by the vehicle wiring.

Suspect Parameter Number (SPN) The SPNis a three digit code which is assigned to eachcomponent in order to identify data via the data linkto the ECM. This is used for J1939 diagnostics.

System Configuration Parameters SystemConfiguration Parameters are Parameters that affectthe power rating family or emissions.

T-Harness The T-Harness is a test harness that isdesigned to connect into the vehicle harness or theengine harness. This connection allows a normalcircuit operation and the connection simultaneouslyprovides a breakout T in order to measure thesignals.

Terminating Resistor This is used to terminatethe J1939 CAN data link. Refer to the installationprocedures.

Theft Deterrent This feature uses a four digit codein order to prevent the engine from starting. Thefeature requires a password to be entered via theCAT ID.

Timing Calibration The timing calibration is theadjustment of an electrical signal. This adjustmentis made in order to correct the timing errorbetween the camshaft and the engine speed/timingsensors or between the crankshaft and the enginespeed/timing sensors.

Top Center This refers to the crankshaft positionwhen the engine piston position is at the highestpoint of travel. The engine must be turned in thenormal direction of rotation in order to reach thispoint.

Torque Limit This is a programmable parameterthat limits the maximum torque which is based onthe PTO configuration and PTO operation.

Total Tattletale The Total Tattletale is the totalnumber of changes to all the Customer SpecifiedParameters that are stored in the ECM.

Transducer (Timing Calibration Probe) This isa device that converts a mechanical signal toan electrical signal. This probe requires a powersource in order to operate.

Transmission Style The Transmission Style isa programmable parameter that designates thetype of transmission in the vehicle and the variouscircuits that are connected to the ECM. The relay forthe transmission, cruise control, PTO/idle set speed,and the operation of the exhaust brake are affectedby this parameter setting.

Trip Recorder The trip recorder is an aftermarketdevice that is dedicated to recording the parametersof the vehicle and the parameters of the operatingengine during the vehicle service. The trip recorderis used to analyze the driving habits and therecorder is used in order to produce the logs of thedriver.

Variable Valve Actuation Allows the engine tovary the closing of the valves in order to optimizeemissions and engine performance.

Vehicle Speed Sensor The vehicle speed sensoris an electromagnetic pickup that measures vehiclespeed from the rotation of gear teeth in the drivetrain of the vehicle.

Wastegate Solenoid Prevents pressurized air fromreaches the turbocharger wastegate. Allows theengine to build boost pressure beyond the presetwastegate setting.


i01938920

Electronic Service ToolsSMCS Code: 0785

Caterpillar electronic service tools are designed tohelp the service technician with the diagnosis andwith the repair of electronic engines. Several toolsare available to assist the service technician.

Required Service ToolsTable 1

Part Number DescriptionN/A 4 mm Allen Wrench

6V-2197 Transducer(Timing CalibrationProbe)

7X-1171 Transducer Adapter(TimingCalibration Probe)

7X-1695 Cable(Timing Calibration)1U-5804 Crimp Tool(12 to 18 AWG)1U-5805 Wire Removal Tool(14 AWG Wire)151-6320 Wire Removal Tool(16 and 18 AWG

Wire)167-9225 Harness(Service Tool Adapter)140-2266 Cable(Seventy-Pin Breakout)9U-7330

or146-4080

Digital Multimeter

Digital Multimeter(RS-232)190-8900 Connector Repair Kit

Two short jumper wires are needed to check thecontinuity of some wiring harness circuits. A longextension wire may also be needed to check thecontinuity of some wiring harness circuits.

Caterpillar Electronic Technician (Cat ET)Cat ET can display the following information:

Parameters

Diagnostic codes

Engine rating history

Driver and fleet trip segments

Histograms

Custom data

ECM date/time clock

Maintenance intervals

Cat ET can also be used to perform the followingfunctions:

Diagnostic tests

Sensor calibrations

Flash programming

Set parameters

Copy the configuration for ECM replacement.

Data logging

Snapshot recorder

The following components are required to use CatET to service the engine.

Table 2

Required Electronic Service Tools forthe Use of Cat ET

PartNumber

Description

Caterpillar Electronic TechnicianJERD2124 Electronic Technician Program (Cat ET)

JERD2125 Electronic Technician Truck Engine DataSubscriptionor

JERD2129 Electronic Technician Engine/MachineData Subscription171-4400(1) Communication Adapter II Gp237-7547(2) Adapter Cable As

(1) The 7X-1700 Communication Adapter Gp may also be used.(2) The 237-7547 Adapter Cable As is required to connect to the

USB port on computers that are not equipped with a RS232serial port.

Note: For more information regarding the use of CatET and the PC requirements for Cat ET, refer tothe documentation that accompanies your Cat ETsoftware.


Connecting Cat ET and the CommunicationAdapter II

g00647144Illustration 4(1) Personal computer (PC)(2) 196-0055 Adapter Cable As (PC Serial)(3) 171-4401 Communication Adapter II(4) 207-6845 Adapter Cable As

Note: Items (2), (3), and (4) are part of the171-4400 Communication Adapter II Gp.

Use the following procedure to connect Cat ET andthe Communication Adapter II.

1. Turn the keyswitch to the OFF/RESET position. Ifthe keyswitch is not placed in the OFF/RESETposition, the engine may start.

2. Connect cable (2) between the COMPUTERend of communication adapter (3) and theRS232 serial port of PC (1).

3. Connect cable (4) between the DATA LINK endof communication adapter (3) and the servicetool connector.

4. Turn the keyswitch to the ON position. IfCat ET and the communication adapter donot communicate with the ECM, refer toTroubleshooting, Electronic Service Tool Will NotCommunicate With ECM.

Optional Service ToolsTable 3

Part Number Description7X-6370 Adapter Cable As(Three-Pin

Breakout)8T-8726 Adapter Cable As(Three-Pin

Breakout)5P-7277 Voltage Tester9U-5103 Socket(Slotted)7X-1710 Multimeter Probe1U-5718 Vacuum Pump1U-8757 Tube(Fluid Sampling)169-7372 Fluid Sampling Bottle9S-9082 Engine Turning Tool198-4240

or1U-5470

Digital Pressure Indicator

Engine Pressure Group6V-9130 Temperature Adapter124-5643 Cable(Service Tool Breakout)125-3662 Cable(Sensor Bypass)157-4829 Cable Adapter(9 Pin J1939 Dash)7X-1403 Adapter Cable As(9 Pin Navistar

Dash)7X-1686 Cable Adapter(6 Pin Dash)139-4166 Data Link Cable As(Eighteen Feet)

i01902956

Replacing the ECMSMCS Code: 1901-510

Replacing the ECM with the Use ofthe ECM Replacement Feature fromthe Electronic Service Tool1. Ensure that the ECM is the problem by first

connecting a test ECM. This is a temporaryconnection. Hang the test ECM on the side ofthe engine. Refer to Troubleshooting, Test ECMMode.

2. If the test ECM repairs the problem, reconnectthe suspect ECM. Verify that the problem returnswhen the suspect ECM is reconnected.

3. Select the ECM Replacement Feature under theService/Copy Configuration menu and load theparameters from the failed ECM.


4. Temporarily connect the new ECM by connectingboth ECM connectors. Do not mount the ECMon the engine yet.

5. Flash program the Personality Module into thenew ECM if the personality module is not alreadyinstalled. The new ECM is shipped with a blankPersonality Module.

6. Use the ECM replacement feature in theelect

C15 Troubleshooting

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