CAT C15 Troubleshooting RENR5042

7/22/2019 CAT C15 Troubleshooting RENR5042

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RENR5042-03

January 2006

TroubleshootingC11, C13, C15 and C18 IndustrialEngines

JRE1-Up (Engine)WJH1-Up(Engine)LGK1-Up (Engine)GLS1-Up (Engine)


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i01658146

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave 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 hazard warningsare 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 or pictoriallypresented.

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.The warningsin 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 Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product 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 before youstart 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.


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RENR5042-03 3Table of Contents

Table of Contents

Troubleshooting Section

Electronic TroubleshootingSystem Overview .................................................... 5Electronic Service Tools .......................................... 6Electronic Display Module (If Equipped) ................. 8Replacing the ECM ................................................. 9Self-Diagnostics .................................................... 10Sensors and Electrical Connectors ....................... 10Engine Wiring Information .................................... 13

Programming ParametersProgramming Parameters ..................................... 15Customer Passwords ............................................ 15Factory Passwords ............................................... 15Factory Passwords Worksheet ............................. 16Flash Programming .............................................. 16

Injector Trim File ................................................... 17Service Information Report ................................... 17

System Configuration ParametersSystem Configuration Parameters ........................ 19

Troubleshooting without a Diagnostic CodeAlternator (Charging Problem) .............................. 26Battery .................................................................. 26Can Not Reach Top Engine RPM ......................... 26Coolant in Engine Oil ............................................ 28Coolant Temperature Is Too High ......................... 28ECM Will Not Accept Factory Passwords ............. 29ECM Will Not Communicate with Other Systems or

Display Modules .................................................. 29Electronic Service Tool Will Not Communicate withECM .................................................................... 29

Engine Cranks but Will Not Start .......................... 30Engine Has Early Wear ........................................ 32Engine Misfires, Runs Rough or Is Unstable ........ 33Engine Oil in Cooling System ............................... 34Engine Oil Temperature Is Too High ..................... 34Engine Stalls at Low RPM .................................... 35Engine Vibration ................................................... 35Engine Will Not Crank ........................................... 36Excessive Black Smoke ........................................ 37Excessive Engine Oil Consumption ...................... 38Excessive Fuel Consumption ............................... 38

Excessive Valve Lash ........................................... 39Excessive White Smoke ....................................... 39Exhaust Temperature Is Too High ......................... 40Fuel in Cooling System ......................................... 41Fuel Dilution of Engine Oil .................................... 41Intermittent Engine Shutdown ............................... 42Intermittent Low Power or Power Cutout .............. 43Low Engine Oil Pressure ...................................... 44Low Power/Poor or No Response to Throttle ....... 44Mechanical Noise (Knock) in Engine .................... 46Noise Coming from Cylinder ................................. 47Poor Acceleration or Response ............................ 47Valve Rotator or Spring Lock Is Free .................... 49

Troubleshooting with a Diagnostic CodeFlash Codes .......................................................... 50Diagnostic Codes .................................................. 50Diagnostic Code Cross Reference ....................... 51CID 0001 FMI 05 Cylinder #1 Injector open

circuit ................................................................... 54CID 0001 FMI 06 Cylinder #1 Injector short ......... 54

CID 0002 FMI 05 Cylinder #2 Injector opencircuit ................................................................... 55

CID 0002 FMI 06 Cylinder #2 Injector short ......... 55CID 0003 FMI 05 Cylinder #3 Injector open

circuit ................................................................... 55CID 0003 FMI 06 Cylinder #3 Injector short ......... 56CID 0004 FMI 05 Cylinder #4 Injector open



circuit ................................................................... 57

CID 0006 FMI 06 Cylinder #6 Injector short ......... 57CID 0041 FMI 03 8 Volt DC Supply short to +batt .. 58CID 0041 FMI 04 8 Volt DC Supply short to

ground ................................................................. 58CID 0091 FMI 08 Throttle Position signal

abnormal ............................................................. 58CID 0091 FMI 13 Throttle Position calibration

required ............................................................... 59CID 0094 FMI 03 Fuel Pressure open/short to

+batt .................................................................... 59CID 0094 FMI 04 Fuel Pressure short to ground .. 59CID 0100 FMI 03 Engine Oil Pressure open/short to

+batt .................................................................... 59CID 0100 FMI 04 Engine Oil Pressure short to

ground ................................................................. 60CID 0100 FMI 10 Engine Oil Pressure Sensor

abnormal rate ofchange ..................................... 60CID 0102 FMI 03 Boost Pressure Sensor short to

+batt .................................................................... 60CID 0102 FMI 04 Boost Pressure Sensor short to

ground ................................................................. 61CID 0102 FMI 10 Boost Pressure Sensor abnormal

rate of change ..................................................... 61CID 0110 FMI 03 Engine Coolant Temperature

open/short to +batt .............................................. 61CID 0110 FMI 04 Engine Coolant Temperature short

to ground ............................................................. 62CID 0111 FMI 02 Engine Coolant Level Sensor Loss

of Signal .............................................................. 62CID 0168 FMI 00 System Voltage High ................ 62CID 0168 FMI 01 System Voltage Low ................. 62CID 0168 FMI 02 System Voltage intermittent/

erratic .................................................................. 63CID 0172 FMI 03 Intake Manifold Air Temp open/short

to +batt ................................................................ 63CID 0172 FMI 04 Intake Manifold Air Temp short to

ground ................................................................. 63CID 0174 FMI 03 Fuel Temperature open/short to

+batt .................................................................... 64CID 0174 FMI 04 Fuel Temperature short to

ground ................................................................. 64CID 0190 FMI 08 Engine Speed signal abnormal .. 64


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4 RENR5042-03Table of Contents

CID 0247 FMI 09 J1939 Data Linkcommunications .................................................. 65

CID 0253 FMI 02 Personality Module mismatch .. 65CID 0261 FMI 13 Engine Timing Calibration

required ............................................................... 65CID 0262 FMI 03 5 Volt Sensor DC Power Supply

short to +batt ....................................................... 66

CID 0262 FMI 04 5Volt Sensor DC Power Supplyshort to ground .................................................... 66

CID 0268 FMI 02 Check ProgrammableParameters ......................................................... 66

CID 0274 FMI 03 Atmospheric Pressure open/shortto +batt ................................................................ 67

CID 0274 FMI 04 Atmospheric Pressure short toground ................................................................. 67

CID 0342 FMI 08 Secondary Engine Speed signalabnormal ............................................................. 67

CID 0545 FMI 05 Ether Start Relay open/short to+batt .................................................................... 67

CID 0545 FMI 06 Ether Start Relay short toground ................................................................. 68

CID 0791 FMI 05 Compression Brake Low/HighSolenoid current low ........................................... 68

CID 0791 FMI 06 Compression Brake Low/HighSolenoid current high .......................................... 68

CID 0792 FMI 05 Compression Brake Medium/HighSolenoid current low ........................................... 69

CID 0792 FMI 06 Compression Brake Medium/HighSolenoid current high .......................................... 69

CID 1835 FMI 03 Auxiliary Pressure Sensoropen/short to +batt .............................................. 69

CID 1835 FMI 04Auxiliary Pressure Sensor short toground ................................................................. 69

CID 1836 FMI 03 Auxiliary Temperature Sensoropen/short to+batt .............................................. 70

CID 1836 FMI 04 Auxiliary Temperature Sensor shortto ground ............................................................. 70

CID 2417 FMI 05Ether Injection Control Solenoidcurrent low .......................................................... 70

CID 2417 FMI 06 Ether Injection Control Solenoidcurrent high ......................................................... 70

Troubleshooting with an Event CodeEvent Codes ........................................................ 72E057 Low Engine Coolant Level Derate ............... 75E058 Low Engine Coolant Level Shutdown .......... 76E059 Low EngineCoolant Level Warning ............ 77E096 High Fuel Pressure ...................................... 77E360 Low Engine Oil Pressure ............................. 78

E361 High Engine Coolant Temperature .............. 78E362 Engine Overspeed ....................................... 80E363 High Fuel Supply Temperature .................... 80E443 High Auxiliary Pressure ............................... 81E445 High Auxiliary Temperature ......................... 81E539 High Intake Manifold Air Temperature ......... 81

Diagnostic Functional Tests5 Volt Engine Pressure Sensor Supply Circuit -

Test ..................................................................... 83Air Shutoff System - Test ...................................... 90CAN Data Link Circuit - Test ................................. 97

Cat Data Link Circuit - Test ................................. 101Coolant Level Sensor Circuit - Test .................... 104Compression Brake Solenoid Circuit - Test ........ 108Diagnostic Lamp Circuit - Test ............................. 117Digital Sensor Supply Circuit - Test .................... 121ECM/Personality Module - Test .......................... 125Electrical Connectors - Inspect ........................... 127

Electrical Power Supply Circuit - Test ................. 132Engine Pressure Sensor Open or Short Circuit -

Test ................................................................... 136Engine Speed/Timing Sensor Circuit - Test ........ 141Engine Temperature Sensor Open or Short Circuit -

Test ................................................................... 147Ether InjectionSystem - Test .............................. 154Injector Solenoid Circuit - Test ............................ 160Maintenance Due Lamp Circuit - Test ................. 168PTO Switch Circuit - Test .................................... 171Switch Circuits - Test .......................................... 176Throttle Position Sensor Circuit - Test ................ 179Warning Lamp Circuit - Test ................................ 184

Calibration ProceduresEngine Speed/Timing Sensor - Calibrate ............ 188Throttle Position Sensor - Calibrate .................... 191

Index Section

Index ................................................................... 193


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RENR5042-03 5Troubleshooting Section

Troubleshooting Section

Electronic Troubleshooting

i02397878

System Overview

SMCS Code: 1900

System Operation

This engine is electronically controlled. Each cylinderhas an electronic unit injector. The Electronic ControlModule (ECM) sends a signal to each injectorsolenoid in order to control the operation of the fuelinjection system.

Electronic Controls

The electronic system consists of the followingcomponents: the ECM, the Mechanically ActuatedElectronically Controlled Unit Injectors (MEUI), thewiring harness, the switches, and the sensors. TheECM is the computer. The flash file is the softwarefor the computer. The flash file contains the operatingmaps. The operating maps define the followingcharacteristics of the engine:

Horsepower

Torque curvesThe ECM determines the timing and the amount offuel thatis delivered to the cylinders. These decisionsare based on the actual conditions and/or on thedesired conditions at any given time.

The ECM compares the desired engine speed tothe actual engine speed. The actual engine speedis determined through a signal from the enginespeed/timing sensor. The desired engine speed isdetermined with the following factors:

Throttle signal

Other input signals from sensors

Certain diagnostic codes

If the desired engine speed is greater than the actualengine speed, the ECM injects more fuel in order toincrease the actual engine speed.

Cold Mode

The ECM limits engine power during cold modeoperation and the ECM modifies injection timingduring cold mode operation. Cold mode operationprovides the following benefits:

Increased cold weather starting capability

Reduced warm-up time

Reduced white smoke

Cold mode is activated whenever the enginetemperature falls below a predetermined value. Coldmode remains active until the engine temperaturerises above apredetermined value or until a timelimit is exceeded.

Fuel Injection

The ECM controls the amount of fuel that is injectedby varying the signals to the injectors. The injector willpump fuel only if the injector solenoid is energized.The ECM sends a high voltage signal to the solenoid.This high voltage signal energizes the solenoid. Bycontrolling the timing and the duration of the highvoltage signal, the ECM can control injection timingand the engine RPM.

The flash file inside the ECM sets certain limits onthe amountof fuel that can be injected. The FRCFuel Limit is used to control the air/fuel ratio forcontrol of emissions. The FRC Fuel Limit is a limitthat is based on the turbocharger outlet pressure.

A higher turbocharger outlet pressure indicates thatthere is more air in the cylinder. When the ECMsenses a higher turbocharger outlet pressure, theECM increases the FRC Fuel Limit. When the ECMincreases the FRC Fuel Limit, the ECM allowsmore fuelinto the cylinder. The FRC Fuel Limit isprogrammed into the ECM at the factory. The FRCFuel Limit cannot be changed.

The Rated Fuel Limit is a limit that is based on thepower rating of the engine and on engine rpm. TheRated Fuel Limit is similar to the rack stops and tothe torque spring on a mechanically governed engine.

The Rated Fuel Limit provides the power curvesand thetorque curves for a specific engine family andfor a specific engine rating. The Rated Fuel Limit isprogrammed into the ECM at the factory. The RatedFuel Limit cannot be changed.


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6 RENR5042-03Troubleshooting Section

Once the ECM determines the amount of fuel thatis required, the ECM must determine the timingof the fuel injection. The ECM calculates the topcenter position of each cylinder from the enginespeed/timingsensors signal. The ECM decides whenfuel injection should occur relative to the top centerposition and the ECM provides the signal to the

injector at the desired time. The ECM adjusts timingfor optimum engine performance, for optimum fueleconomy, and for optimum control of white smoke.

Programmable Parameters

Certain parameters that affect the engine operationmay be changed with Caterpillar ElectronicTechnician (ET). The parameters are stored inthe ECM, and some parameters are protectedfrom unauthorized changes by passwords. Thesepasswords are called factory passwords.

PasswordsSeveral system configuration parameters and mostlogged events are protected by factory passwords.Factory passwords are available only to Caterpillardealers. Refer to Troubleshooting, FactoryPasswords for additional information.

i02474292

Electronic Service Tools

SMCS Code: 0785

Caterpillar electronic service tools are designed tohelp the service technician perform the followingtasks:

Information access

System diagnostics

System calibrations

System configurations

Data link communications

Required Service Tools

The toolsthat are listed in Table 1 are required inorder to enable a service technician to perform thetest procedures that are found in this manual.

Table 1

Required Service Tools

PartNumber

Description

N/A 4 mm Allen Wrench

6V-2197 Transducer

7X-1171 Transducer Adapter

7X-1695 Cable As

146-4080 Digital Multimeter Gp (RS232)

7X-1710 Multimeter Probes

7X-6370 Adapter Cable As (3-PIN BREAKOUT)

208-0059 Adapter Cable As (70-PIN BREAKOUT)

257-8718 Adapter Cable As (120-PIN BREAKOUT)

167-9225 Harness (SERVICE TOOL ADAPTER)

1U-5804

Crimp Tool (12

AWG TO 18

AWG)175-3700 Connector Repair Kit (DEUTSCH DT)

Two short jumper wires are needed to check thecontinuity of some wiring harness circuits by shortingtwo adjacent terminals together in a connector. Along extension wire may also be needed to check thecontinuity of some wiring harness circuits.

Optional Service Tools

Table 2 lists the optional service tools that may beneeded during testing or repair.


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Table 2

Optional Service Tools

Part Number Description

198-4240

or1U-5470

Digital Pressure Indicator

Engine Pressure Group

4C-4075 Crimp Tool (4AWG TO 10AWG)

4C-4911(1) Battery Load Tester

5P-7277 Voltage Tester

6V-9130(2) Temperature Adapter (MULTIMETER)

8T-5319 Connector Tool Group

155-5176 AC/DC Current Probe

(1) Refer to Special Instructions, SEHS9249, Use of 4C-4911Battery Load Tester for 6, 8, and 12 Volt Lead Acid Batteriesand Special Instructions, SEHS7633, Battery Test Procedure.

(2) Refer to Special Instructions, SEHS8382, Use of the 6V-9130Temperature Adapter Group.

Caterpillar Electronic Technician(ET)

Cat ET can display the following information:

Parameters

Event codes

Diagnostic codes

Engine configuration

Cat ET can be used by the technician to perform thefollowing functions:

Diagnostic tests

Calibrations

Flash programming

ECM configuration

Table 3 lists the software that is required in order touse Cat ET.

Table 3

Software Requirements for Cat ET

PartNumber

Description

JERD2124 Single user license for Cat ET

JERD2129 Data Subscription for All Engines and

Machines

Note: For more information regarding the use ofCat ET and the PCrequirements for Cat ET, refer tothe documentation that accompanies your Cat ETsoftware.

Connecting Cat ET

Connecting with the Communication Adapter II

Table 4 lists the standard hardware that is required inorder to connect Cat ET.

Table 4

Standard Hardware for the Use of Cat ET


N/A Personal Computer (PC)

171-4400(1)Communication AdapterGp (CAT ET TO ECMINTERFACE)

237-7547(2) Adapter Cable As

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

Universal Serial Bus (USB) on computers that are not equippedwith a RS232 serial port.

g01178796Illustration 1

Connecting Cat ET

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

Note:Items (2), (3), and (4) are part of the 171-4400Communication Adapter Gp.

Use the following procedure in order to connect CatET and the Communication Adapter II.

1. Remove the electrical power from the ECM.


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2. Connect cable (2) between the COMPUTERend of communication adapter (3) and the RS232serial port of PC (1).

Note: The 237-7547 Adapter Cable As is requiredto connect to the USB port on computers that are notequipped with a RS232 serial port.

3. Connect cable (4) between the DATA LINK endof communication adapter (3) and the service toolconnector.

4. Restore the electrical power to the ECM. IfCat ET and the communication adapter donot communicate with the Electronic ControlModule (ECM), refer to troubleshooting withouta diagnostic code Troubleshooting, ElectronicService Tool Will Not Communicate with ECM.

Communicating with the Wireless CommunicationAdapter

Table 5 lists the optional hardware that is neededin order to connect Cat ET by using a wirelessconnection.

Table 5

Optional Hardware for the Use of Cat ET


N/A Personal Computer (PC)

261-3363(1) Wireless Communication

Adapter Gp

(1)

Refer to Tool Operating Manual, Using the 261-3363Wireless Communication Adapter Gp for information that isrelated to the installation and the configuration.


(1) Personal computer (PC)(5) 261-4867 Card (PCMCIA)(6) 239-9955 Communication Radio Gp(7) 259-3183 Data Link Cable As

Note:Items (5), (6), and (7) are part of the 261-3363Wireless Communication Adapter Gp.

Use the following procedure in order to connect thewireless communication adapter for use with Cat ET.

1. Remove the electrical power from the ECM.

2. Ensure that the computer has been correctlyconfigured for the 261-4867 Card (PCMCIA).Verify that the PC card is installed in thecomputers PCI expansion slot.

3. Connect cable (7) between communication radio(6) and the service tool connector.

4. Restore the electrical power to the ECM. If Cat ETand the communication radio do not communicatewith the ECM, refer to troubleshooting withouta diagnostic code Troubleshooting, ElectronicService Tool Will Not Communicate with ECM.

i02139021

Electronic Display Module(If Equipped)

SMCS Code: 7490

An electronic display module may be used todisplay CID-FMI information from the electroniccontrol system. Refer to the service manual for yourelectronic display module for more information.


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i02471359

Replacing the ECM

SMCS Code:1901-510

NOTICE

Care must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

The Electronic Control Module (ECM) contains nomoving parts. Replacement of the ECM can becostly. Replacement can also be a time consumingtask. Followthe troubleshooting procedures in thismanual in order to ensure that replacing the ECM willcorrect the problem. Verify that the suspect ECM isthe cause ofthe problem.

Note: Ensure that the ECM is receiving powerand that theECM is properly wired to the negativebattery circuit before a replacement of the ECM isattempted. Refer to the diagnostic functional testTroubleshooting, Electrical Power Supply Circuit -Test.

Some application software supports the use of anECM as a test ECM. A test ECM can be temporarilyused to replace a suspect ECM in order to determineif the suspect ECM is faulty. Refer to programmingparameters Troubleshooting, Test ECM Mode forinformation on using an ECM as a test ECM. Installa test ECMin place of the suspect ECM. Flashprogram the correct flash file into the test ECM.Program the parameters for normal operation of theengine.The parameters must match the parametersin the suspect ECM. Refer to the following test stepsfor details. If the test ECM resolves the problem,replacethe suspect ECM with a new ECM.

NOTICEIf the flash file andengine application are not matched,engine damage may result.

Perform the following procedure in order to replacethe ECM:

1. Record the configuration data:

a. Connect Cat ET to the service toolconnector. Refer to electronic troubleshooting

Troubleshooting, Electronic Service Tools.

b. Print the parameters from the Configurationscreen on Cat ET. If a printer is unavailable,record all of the parameters. Record anylogged diagnostic codes and logged eventcodes for your records. Record the injectorcodes from the Calibrations screen in theService menu on Cat ET.

c. Use the Copy Configuration/ECMReplacement feature that is found under theService menu on Cat ET. Select Load fromECM in order to copy the configuration data

from the suspect ECM.

Note: If the Copy Configuration process fails andthe parameters were not obtained in Step 1.b, theparameters must be obtained elsewhere. Some of theparameters are stamped on the engine informationplate. Most of the parameters must be obtained fromthe factory.

2. Remove the ECM:

a. Remove the electrical power from the ECM.

b. Disconnect the P1 and P2 connectors from

the ECM.

NOTICEUse a suitable container to catch any fuel that mightspill. Clean up any spilled fuel immediately.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

c. Remove the fuel lines (if equipped) from theECM.

d. Disconnect the ECM ground strap.

e. Remove the mounting bolts from the ECM.

3. Install the replacement ECM:

a. Use the old mounting hardware to install thereplacement ECM.

b. Connect the fuel lines (if equipped).


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Note: Verify that the fuel lines are installed correctly.The fuel lines must not put tension on the ECM.Rubber grommets are used to protect the ECM fromexcessive vibration. The ECM should move slightly inthe rubber grommets. If the ECM cannot be movedslightly, check that the fuel lines are not pulling theECM against one side of the grommets.

c. Connect the ECM ground strap.

d. Connect the P1 and P2 connectors. Tightenthe ECM connector (allen head screw) to theproper torque. Refer to the diagnostic functionaltest Troubleshooting, Electrical Connectors -Inspect for the correct torque value.

4. Configure the replacement ECM:

a. Flash program the flash file into the ECM. Referto programming parameters Troubleshooting,Flash Programming.

b. Use Cat ET to match the engine applicationand the interlock code if the replacement ECMwas used for a different application.

c. If the Copy Configuration process fromStep 1.b was successful, return to the CopyConfiguration/ECM Replacement screen onCat ET and select Program ECM. Proceed toStep 4.e when programming is complete.

d. If the Copy Configuration process from Step1.b was unsuccessful, manually program theECM parameters. The parameters must match

the parameters from Step 1.b.

e. Program the engine monitoring system, ifnecessary.

f. Load the injector trim files for the injectors. Referto programming parameters Troubleshooting,Injector Trim File.

g. Calibrate the engine speed/timing. Referto calibration procedures Troubleshooting,EngineSpeed/Timing Sensor - Calibrate.

i02378227

Self-Diagnostics

SMCS Code: 1901

The Electronic Control Module (ECM) has the abilityto detect problems with the electronic system andwith engine operation. When a problem is detected, acode is generated. An alarm may also be generated.There are two types of codes:

Diagnostic

Event

Diagnostic Code When a problem with theelectronic system is detected, the ECM generates adiagnostic code. This indicates the specific problem

with the circuitry.

Diagnostic codes can have two different states:

Active

Logged

Active Code

An active diagnostic code indicates that an activeproblem has been detected. Active codes requireimmediate attention. Always service active codesprior to servicing logged codes.

Logged Code

Every generated code is stored in the permanentmemory of theECM. The codes are logged.

Logged codes may not indicate that a repair isneeded. The problem may have been temporary. Theproblem may have been resolved since the loggingof the code. If the system is powered, it is possibleto generatean active diagnostic code whenever acomponent is disconnected. When the component isreconnected, the code is no longer active. Loggedcodes may beuseful to help troubleshoot intermittent

problems. Logged codes can also be used to reviewthe performance of the engine and of the electronicsystem.

Event Code

An event code is generated by the detection of anabnormal engine operating condition. For example,an event code will be generated if the oil pressure istoo low. In this case, the event code indicates thesymptom of a problem.

i02431535

Sensors and ElectricalConnectors

SMCS Code: 1900-NS; 7553-WW


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C11 and C13 Engines


Locations of the sensors on C11 and C13 engines

(1) Engine coolant temperature sensor(2) Atmospheric pressure sensor(3) Secondary engine speed/timing sensor

(4) Fuel pressure sensor(5) Engine oil pressure sensor(6) Boost pressure sensor

(7) Fuel temperature sensor(8) Intake manifold air temperature sensor(9) Primary engine speed/timing sensor


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C15 and C18 Engines


Locations of the sensors on C15 and C18 engines

(1) Engine coolant temperature sensor(2) Secondary engine speed/timing sensor(3) Boost pressure sensor

(4) Fuel pressure sensor(5) Fuel temperature sensor(6) Intake manifold air temperature sensor

(7) Engine oil pressure sensor(8) Atmospheric pressure sensor(9) Primary engine speed/timing sensor

i02469003

Engine Wiring Information

SMCS Code: 1408

The wiring schematics are revised periodically.The wiring schematics will change as updates aremade to the machine harness. For the most currentinformation, always check the revision number of theschematic. Use the schematic with the latest revisionnumber.

Harness Wire IdentificationCaterpillar identifies all wires with eleven solid colors.The circuit number is stamped on the wire at a 25 mm(1 inch) spacing. Table 6 lists the wire colors and thecolor codes.

Table 6

Color Codes for the Harness Wire

Color Code Color Color Code Color

BK Black GN Green

BR Brown BU Blue

RD Red PU Purple

OR Orange GY Gray

YL Yellow WH White

PK Pink

For example, a wire identification of A701-GY on theschematic would signify a gray wire with the circuitnumber A701. A701-GY identifies the power circuitfor the No. 1 Injector solenoid.

Another wire identification on the schematic is thesize of the wire. The size of the wire will follow thewire color. Wire size or gauge is referred to as AWG(Americal Wire Gauge). AWG is a description of thediameter of the wire.


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For example, a code of 150-OR-14 on the schematicwould indicatethat the orange wire in circuit 150 is a14 AWG wire.

If the gauge ofthe wire is not listed, the wire is 16AWG.

Conversion ofAWG Numbers to MetricMeasurements

Table 7 shows the various AWG numbers that areused for the wires. The metric equivalent for thediameter of each AWG number are also shown.

Table 7

Metric Equivalents for AWG Numbers

AWGNumber

Diameter(mm)

AWGNumber

Diameter(mm)

20 0.8 14 1.6

18 1.0 12 2.0

16 1.3 4 3.2

Welding on a Machine that is Equippedwith an Electronic Control Module

Proper welding procedures are necessary in orderto avoid damage to the engines electronic controlmodule, sensors, and associated components. Thecomponent that requires welding should be removed.When welding on a machine that is equipped with anECM and removal of the component is not possible,

the following procedure must be followed. Thisprocedure provides the minimum amount of risk tothe electronic components.

NOTICEDo not ground the welder to electrical componentssuch as the ECM or sensors. Improper grounding cancause damage to the drive train bearings, hydrauliccomponents, electrical components, and other com-ponents.

Clamp the ground cable from the welder to the com-ponent that will be welded. Place the clamp as closeas possible to the weld. This will help reduce the pos-sibility of damage.

1. Stop the engine. Turn the keyswitch to the OFFposition.

2. Disconnect the negative battery cable from thebattery. If a battery disconnect switch is installed,open the switch.


Service welding guide (typical diagram)

3. Connect the welding ground cable as closeas possible to the area that will be welded.Components which may be damaged by weldinginclude bearings, hydraulic components, andelectrical/electronic components.

4. Protect the wiring harness from welding debrisand from spatter.

5. Weld the materials by using standard welding

methods.


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Programming Parameters

i02253984

Programming Parameters

SMCS Code: 1901

The Caterpillar Electronic Technician (ET) can beused to view certain parameters that can affect theoperation of the engine. Cat ET can also be usedto change certain parameters. The parameters arestored in the Electronic Control Module (ECM). Someof the parameters are protected from unauthorizedchanges by passwords. Parameters that can bechanged have a tattletale number. The tattletalenumber shows if a parameter has been changed.

i02419716

Customer PasswordsSMCS Code: 0785

Customer passwords may be used to protectcustomer parameters from being changed. Thepasswords are programmed into the ElectronicControl Module (ECM) with the Caterpillar ElectronicTechnician (ET). One password may be programmedor both passwords may be programmed. Ifcustomer passwords are not programmed, customerparameters may be changed by anyone.

To obtaincustomer passwords, contact the owner ofthe engine. If the owner has forgotten the customerpasswords, customer passwords may be read byusing CatET. Factory passwords are required inorder to read customer passwords.

Use the following procedure in order to read customerpasswords with Cat ET:

1. Select the Information menu. Then selectPasswords.

2. When theFactory Password screen appears,record the information that is listed on the FactoryPasswords Worksheet. Refer to programmingparameters Troubleshooting, Factory PasswordsWorksheet for additional information.

3. Obtainthe factory passwords. The informationthat is recorded on the Factory PasswordsWorksheet must be provided. When you obtainthe factory passwords, a permanent record of youraccess is generated at Caterpillar.

4. From the Factory Password screen, enter thefactory passwords.

5. When the Read Customer Passwords screenappears, record the customer passwords. Thecustomer passwords may then be used to changeparameters that are customer programmable.

i02433393

Factory PasswordsSMCS Code: 0785

NOTICEOperating the engine with a flash file not designed forthat engine will damage the engine. Be sure the flashfile is correct for your engine.

Note: Factory passwords are provided only toCaterpillar dealers.

Factory passwords are required to perform each of

the following functions:

Program a new Electronic Control Module (ECM).

When an ECM is replaced, the systemconfiguration parameters must be programmedinto the new ECM. A new ECM will allow theseparameters to be programmed once without factorypasswords. After the initial programming, someparameters are protected by factory passwords.

Clear event codes.

Most event codes require the use of factorypasswords to clear the code once the code hasbeen logged. Clear these codes only when you arecertain that the problem has been corrected.

Unlock parameters.

Factory passwords are required in order to unlockcertain system configuration parameters. Referto Troubleshooting, System ConfigurationParameters.

Since factory passwords contain alphabeticcharacters, the Caterpillar Electronic Technician (ET)must be used to perform these functions. In order toobtain factory passwords, proceed as if you alreadyhave the password. If factory passwords are needed,Cat ET will request the factory passwords and Cat ETwill display the information that is required to obtainthe passwords. For the worksheet that is used foracquiring factory passwords, refer to programmingparameters Troubleshooting, Factory PasswordsWorksheet.


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i02170328

Factory Passwords Worksheet

SMCS Code: 0785

Note: A mistake in recording these parameters will

result in incorrect passwords.

Table 8

Factory Passwords Worksheet

Dealer Code

Customers Name

Address

Telephone Number

Information From the Engine Information Plate

Engine Serial Number

Full Load Setting

Full Torque Setting

Information From the Vehicle Odometer

Engines Miles (km)

Information From the Factory Password EntryScreen on the Caterpillar Electronic Technician (ET)

Electronic Service ToolSerial Number


ECM Serial Number

Total Tattletale

Reason Code

From Interlock(1)

To Interlock(1)

Factory Passwords

Factory Password (No. 1)

Factory Password (No. 2)

(1) This parameter is required when the engine is being rerated.

This parameter is displayed only when the engine is beingrerated.

i02419726

Flash Programming

SMCS Code:1901-591

Flash Programming This is a method ofprogramming or updating the flash file in an enginesElectronic Control Module (ECM).

Caterpillar Electronic Technician (ET) is used to flashprogram a file into the memory of the engines ECM.

If you do not have the flash file, use the Flash FileSearch tool on the Service Technician Workbench(STW) to obtain the flash file for your engine.

Alternatively, use the Service Software Files feature

on SIS Web to obtain the flash file for your engine.You must have the engine serial number in order tosearch for the flash file. After locating the correctflash file, download the flash file to your PC. Writedown the name of the flash file for future reference.

Programming a Flash File

1. Establish communication between Cat ET and theengines ECM.

2. Select WinFlash from the Utilities menu on CatET.

Note: If WinFlash will not communicate with theECM, refer to troubleshooting without a diagnosticcode Troubleshooting, Electronic Service Tool WillNot Communicate with ECM.

3. Program the flash file into the ECM.

a. Select the engine ECM under the DetectedECMs.

b. Press the Browse button in order to select thename of the flash file that will be programmedinto the ECM.

c. When the correct flash file is selected, pressthe Openbutton.

d. Verify that the File Values match theapplication. If the File Values do not matchthe application, obtain the correct flash file.

e. When the correct flash file is selected, pressthe Begin Flash button.

f. Cat ET will indicate when flash programminghas been successfully completed.

4. Start theengine and check for proper operation.Repair any active diagnostic or event codes.

WinFlash Error Messages

If you receive any error messages during flashprogramming, click on the Cancel button in orderto stop the process. Access the information aboutthe ECM Summary under the Information menu.Make sure that you are flashing the correct file foryour engine.


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i02428583

Injector Trim File

SMCS Code: 1290

The Caterpillar Electronic Technician (ET) is used to

load the injector trim files into the Electronic ControlModule (ECM).

The injector trim files must be loaded into the ECM ifany of the following conditions occur:

An injector isreplaced.

The ECM is replaced.

Injector Code is displayed below a 268-02diagnostic code on Cat ET.

Injectors are exchanged between cylinders.

Exchanging Injectors

Exchanging injectors can help determine if acombustion problem is in the injector or in thecylinder. If two injectors that are currently installedin the engine are exchanged between cylinders,the injectortrim files can also be exchanged. Pressthe Exchange button at the bottom of the InjectorTrim Calibration screen on Cat ET. Select the twoinjectors that will be exchanged and press the OKbutton. The tattletale for the injectors that wereexchanged will increase by one.

Note: The injector serial number and the injectorconfirmation code are located on the injector.

1. Record the injector serial number and the injectorconfirmation code for each injector.

2. Click on Service Software Files in SIS Web.

3. Enter the serial number for the injector in thesearch field.

4. Download the injector trim file to the PC. Repeatthis procedure for each injector, as required.

5. Connect Cat ET to the service tool connector. Referto electronic troubleshooting Troubleshooting,Electronic Service Tools.

6. Select the following menu options on Cat ET:

Service

Calibrations

Injector Trim Calibration

7. Select the appropriate cylinder.

8. Click on the Change button.

9. Select the appropriate injector trim file from thePC.

10. Click on the Open button.

11. If you are prompted by Cat ET enter the injectorconfirmation code into the field.

12. Click on the OK button.

The injector trim file is loaded into the ECM.

13. Repeat the procedure for each cylinder, asrequired.

i02278907

Service Information Report

SMCS Code: 0336

After verifying the correct repair has been performedon the engine, it is critical to provide brief, detailedinformation. This information helps Caterpillar betterserve you and the customer.

Recommendations

Customers Complaint

Obtain as much information from the customeras possible. Investigate any written information

that is available and document any informationthat is gathered from the customer. The followinginformation is of particular importance:

Indicate if the diagnostic lamp was flashing.

Indicate if the warning lamp was flashing, or if thelamp was oncontinuously.

Indicate the symptoms of engine operation that arepresent.

Be as specific as possible.

Cause of Failure

Comments on the cause of failure should includethe number of diagnostic codes that were logged.Comments should also indicate if the code was anactive code. Indicate the source of the problem. Alsoindicate the method that was used to discover theproblem. Examples of the methods that were used todiscoverthe problem could be one of the followingmethods:

A specific procedure in the manual was followed.


18/196


A visual inspection indicated that wire abrasion onthe engine harness existed.

An engine dynamometer test indicated that thepower was below the specification at 1700 rpmdue to the loss of the no. 4 injector and an enginedynamometer test indicated that the power was

below the specification at all engine speeds above1700 rpm due to the loss of the no. 4 injector.


Repair Procedure

Comments on the repair procedure should includethe following types of information:

The wiring harness was repaired.

The Full LoadSetting (FLS) was changed per thefactorys instructions.



19/196


System ConfigurationParameters

i02427100

System ConfigurationParameters

SMCS Code: 1901

System configuration parameters are parametersthat affect the emissions and the power of the engine.Default values for the parameters are programmedat the factory. Some parameters may be changed bythe customer in order to suit the needs of the specificapplication.

Parameter Descriptions

Equipment ID

Equipment ID allows the customer to enter adescription into the Electronic Control Module (ECM)in order to identify the machine. A maximum of17 characters may be entered in the field. Thisparameter is only for reference by the customer. Thisparameter is not required.


Program the Engine Serial Number to match theengine serial number that is stamped on the engine

information plate. If the ECM is replaced, the engineserial number from the engine information plate mustbe programmed into the new ECM.

Note: When you are requesting factory passwords,always use the engine serial number that isprogrammed in the ECM.

Rating Number

The Rating Number corresponds to the selectedset of performance maps for the application. Thisselected set of performance maps comes out of

several unique sets of maps that are resident in theflash file. The dealer and/or the OEM will need toselect the appropriate rating tier, if more than onerating tier is present. The rating tiers are A through E.

Note: Factory passwords are required in order tochange the Rating Number.

Top Engine Limit (TEL)


TEL is a customer programmable parameter thatdefines the maximum allowable engine speed formaximum power. TEL can be programmed up tothe maximum rated engine speed. TEL is definedalong the engines lug curve.

Engine Accel. Rate

Engine Accel. Rate determines the rate of changeof the engine speed (acceleration or deceleration)

during PTO operation. This rate of change is alsoused to achieve intermediate engine speed.

Low Idle Speed

Low Idle Speed is the minimum allowable operatingspeed for the engine. This parameter can beprogrammed between 600 and 1400 rpm.

PTO Mode

PTO Mode allows the ECM to be programmed toeither one of the two PTO configurations that are

available.

Ramp Up/Ramp Down When PTO Mode isprogrammed to Ramp Up/Ramp Down, the ECMallows PTO operation with traditional features.

Set/Resume When PTO Mode is programmedto Set/Resume, the ECM allows PTO operation withenhanced features.


20/196


High Idle Speed


High Idle Speed is the maximum no-load enginespeed when the throttle or the PTO switch is in themaximum position.

Note: High Idle Speed cannot be programmedlower than TEL.

Intermediate Engine Speed

Intermediate Engine Speed defines the speed

for the engine when the intermediate enginespeed switch is activated. This parameter can beprogrammed to any engine speed between Low IdleSpeed and TEL. Engine speed will increase orengine speed will decrease at the rate that is definedby the programmed value for Engine Accel. Rate.

Engine Power Trim

This parameter cannot be changed.

Maximum Engine Torque Limit


Engine Torque Limit can be used to limit torqueoutput to the programmed value when the torquelimit switch is activated.

FLS (Full Load Setting)

FLS is a number that represents the adjustment tothe fuel system that was made at the factory in orderto fine tune the fuel system. The correct value forthis parameter is stamped on the engine information

plate. Factory passwords are required in order tochange this parameter.

FTS (Full Torque Setting)

FTS is similar to FLS. Factory passwords arerequired in order to change this parameter.

Ether Control

Program the Ether Control to Enabled if anether injection system is installed on the engine.This allows the ECM to control ether injection. If

the engine is not equipped with ether, program thisparameter to Disabled.

Air Shutoff

Air Shutoff allows the ECM to be programmed foroperation of an air shutoff system. If this parameteris programmed to Installed, the ECM will activatethe air shutoff solenoid in the event of an engineoverspeed condition.


21/196


Note: If an engine overspeed condition occursand Air Shutoff is programmed to Enabled, theswitched power to the ECM must be cycled and theair shutoff solenoid must be manually reset beforethe engine will restart.

Maintenance Indicator Mode

The ECM records data that is related to equipmentmaintenance. The ECM will activate the maintenanceindicator lamp when scheduled maintenance isdue. The maintenance indicator lamp can be resetby actuating the maintenance clear switch. Themaintenanceinterval may be based on operatinghours or on fuel consumption. The ECM providesinformation that pertains to maintenance intervalsand the lastmaintenance that was performed.

PM1 Interval

PM1 Interval allows the customer to define themaintenance interval if Maintenance Indicator Modeis programmed to one of the manual options. Referto the engines Operation and Maintenance Manualfor more information.

Throttle Position Sensor

Program the Throttle Position Sensor to Installedif a throttle position sensor is used for desired speedcontrol. Otherwise program this parameter to NotInstalled.

Coolant Level Sensor

Program the Coolant Level Sensor to Installedif a coolant level sensor is installed on the engine.Otherwise program this parameter to Not Installed.

Direct Fuel Control Mode

Program the Direct Fuel Control Mode to Enabledif an external governor is used. Once this parameteris enabled, the governing system in the ECM isdisabled. Otherwise program this parameter toDisabled.

Aux Press Sensor Installation Status

ProgramAux Press Enable to Installed if anauxiliary pressure sensor is installed. This will allowthe Caterpillar Messenger Driver Information Displayto monitor the pressure of another system. Programthis parameter to Not Installed if an auxiliarypressure sensor is not installed.

Aux Temp Sensor Installation Status

Program Aux Temp Enable to Installed if anauxiliary temperature sensor is installed. This willallow the Caterpillar Messenger Driver InformationDisplay to monitor the temperature of anothersystem. Program this parameter to Not Installed if

an auxiliarytemperature sensor is not installed.


22/196


System Configuration Parameters

Table 9


Parameter Available Range or Options Default Required

Password

ECM Identification Parameters

Equipment ID 17 alphanumeric characters NOT PROGRAMMED None

Engine Serial Number 0XX00000 or XXX00000 0XX00000 None

ECM Serial Number Read Only (1)

Software Gp Part Number Software Dependent Read Only (1)

Software Gp Release Date Software Dependent Read Only (1)

Selected Engine Rating

Rating Number Software Dependent Customer

Rated Power Software Dependent Read Only (1)

Rated Peak Torque Software Dependent Read Only (1)

Top Engine Speed Range Software Dependent Read Only (1)

Test Spec Software Dependent Read Only (1)

Top Engine Limit Software Dependent Customer

Engine Accel. Rate 50 to 1000 50 None

Low Idle Speed 600 to 1400 700 None

PTO Mode Ramp Up/Ramp Down

Set/Resume Ramp Up/Ramp Down None

High Idle Speed 1800 to 2310 2310 Customer

Intermediate Engine Speed Programmed Low Idle to TEL 1100 None

Engine Power Trim This parameter cannot be changed.

Maximum Engine Torque Limit Software Dependent None

Customer Password #1 8 alphanumeric characters Blank Customer

Customer Password #2 8 alphanumeric characters Blank Customer

FLS (Full Load Setting) - 128 to 127 0 Factory

FTS (Full Torque Setting) -128 to 127 0 Factory

Ether Control No Ether

Continuous Flow No Ether None

Air Shutoff Enabled

Disabled Disabled None

Maintenance Indicator Mode

OFFAuto FuelAuto HourMan FuelMan Hour

OFF None

PM1 Interval100 to 750 Hours

or3785to 28390 L (1000 to 7500 US gal)

250 Hoursor

9463L (2500 US gal)None

Throttle Position Sensor Installed

Not Installed Not Installed None

(continued)


23/196


(Table 9, contd)


Parameter Available Range or Options Default Required

Password

Coolant Level On Installed

Not Installed Not Installed None

Direct Fuel Control Mode Installed

Not Installed Not Installed Factory

Last Tool to change CustomerParameters

Read Only (1)

Last Tool to change SystemParameters

Read Only (1)

Aux Temp Sensor InstallationStatus

OnOff

Off None

Aux Press Sensor InstallationStatus

OnOff

Off None

Total Tattletale Read Only (1)

(1) The parameter can only be viewed. No changes are allowed.

Parameters Worksheet

Note: A mistake in recording this information willresult in incorrect passwords.

Table 10

Engine Parameters

ECM Identification Parameters

Equipment ID


ECM Serial Number

Software Gp Part Number

Software Gp ReleaseDate

Selected Engine Rating

Rating Number

Rated Power

Rated Peak Torque

Top Engine Speed Range

Test Spec

Top Engine Limit

Engine Accel Rate

(continued)

(Table 10, contd)

Engine Parameters

Low Idle Speed

PTO Mode

High Idle Speed

Intermediate EngineSpeed

Engine Power Trim

Maximum Engine TorqueLimit

Customer Password #1

Customer Password #2

FLS

FTS

Ether Control

Air Shutoff

Maintenance IndicatorMode

PM1 Interval


(continued)


24/196


(Table 10, contd)

Engine Parameters

Coolant Level Sensor


Last Tool to changeCustomer Parameters

Last Tool to changeSystem Parameters

Aux Press TempInstallation Status

Aux Press SensorInstallation Status

Total Tattletale

Information from Engine Information Plate


FLS

FTS

Injector Codes

Injector Code (1)

Injector Code (2)

Injector Code (3)

Injector Code (4)

Injector Code (5)

Injector Code (6)

Note: Compare the FLS and the FTS from theECM with the values that are listed on the engineinformation plate. Only change the FLS and the FTSbecause of a mechanical change in the engine. Theuse of the wrong parameters could cause damage to

the engine. The use of the wrong parameters mayalso void the Caterpillar warranty.

Monitoring System

The monitoring system determines the level of actionthat is taken by the ECM in response to a conditionthat can damage the engine. The monitoring of thevarious sensors by the ECM can be turned On orOff. These conditions are identified by the ECMfrom the signals that are produced from the followingsensors:

Engine oil pressure sensor

Engine coolant temperature sensor

Engine speed/timing sensors

Inlet air temperature sensor

Boost pressure sensor

Coolant levelsensor

Fuel temperature sensor

Fuel pressure sensor

Auxiliary temperature sensor

Auxiliary pressure sensor

The monitoring system can be locked out. In order

to change the settings, the monitoring system mustbe unlocked. Access the Parameter Lockout underthe Service menu on Cat ET in order to unlock themonitoring system.

Warnings, derates, and shutdowns can be disabledfor any parameter or for all of the parameters.


25/196


Table 11

Settings for the Monitoring System

Time Delay inSeconds

Set PointsParameter

EventCode

Action Default

ValueRange Default Range Default

Derate On 1 to 54 10

Shutdown Off 1 to 54 10Low Coolant Level E2143

Warning On 1 to 54 10

None

High Fuel Pressure E096 Warning On None 8 Maps are not programmable. (1)

Warning

DerateOn 8

Low Engine Oil Pressure E360

Shutdown Off

None

4

Maps are not programmable.(1)

Warning None 1085 C (185 F)

to110 C (230 F)

110 C(230 F)

Derate

On

1 to 54 1086 C (187 F)

to111 C (232 F)

High Engine CoolantTemperature

E361

Shutdown Off 1 to 54 1087 C (189 F)

to111 C (232 F)

111 C(232 F)

C11/C13

C15

1800-2600 2600Warning

C18 1800-2500 2500

C11/C13

C15

1800-2800 2800

Engine Overspeed E362

Shutdown

On None 1

C18 1800-2700 2700

Warning 1 to 54 3070 C (158 F)

to90 C (194 F)

90 C (194 F)

Derate

On

1 to 54 10High Fuel Temperature E363

Shutdown Off 1 to 54 10

71 C (160 F)to

91 C (196 F)91 C (196 F)

Warning On 1 to 54 4

Derate 1 to 54 3High Auxiliary Pressure(2) E443

ShutdownOff

1 to 54 3

0 kPa (0 psi)to

3150 kPa (457 psi)

1500 kPa(218 psi)

Warning On 1 to 54 4 105 C

(221 F)

Derate 1 to 54 4 106 C

(223 F)High AuxiliaryTemperature(2)

E445

Shutdown

Off

1 to 54 4

0 C (0 F)to

140 C (284 F)

107 C(224 F)

Warning None 8 75 C (167 F)High Engine Air InletTemperature

E539Derate

On1 to 54 8

None79 C (174 F)

(1) The maps may be different. The maps depend on the model of the engine.(2) The engine must be equipped with the appropriate sensor.


26/196


Troubleshooting without aDiagnostic Code

i02121176

Alternator(Charging Problem)

SMCS Code:1405-035

The connection of any electrical equipment andthe disconnection of any electrical equipment maycause an explosion hazard which may result in in-

jury or death. Do not connect any electrical equip-ment or disconnect any electrical equipment in anexplosive atmosphere.

Refer to Special Instruction, REHS0354, ChargingSystem Troubleshooting for the proper testingprocedures.

Probable Causes

Alternator drive belts

Charging circuit

Regulator

Alternator

Recommended Actions

Alternator Drive Belts

1. Inspect the condition of the alternator drive belts.If the alternator drive belts are worn or damaged,replace the belts.

2. Check the tension on the alternator drive belts.Adjust the tension, if necessary.

Charging Circuit

Inspect the battery cables, wiring, and connections inthe charging circuit. Clean all connections and tightenall connections. Replace any faulty parts.

Alternator or Regulator

Verify that the alternator or the regulator is operatingcorrectly. Refer to Special Instruction, REHS0354,Charging System Troubleshooting for the propertesting procedures. Repair the alternator or replacethe alternator, as needed.

i02475244

Battery

SMCS Code: 1401-035

Refer to Special Instruction, SEHS7633, BatteryTest Procedure for the proper testing procedures.

Probable Causes

Worn battery

Switched battery circuit

Recommended Actions

Worn Battery

1. Verify that the battery is no longer able to hold acharge.

2. Replace the battery.

Switched Battery Circuit

1. Verify that a switched battery circuit drained thebattery by being left in the ON position.

2. Charge the battery.

3. Verify thatthe battery is able to maintain a charge.

i02436323

Can Not Reach Top EngineRPM

SMCS Code: 1915-035

Note: If this problem occurs only under load, refer toTroubleshooting, Low Power/Poor or No Responseto Throttle.

Probable Causes

Diagnostic codes

Event codes


27/196


Programmable parameters

Cold mode

Derate due to high exhaust temperature

Throttle signal

Rated fuel position and/or FRC fuel position

Boost pressure sensor

Fuel supply

Air inlet and exhaust system

Accessory equipment

Recommended Actions

Diagnostic Codes and Event Codes

Certain diagnostic codes and/or event codes maycause poor performance. Connect the CaterpillarElectronic Technician (ET) and check for active codesand logged codes. Troubleshoot any codes that arepresent before continuing with this procedure.


Check the following parameters on Cat ET:


Desired Speed Input Configuration

Direct FuelControl Mode

Determine the type of throttle that is used in theapplication. Program the parameters to match thetype of throttle that is used. Refer to Troubleshooting,Throttle Position Sensor Circuit - Test for moreinformation.

Note: The engine will have poor performance if theparametersare not programmed correctly.

Cold ModeConnect Cat ET to the service tool connector. Verifythat the engine has exited cold mode. A status flagwill appear if the engine is operating in cold mode.This may limit engine speed.

High Exhaust Temperature

The engine may be derated due to high exhausttemperature. Connect Cat ET to the service toolconnector. Check for an active engine derate on thestatus screens.

Note: High exhaust temperature is a calculatedvalue. The engine does not have an exhausttemperature sensor.

Throttle Signal

Connect Cat ET to the service tool connector. View

the status forthe throttle position on the statusscreen. Operate the throttle from the low idle positionto the high idle position. The status should be 0percent at low idle and the status should be 100percent at high idle. If the status can not operatein the full range, refer to Troubleshooting, ThrottlePosition Sensor - Calibrate.

Diagnostic codes that are related to the J1939 datalink will prevent correct operation of the throttle if thethrottle position is transmitted over the data link. Ifthere is a problem with the data link, the engine willremain at low idle until the data link is repaired.

Boost Pressure Sensor, Rated Fuel

Position and/or FRC Fuel Position

1. With the engine at full load, monitor Fuel Positionand RatedFuel Limit on the status screen. IfFuel Position does not equal Rated Fuel Limitthen check air inlet manifold pressure.

2. Verify that there are no active diagnostic codesthat are associated with the boost pressure sensoror with theatmospheric pressure sensor.

3. Monitor boost pressure and atmospheric pressure

on the status screen for normal operation.

Note: Atmospheric pressure is not a defaultparameter on a status screen. You must manuallyselect the parameter for the atmospheric pressure inorder to monitor the atmospheric pressure sensor.

Fuel Supply

1. Check thefuel lines for the following problems:restrictions, collapsed lines, and pinched lines. Ifproblems are found with the fuel lines, repair thelines and/or replace the lines.

2. Check the fuel tank for foreign objects which mayblock the fuel supply.

3. Prime the fuel system if any of the followingprocedures have been performed:

Replacement of the fuel filters

Service on the low pressure fuel supply circuit

Replacement of unit injectors

Note: A sight glass in the low pressure supply line ishelpfulin diagnosing air in the fuel.


28/196


4. Cold weather adversely affects the characteristicsof the fuel. Refer to the Operation andMaintenance Manual for information on improvingthe characteristics of the fuel during cold weatheroperation.

5. Check the fuel pressure during engine cranking.

Check the fuel pressure on the outlet side ofthe fuel filter. Refer to Specifications for correctpressure values. If the fuel pressure is low,replace the fuel filters. If the fuel pressure is stilllow, check the following items: fuel transfer pump,fuel transfer pump coupling, and fuel pressureregulatingvalve.

Air Inlet and Exhaust System

1. Clean plugged air filters or replace plugged airfilters. Refer to the Operation and MaintenanceManual.

2. Check the air inlet and exhaust system forrestrictions and/or leaks. Refer to Testing and

Adjusting, Air Inlet and Exhaust System.

AccessoryEquipment

Check all accessory equipment for problems thatmay createexcessive load on the engine. Repairany damaged components or replace any damagedcomponents.

i02381103

Coolant in Engine OilSMCS Code:1348-035; 1395-035

ProbableCauses

Engine oil cooler core

Cylinder head gasket

Cylinderhead

Cylinder liner

Cylinder block

Recommended Actions

Engine Oil Cooler Core

1. Check for leaks in the oil cooler core. If a leak isfound, install a new oil cooler core. Refer to theDisassembly and Assembly manual.

2. Drain the crankcase and refill the crankcase withclean engine oil. Install new engine oil filters.Refer to the Operation and Maintenance Manual.

Cylinder HeadGasket

1. Remove the cylinder head. Refer to the

Disassembly and Assembly manual.

2. Check the cylinder liner projection. Refer to theSystems Operation/Testing and Adjusting manual.

3. Install a new cylinder head gasket and new waterseals in the spacer plate. Refer to the Disassemblyand Assembly manual.

Cylinder Head

Check for cracks in the cylinder head. If a crackis found, repair the cylinder head and/or replace

the cylinder head. Refer to the Disassembly andAssembly manual.

Cylinder Liner

Check for cracked cylinder liners. Replace anycracked cylinder liners. Refer to the Disassembly and

Assembly manual.

Cylinder Block

Inspect thecylinder block for cracks. If a crack isfound, repair the cylinder block or replace the cylinderblock.

i02194394

Coolant Temperature Is TooHigh

SMCS Code: 1395-035

Refer to Systems Operation/Testing and Adjusting,Cooling System - Check for information ondetermining the cause of this condition.


29/196


i02419115

ECM Will Not Accept FactoryPasswords

SMCS Code:1901-035

Probable Causes

One of the following items may not be recordedcorrectly on the Caterpillar Electronic Technician(ET):

Passwords

Serial numbers

Total tattletale

Reason code

Recommended Actions

1. Verify that the correct passwords were entered.Check every character in each password. Removethe electrical power from the engine for 30seconds and then retry.

2. Verify that Cat ET is on the Factory Passwordscreen.

3. Use Cat ET to verify that the following informationhas been entered correctly:

Engine serial number

Serial number for the electronic control module

Serial number for Cat ET

Total tattletale

Reason code

i02480112

ECM Will Not Communicate

with Other Systems or DisplayModules

SMCS Code:1901-035

Probable Causes

Wiring and/or electrical connectors

Cat Data Link

CAN data link (if equipped)

Electronic Control Module (ECM)

Recommended Actions

1. Check for correct installation of the connectors forthe Electronic Control Module (ECM) J1/P1, J2/P2and J3/P3. Refer to the diagnostic functional testTroubleshooting, Electrical Connectors - Inspect.

2. Connect the electronic service tool to theservice tool connector. If the ECM does notcommunicate with the electronic service tool,refer to troubleshooting without a diagnostic codeTroubleshooting, Electronic Service Tool Will NotCommunicate with ECM.

3. Troubleshoot the Cat Data Link for possibleproblems. Refer to the diagnostic functional testTroubleshooting, Cat Data Link Circuit - Test.

4. Troubleshoot the CAN data link (if equipped)for possible problems. Refer to the diagnosticfunctional test Troubleshooting, CAN Data LinkCircuit - Test.

i02429900

Electronic Service Tool WillNot Communicate with ECM

SMCS Code: 0785-035; 1901-035

Probable Causes

Configuration for the communications adapter

Electrical connectors

Communication adapter and/or cables

Electrical power supply to the service toolconnector

Caterpillar Electronic Technician (ET) and relatedhardware

Electrical power supply to the Electronic ControlModule (ECM)

Flash file

Cat Data Link


30/196


Recommended Actions

Start the engine. If the engine starts, but the ECMwill not communicate with Cat ET, continue withthis procedure. If the engine will not start, referto the troubleshooting without a diagnostic codeprocedure Troubleshooting, Engine Cranks but Will

Not Start. If the engine will not crank, refer to thetroubleshooting without a diagnostic code procedureTroubleshooting, Engine Will Not Crank.

Configuration for the Communications

Adapter

1. Access Preferences under the Utilities menuon Cat ET.

2. Verify that the correct Communications InterfaceDevice is selected.

3. Verify that the correct port is selected for use bythe communication adapter.

Note: The most commonly used port is COM 1.

4. Check for any hardware that is utilizing thesame port as the communications adapter. If anydevices areconfigured to use the same port, exitor close the software programs for that device.

Electrical Connectors

Check for correct installation of the J1/P1 andJ2/P2 ECM connectors and of the service tool

connector. Refer to the diagnostic functional testTroubleshooting, Electrical Connectors - Inspect.

Communication Adapter and/or Cables

1. If you are using a Communication Adapter II,ensure that the firmware and driver files for thecommunication adapter are the most current filesthat are available. If the firmware and driver filesdo not match, the communication adapter will notcommunicate with Cat ET.

2. Disconnect the communication adapter and thecables from the service tool connector. Reconnectthe communication adapter to the service toolconnector.

3. Verify that the correct cable is being used betweenthe communication adapter and the service toolconnector. Refer to electronic troubleshootingTroubleshooting, Electronic Service Tools.

Electrical Power Supply to the ServiceTool Connector

Verify that battery voltage is present betweenterminals A and B of the service tool connector. If thecommunication adapter is not receiving power, thedisplay on the communication adapter will be blank.

Cat ET and Related Hardware

In order to eliminate Cat ET and the related hardwareas the problem, connect Cat ET to a different engine.If the same problem occurs on a different engine,check Cat ET and the related hardware in order todetermine the cause of the problem.

Electrical Power Supply to the ElectronicControl Module (ECM)

Check power to the ECM. Refer to the diagnostic

functional test Troubleshooting, Electrical PowerSupply Circuit - Test.

Note: If the ECM is not receiving battery voltage, theECM will not communicate.

Flash File

Ensure thatthe correct flash file is properly installedin the ECM.

Note: A new ECM is not programmed to any specificengine until a flash file has been installed. The engine

will not start and the engine will not communicatewith Cat ETuntil the flash file has been downloaded.Refer to programming parameters Troubleshooting,Flash Programming.

Cat Data Link

Troubleshoot the Cat Data Link for possibleproblems. Refer to the diagnostic functional testTroubleshooting, Cat Data Link Circuit - Test.

i02431479

Engine Cranks but Will NotStart

SMCS Code: 1000-035

Probable Causes

Fuel supply

Diagnostic codes and event codes


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Electrical power to the Electronic Control Module(ECM)

Starting aids

Engine shutdown switches

Air shutoff system

Starting motor, solenoid, or starting circuit

Engine speed/timing

Unit injector

Combustion

Recommended Actions

Fuel Supply

1. Visually check the fuel level. Do not rely on the fuelgauge only. If necessary, add fuel. If the enginehas been run out of fuel, it will be necessaryto purge the air from the fuel system. Refer toOperation and Maintenance Manual, Fuel System- Prime for the correct procedure.

2. Check the fuel lines for the following problems:restrictions, collapsed lines, and pinched lines. Ifproblems arefound with the fuel lines, repair thelines and/or replace the lines.

3. Check the fuel tank for foreign objects which may

block the fuel supply.

4. Prime the fuel system if any of the followingprocedures have been performed:

Replacement of the fuel filters

Service on the low pressure fuel supply circuit

Replacement of unit injectors

Note: A sight glass in the low pressure supply line ishelpful in diagnosing air in the fuel. Refer to Testingand Adjusting for more information.

5. Check the fuel filters.

6. Cold weather adversely affects the characteristicsof the fuel. Refer to the Operation andMaintenance Manual for information on improvingthe characteristics of the fuel during cold weatheroperation.

7. Check the fuel pressure during engine cranking.Check the fuel pressure after the fuel filter. Referto Systems Operation/Testing and Adjusting, FuelSystem for the correct pressure values. If the fuelpressure is low, replace the fuel filters. If the fuelpressure is still low, check the following items: fueltransfer pump, fuel transfer pump coupling, and

fuel pressure regulating valve.

Diagnostic Codes and Event Codes

Certain diagnostic codes and/or event codes mayprevent the engine from starting. Connect theCaterpillarElectronic Technician (ET) and check foractive codes and/or for logged codes. Troubleshootany codes that are present before continuing withthis procedure.

Electrical Power Supply to the ECM

If the ECM is not receiving battery voltage, the ECMwill not operate. Refer to Troubleshooting, ElectricalPower Supply Circuit - Test.

Starting Aids

If cold ambient conditions exist, check operation ofstarting aids. Verify that the ether system is operatingcorrectly. Refer to Troubleshooting, Ether InjectionSystem - Test.

Engine Shutdown Switches

The engine shutdown switches must be in the RUN

positionin order to start the engine. Use Cat ET toverify the status of the shutdown switches. When anengine shutdown switch is used to shut down theengine, the keyswitch must be turned to the RUNposition for at least 15 seconds before restarting theengine.

Air Shutoff System

Check theair shutoff mechanism. If an engineoverspeed has occurred, the keyswitch must becycled. There may be a manual reset for the airshutoffmechanism that is on the engine. Refer to

Troubleshooting, Air Shutoff System - Test forinformation.

Starting Motor, Solenoid, or Starting

Circuit

Remove the starter and visually inspect the pinion ofthe starter and the flywheel ring gear for damage.

Test the operation of the starting motor solenoid.Check the condition of the engine wiring for thestarting motor solenoid. Test the operation of thestarting motor.


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If necessary, repair the starter or the starter circuit.

Engine Speed/Timing

1. Crank the engine and observe the engine speedon the Cat ET status screen. If Cat ET indicateszero rpm, refer to Troubleshooting, Engine

Speed/TimingSensor Circuit - Test.

Note: Upon initial cranking, the status for enginespeed may indicate that the engine speed signal isabnormal. This message will be replaced with anengine speed once the ECM is able to calculate aspeed from the signal.

2. If an engine speed is present, check the sensorinstallation. If the sensor is not properly installed,the ECM may read engine speed, but the ECMcannot determine the tooth pattern. The ability forthe ECM to read the tooth pattern is necessaryto determine the cylinder position. Engine speedis present when engine speed is greater than50 rpm. Refer to Troubleshooting, EngineSpeed/Timing Sensor Circuit - Test.

Unit Injector

1. Ensure that the valve cover connectors for theinjector harnesses are fully connected and free ofcorrosion.

2. Perform the Injector Solenoid Test on Cat ET inorder to determine if all of the injector solenoidsare being energized by the ECM. Refer to

Troubleshooting, Injector Solenoid Circuit - Testfor additional information.

Combustion

Check the engine for combustion problems.

i02170800

Engine Has Early Wear

SMCS Code:1000-035

Probable Causes Incorrect engine oil

Contaminated engine oil

Contaminated air

Contaminated fuel

Low oil pressure

Recommended Actions

Incorrect Engine Oil

Use engine oil that is recommended and change theengine oil at the interval that is recommended by theengines Operation and Maintenance Manual.

Contaminated Engine Oil

Drain the crankcase and refill the crankcase withclean engine oil. Install new engine oil filters. Referto the engines Operation and Maintenance Manualfor more information.

If the oil filter bypass valve is open, the oil will not befiltered. Check the oil filter bypass valve for a weakspring or for a broken spring. If the spring is broken,replace the spring. Refer to the engines Disassemblyand Assembly manual. Make sure that the oil bypass

valve is operating correctly.

Contaminated Air

Inspect theair inlet system for leaks. Inspect all ofthe gaskets and the connections. Repair any leaks.

Inspect theair filter. Replace the air filter, if necessary.

Contaminated Fuel

Inspect the fuel filter. Replace the fuel filter, ifnecessary.

Contaminants in the fuel such as hydrogen sulfideand sulfur can lead to the formation of acids in thecrankcase. Obtain a fuel analysis.

Low Oil Pressure

When some components of the engine show bearingwear in a short time, the cause can be a restriction ina passage for engine oil.

An indicator for the engine oil pressure may indicatesufficient pressure, but a component is worn dueto a lack of lubrication. In such a case, look at the

passage for the engine oil supply to the component.Refer to Systems Operation/Testing and Adjusting,Lubrication System for additional information.


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i02424560

Engine Misfires, Runs Roughor Is Unstable

SMCS Code:1000-035

Note:If the symptom is intermittent and the symptomcannot be repeated, refer to Troubleshooting,Intermittent Low Power or Power Cutout. If thesymptom is consistent and the symptom can berepeated, continue with this procedure.

Probable Causes

Diagnostic codes

Programmable parameters

Electrical connectors

Cold mode

Throttle signal

Unit injectors

Fuel supply

Air inlet and exhaust system

Recommended Actions

Note: If the symptom only occurs under certainoperating conditions (high idle, full load, engineoperating temperature, etc), test the engine underthose conditions. Troubleshooting the symptomunder other conditions can give misleading results.

Diagnostic Codes

Check for active diagnostic codes on the CaterpillarElectronic Technician (ET). Troubleshoot any activecodes before continuing with this procedure.


Check the following parameters on Cat ET:



Determine the type of throttle that is used in theapplication. Program the parameters to match thetype of throttle that is used. Refer to Troubleshooting,Throttle Position Sensor Circuit - Test for moreinformation.

Note: The engine will have poor performance if theparameters are not programmed correctly.

Electrical Connectors

Check the connectors for the Electronic ControlModule (ECM) and the connectors for theunit injectors for correct installation. Refer toTroubleshooting, Electrical Connectors - Inspect.

Cold Mode

Use Cat ET to verify that the engine has exited coldmode. Cold mode operation may cause the engine torun rough and the engine power may be limited.

Throttle Signal

Monitor the throttle signal on Cat ET. Verify that thethrottle signal is stable from the low idle position tothe high idle position.

Unit Injectors

1. Use Cat ET to determine if there are any activediagnosticcodes for the unit injectors.

2. Perform the injector solenoid test on Cat ET inorder to determine if all of the injector solenoidsare being energized by the ECM. Refer toTroubleshooting, Injector Solenoid Circuit - Testfor the proper procedure.

3. Perform the cylinder cutout test on Cat ET in orderto identifyany injectors that might be misfiring.Refer to Troubleshooting, Injector SolenoidCircuit - Test for the proper procedure.

Fuel Supply

1. Check the fuel lines for the following problems:restrictions, collapsed lines, and pinched lines. Ifproblems are found with the fuel lines, repair thelines and/or replace the lines.

CAT C15 Troubleshooting RENR5042

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