Troubleshooting Ingles Scan

RENR5910February 2002

TroubleshootingG3612 and G3616 EnginesBLB1-Up (Engine)BKE1-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 .................................................. 10Electrical Connectors and Functions .................... 12Electronic Service Tools ........................................ 18Engine Monitoring System .................................... 21

Programming ParametersProgramming Parameters ..................................... 22Customer Passwords ............................................ 22Factory Passwords ................................................ 22Flash Programming .............................................. 23System Configuration Parameters ........................ 24Factory Passwords Worksheet ............................. 25Replacing the ECM ............................................... 25Replacing the ICSM .............................................. 26Troubleshooting Data Sheet ................................. 28

Troubleshooting without a Diagnostic CodeSymptoms ............................................................. 31Air Starting Motor .................................................. 31Crankcase Pressure (High) .................................. 32Detonation ............................................................ 33Driven Equipment ................................................. 34ECM Will Not Accept Factory Passwords ............. 35Electrohydraulic System Oil Pressure (Low) ......... 35Electronic Service Tool Will Not Communicate withECM or ICSM ...................................................... 36

Engine Coolant Temperature (High) ..................... 37Engine Coolant Temperature (Low) ...................... 39Engine Cranks but Will Not Start .......................... 39Engine Misfires, Runs Rough or Is Unstable ........ 41Engine Oil Filter Differential Pressure ................... 43Engine Oil Pressure (Low) .................................... 43Engine Oil Temperature (High) ............................. 44Engine Overcrank ................................................. 45Engine Overload ................................................... 46Engine Overspeed ................................................ 46Engine Pre-Lube Pressure (Low) ......................... 47Engine Shutdown .................................................. 48Engine Shutdown (Unexpected) ........................... 48Engine Shutdown without a Diagnostic Code ....... 50Engine Starts but Stalls Immediately .................... 50Excessive Engine Oil Consumption ...................... 51Exhaust Emission Too High/Fuel Consumption TooHigh ..................................................................... 52

Exhaust Port Temperature (High) ......................... 53Exhaust Port Temperature (Low) .......................... 54Fuel Energy Content ............................................. 55Fuel Pressure ....................................................... 55Gas Temperature (High) ....................................... 56Inlet Air Temperature (High) .................................. 56Intermittent Engine Shutdown ............................... 57Jacket Water Inlet Pressure (High) ....................... 58Jacket Water Pressure (Low) ................................ 58Jacket Water to Engine Oil Differential Temperature(Low) ................................................................... 59

Mechanical Noise (Knock) in Engine .................... 59

Noise Coming from Cylinder (Noisy CylinderHead) .................................................................. 60

Poor Coolant Flow ................................................ 60System Voltage ..................................................... 61Short Spark Plug Life ............................................ 61Starting Motor Runs, Pinion Engages But Does NotTurn the Flywheel ................................................ 62

Too Much Vibration ............................................... 62Turbocharger Turbine Temperature (High) ............ 63Troubleshooting with a Diagnostic CodeDiagnostic Codes .................................................. 64MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve opencircuit ................................................................... 65

MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve shortto ground ............................................................. 66

MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valvemalfunction .......................................................... 66

MID 036 - CID 0041 - FMI 03 8 Volt DC Supply shortto +batt ................................................................ 66

MID 036 - CID 0041 - FMI 04 8 Volt DC Supply shortto ground ............................................................. 67

MID 036 - CID 0094 - FMI 03 Fuel Pressureopen/short to +batt .............................................. 67

MID 036 - CID 0094 - FMI 08 Fuel PressureNoisy ................................................................... 67

MID 036 - CID 0100 - FMI 03 Engine Oil Pressureopen/short to +batt .............................................. 68

MID 036 - CID 0100 - FMI 04 Engine Oil Pressureshort to ground .................................................... 68

MID 036 - CID 0101 - FMI 03 Crankcase Pressureopen/short to +batt .............................................. 68

MID 036 - CID 0101 - FMI 04 Crankcase Pressureshort to ground .................................................... 69

MID 036 - CID 0106 - FMI 03 Air Inlet PressureSensor short to +batt .......................................... 69

MID 036 - CID 0106 - FMI 08 Air Inlet PressureSensor noisy signal ............................................. 70

MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressureopen/short to +batt .............................................. 70

MID 036 - CID 0109 - FMI 08 Engine Coolant OutletPressure Sensor noisy signal ............................. 70

MID 036 - CID 0110 - FMI 03 Engine CoolantTemperature open/short to +batt ......................... 71

MID 036 - CID 0110 - FMI 04 Engine CoolantTemperature short to ground ............................... 71

MID 036 - CID 0168 - FMI 02 System Voltageintermittent/erratic ............................................... 71

MID 036 - CID 0172 - FMI 03 Intake Manifold AirTemp open/short to +batt .................................... 72

MID 036 - CID 0172 - FMI 04 Intake Manifold AirTemp short to ground .......................................... 72

MID 036 - CID 0174 - FMI 03 Fuel Temperatureopen/short to +batt .............................................. 73

MID 036 - CID 0174 - FMI 04 Fuel Temperature shortto ground ............................................................. 73

MID 036 - CID 0175 - FMI 03 Engine Oil Temperatureopen/short to +batt .............................................. 73

MID 036 - CID 0175 - FMI 04 Engine Oil Temperatureshort to ground .................................................... 74

MID 036 - CID 0190 - FMI 02 Loss of Engine Speedsignal ................................................................... 74

4Table of Contents

MID 036 - CID 0190 - FMI 08 Engine Speed signalabnormal ............................................................. 75

MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC PowerSupply short to +batt ........................................... 75

MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC PowerSupply short to ground ........................................ 75

MID 036 - CID 0301 - FMI 05 Cylinder 1 - TransformerPrimary open circuit ............................................ 76

MID 036 - CID 0301 - FMI 06 Cylinder 1 - TransformerPrimary short ...................................................... 76









MID 036 - CID 0306 - FMI 05 Cyinder 6 - TransformerPrimary open circuit ............................................ 79








MID 036 - CID 0310 - FMI 05 Cylinder 10 -Transformer Primary open circuit ........................ 82

MID 036 - CID 0310 - FMI 06 Cylinder 10 -Transformer Primary short .................................. 82













MID 036 - CID 0323 - FMI 03 Shutdown Lamp shortto +batt ................................................................ 87

MID 036 - CID 0324 - FMI 03 Warning Lamp short to+batt .................................................................... 88

MID 036 - CID 0336 - FMI 02 Incorrect ECS Switchinputs .................................................................. 88

MID 036 - CID 0338 - FMI 05 Pre-Lube Relay opencircuit ................................................................... 88

MID 036 - CID 0338 - FMI 06 Pre-Lube Relay shortto ground ............................................................. 88

MID 036 - CID 0339 - FMI 05 Engine Pre-lubePressure Switch open circuit ............................... 89

MID 036 - CID 0401 - FMI 05 Cylinder 1 - TransformerSecondary open circuit ....................................... 89

MID 036 - CID 0401 - FMI 06 Cylinder 1 - TransformerSecondary short to ground ................................. 90

















MID 036 - CID 0410 - FMI 05 Cylinder 10 -Transformer Secondary open circuit ................... 96

5Table of Contents

MID 036 - CID 0410 - FMI 06 Cylinder 10 -Transformer Secondary short to ground ............. 97







MID 036 - CID 0414 - FMI 05 Cylinder 14 -Transformer Secondary open circuit ................. 100

MID 036 - CID 0414 - FMI 06 Cylinder 14 -Transformer Secondary short to ground ........... 100





MID 036 - CID 0443 - FMI 03 Crank Terminate Relayshort to +batt ..................................................... 102

MID 036 - CID 0444 - FMI 05 Start Relay opencircuit ................................................................. 102

MID 036 - CID 0444 - FMI 06 Start Relay short toground ............................................................... 103

MID 036 - CID 0445 - FMI 03 Run Relay short to+batt .................................................................. 103

MID 036 - CID 0524 - FMI 03 Desired Engine SpeedSensor short to +batt ........................................ 103

MID 036 - CID 0524 - FMI 04 Desired Engine SpeedSensor short to ground ..................................... 104

MID 036 - CID 0525 - FMI 05 Choke Actuator opencircuit ................................................................. 104

MID 036 - CID 0525 - FMI 06 Choke Actuator shortto ground ........................................................... 104

MID 036 - CID 0526 - FMI 05 Wastegate Valveopen .................................................................. 105

MID 036 - CID 0526 - FMI 06 Wastegate Valveshort .................................................................. 105

MID 036 - CID 0542 - FMI 03 Unfiltered Engine OilPressure open/short to +batt ............................ 105

MID 036 - CID 0542 - FMI 04 Unfiltered Engine OilPressure short to ground .................................. 106

MID 036 - CID 1040 - FMI 09 ICSM #1 notcommunicating on link ...................................... 106


MID 036 - CID 1501 - FMI 03 Cylinder #1 DetonationSensor open/short to +batt ............................... 107

MID 036 - CID 1501 - FMI 04 Cylinder #1 DetonationSensor short to ground ..................................... 107















MID 036 - CID 1844 - FMI 05 Fuel Actuator opencircuit ................................................................. 112

MID 036 - CID 1844 - FMI 06 Fuel Actuator short toground ............................................................... 112

MID 109 - CID 0253 - FMI 02 Personality Modulemismatch ........................................................... 113

MID 109 - CID 0591 - FMI 12 EEPROM checksumfault or ECM not programmed ........................... 113


MID 109 - CID 1043 - FMI 02 Cylinder #1 FiringSignal noisy ....................................................... 113

MID 109 - CID 1043 - FMI 03 Cylinder #1 FiringSignal open/short to +batt ................................. 114

MID 109 - CID 1043 - FMI 04 Cylinder #1 FiringSignal short to ground ....................................... 114

MID 109 - CID 1043 - FMI 08 Cylinder #1 FiringSignal abnormal signal ...................................... 114

MID 109 - CID 1044 - FMI 02 All Cylinders FiringSignal noisy ....................................................... 115

MID 109 - CID 1044 - FMI 03 All Cylinders FiringSignal open/short to +batt ................................. 115

MID 109 - CID 1044 - FMI 04 All Cylinders FiringSignal short to ground ....................................... 115

MID 109 - CID 1101 - FMI 02 Cylinder #1 CombustionProbe noisy ....................................................... 116

MID 109 - CID 1101 - FMI 04 Cylinder #1 CombustionProbe short to ground ....................................... 116






6Table of Contents




MID 109 - CID 1111 - FMI 02 Cylinder #11Combustion Probe noisy ................................... 120

MID 109 - CID 1111 - FMI 04 Cylinder #11Combustion Probe short to ground ................... 120





MID 109 - CID 1490 - FMI 03 Rt Turbo Turbine OutTemp Sens short to +batt .................................. 122

MID 109 - CID 1490 - FMI 04 Rt Turbo Turbine OutTemp Sens short to ground ............................... 122

MID 109 - CID 1490 - FMI 05 Rt Turbo Turbine OutTemp Sens open circuit ..................................... 123

MID 109 - CID 1491 - FMI 03 Rt Turbo Turbine InTemp Sens short to +batt .................................. 123

MID 109 - CID 1491 - FMI 04 Rt Turbo Turbine InTemp Sens short to ground ............................... 123

MID 109 - CID 1491 - FMI 05 Rt Turbo Turbine InTemp Sens open circuit ..................................... 124

MID 109 - CID 1531 - FMI 03 Cyl #1 Exhaust PortTemp Sensor short to +batt ............................... 124

MID 109 - CID 1531 - FMI 04 Cyl #1 Exhaust PortTemp Sensor short to ground ............................ 124

MID 109 - CID 1531 - FMI 05 Cyl #1 Exhaust PortTemp Sensor open circuit ................................. 124






















MID 110 - CID 0253 - FMI 02 Personality Modulemismatch ........................................................... 131

MID 110 - CID 0591 - FMI 12 EEPROM checksumfault or ECM not programmed ........................... 131


MID 110 - CID 1044 - FMI 02 All Cylinders FiringSignal noisy ....................................................... 132

MID 110 - CID 1044 - FMI 03 All Cylinders FiringSignal open/short to +batt ................................. 132

MID 110 - CID 1044 - FMI 04 All Cylinders FiringSignal short to ground ....................................... 133

MID 110 - CID 1044 - FMI 08 All Cylinders FiringSignal abnormal signal ...................................... 133















7Table of Contents



MID 110 - CID 1489 - FMI 03 Left Turbo Turbine OutTemp Sens short to +batt .................................. 139

MID 110 - CID 1489 - FMI 04 Left Turbo Turbine OutTemp Sens short to ground ............................... 140

MID 110 - CID 1489 - FMI 05 Left Turbo Turbine OutTemp Sens open circuit ..................................... 140

MID 110 - CID 1492 - FMI 03 Left Turbo Turbine InTemp Sens short to +batt .................................. 140

MID 110 - CID 1492 - FMI 04 Left Turbo Turbine InTemp Sens short to ground ............................... 141

MID 110 - CID 1492 - FMI 05 Left Turbo Turbine InTemp Sens open circuit ..................................... 141

























Troubleshooting with an Event CodeEvent Codes ...................................................... 149E004 Engine Overspeed Shutdown .................... 151E013 High Crankcase Pressure Shutdown ........ 151E016 High Engine Coolant TemperatureShutdown .......................................................... 151

E017 High Engine Coolant TemperatureWarning ............................................................. 151

E019 High Engine Oil Temperature Shutdown ... 152E020 High Engine Oil Temperature Warning ...... 152E026 High Inlet Air Temperature Shutdown ........ 152E027 High Inlet Air Temperature Warning .......... 153E038 Low Engine Coolant TemperatureWarning ............................................................. 153

E040 Low Engine Oil Pressure Shutdown .......... 153E042 Low System Voltage Shutdown ................. 153E043 Low System Voltage Warning .................... 154E050 High System Voltage Warning ................... 154E096 High Fuel Pressure .................................... 154E100 Low Engine Oil Pressure Warning ............. 154E101 High Crankcase Pressure Warning ........... 155E127 Engine Oil Filter Diff Pressure LowWarning ............................................................. 155

E128 Engine Oil Filter Diff Pressure LowShutdown .......................................................... 155

E129 Engine Oil Filter Diff Pressure HighWarning ............................................................. 156

E130 Engine Oil Filter Diff Pressure HighShutdown .......................................................... 156

E135 Low Jacket Water Pressure Shutdown ...... 156E200 Continuous Cylinder Misfire ...................... 157E201 Cylinder #1 Intermittent Misfire .................. 157E202 Cylinder #2 Intermittent Misfire .................. 157E203 Cylinder #3 Intermittent Misfire .................. 157E204 Cylinder #4 Intermittent Misfire .................. 158E205 Cylinder #5 Intermittent Misfire .................. 158E206 Cylinder #6 Intermittent Misfire .................. 158E207 Cylinder #7 Intermittent Misfire .................. 159E208 Cylinder #8 Intermittent Misfire .................. 159E209 Cylinder #9 Intermittent Misfire .................. 159E210 Cylinder #10 Intermittent Misfire ................ 159E211 Cylinder #11 Intermittent Misfire ................ 160E212 Cylinder #12 Intermittent Misfire ................ 160E213 Cylinder #13 Intermittent Misfire ................ 160E214 Cylinder #14 Intermittent Misfire ................ 160E215 Cylinder #15 Intermittent Misfire ................ 161E216 Cylinder #16 Intermittent Misfire ................ 161E223 High Gas Temperature .............................. 161E224 High Jacket Water Inlet Pressure .............. 162E225 Engine Overcrank ...................................... 162E226 Driven Equipment Not Ready .................... 162E229 Fuel Energy Content Setting Low .............. 162E230 Fuel Energy Content Setting High ............. 163E231 Fuel Quality Out of Range ......................... 163E233 Low Engine Pre-Lube Pressure ................ 163E242 Engine Overload ........................................ 163E243 High Left Turbo Turbine OutletTemperature ...................................................... 164

E244 High Right Turbo Turbine OutletTemperature ...................................................... 164

8Table of Contents

E245 High Right Turbo Turbine InletTemperature ...................................................... 164

E246 High Left Turbo Turbine Inlet Temperature .. 165E264 Emergency Stop Activated ........................ 165E266 Low Hydrax Oil Pressure ........................... 165E268 Unexpected Engine Shutdown .................. 166E269 Customer Shutdown Requested ............... 166E270 Driven Equipment Shutdown Requested .. 166E337 High Engine Oil to Engine Coolant DiffTemp ................................................................. 166

E401 Cylinder #1 Detonation .............................. 167E402 Cylinder #2 Detonation .............................. 167E403 Cylinder #3 Detonation .............................. 167E404 Cylinder #4 Detonation .............................. 168E405 Cylinder #5 Detonation .............................. 168E406 Cylinder #6 Detonation .............................. 168E407 Cylinder #7 Detonation .............................. 168E408 Cylinder #8 Detonation .............................. 169E409 Cylinder #9 Detonation .............................. 169E410 Cylinder #10 Detonation ............................ 169E411 Cylinder #11 Detonation ............................ 169E412 Cylinder #12 Detonation ............................ 170E413 Cylinder #13 Detonation ............................ 170E414 Cylinder #14 Detonation ............................ 170E415 Cylinder #15 Detonation ............................ 170E416 Cylinder #16 Detonation ............................ 171E421 Cylinder #1 Detonation Shutdown ............. 171E422 Cylinder #2 Detonation Shutdown ............. 171E423 Cylinder #3 Detonation Shutdown ............. 171E424 Cylinder #4 Detonation Shutdown ............. 172E425 Cylinder #5 Detonation Shutdown ............. 172E426 Cylinder #6 Detonation Shutdown ............. 172E427 Cylinder #7 Detonation Shutdown ............. 173E428 Cylinder #8 Detonation Shutdown ............. 173E429 Cylinder #9 Detonation Shutdown ............. 173E430 Cylinder #10 Detonation Shutdown ........... 173E431 Cylinder #11 Detonation Shutdown ........... 174E432 Cylinder #12 Detonation Shutdown ........... 174E433 Cylinder #13 Detonation Shutdown ........... 174E434 Cylinder #14 Detonation Shutdown ........... 175E435 Cylinder #15 Detonation Shutdown ........... 175E436 Cylinder #16 Detonation Shutdown ........... 175E601 Cylinder #1 Continuous Misfire ................. 175E602 Cylinder #2 Continuous Misfire ................. 176E603 Cylinder #3 Continuous Misfire ................. 176E604 Cylinder #4 Continuous Misfire ................. 176E605 Cylinder #5 Continuous Misfire ................. 177E606 Cylinder #6 Continuous Misfire ................. 177E607 Cylinder #7 Continuous Misfire ................. 177E608 Cylinder #8 Continuous Misfire ................. 177E609 Cylinder #9 Continuous Misfire ................. 178E610 Cylinder #10 Continuous Misfire ............... 178E611 Cylinder #11 Continuous Misfire ............... 178E612 Cylinder #12 Continuous Misfire ............... 178E613 Cylinder #13 Continuous Misfire ............... 179E614 Cylinder #14 Continuous Misfire ............... 179E615 Cylinder #15 Continuous Misfire ............... 179E616 Cylinder #16 Continuous Misfire ............... 180E801 Cylinder #1 High Exhaust Port Temp ........ 180E802 Cylinder #2 High Exhaust Port Temp ........ 180E803 Cylinder #3 High Exhaust Port Temp ........ 181

E804 Cylinder #4 High Exhaust Port Temp ........ 181E805 Cylinder #5 High Exhaust Port Temp ........ 181E806 Cylinder #6 High Exhaust Port Temp ........ 182E807 Cylinder #7 High Exhaust Port Temp ........ 182E808 Cylinder #8 High Exhaust Port Temp ........ 183E809 Cylinder #9 High Exhaust Port Temp ........ 183E810 Cylinder #10 High Exhaust Port Temp ...... 183E811 Cylinder #11 High Exhaust Port Temp ...... 184E812 Cylinder #12 High Exhaust Port Temp ...... 184E813 Cylinder #13 High Exhaust Port Temp ...... 185E814 Cylinder #14 High Exhaust Port Temp ...... 185E815 Cylinder #15 High Exhaust Port Temp ...... 185E816 Cylinder #16 High Exhaust Port Temp ...... 186E821 Cyl #1 Exhaust Port Temp Deviating High .. 186E822 Cyl #2 Exhaust Port Temp Deviating High .. 187E823 Cyl #3 Exhaust Port Temp Deviating High .. 187E824 Cyl #4 Exhaust Port Temp Deviating High .. 187E825 Cyl #5 Exhaust Port Temp Deviating High .. 188E826 Cyl #6 Exhaust Port Temp Deviating High .. 188E827 Cyl #7 Exhaust Port Temp Deviating High .. 189E828 Cyl #8 Exhaust Port Temp Deviating High .. 189E829 Cyl #9 Exhaust Port Temp Deviating High .. 189E830 Cyl #10 Exhaust Port Temp DeviatingHigh ................................................................... 190

E831 Cyl #11 Exhaust Port Temp DeviatingHigh ................................................................... 190






E841 Cyl #1 Exhaust Port Temp Deviating Low .. 193E842 Cyl #2 Exhaust Port Temp Deviating Low .. 193E843 Cyl #3 Exhaust Port Temp Deviating Low .. 193E844 Cyl #4 Exhaust Port Temp Deviating Low .. 194E845 Cyl #5 Exhaust Port Temp Deviating Low .. 194E846 Cyl #6 Exhaust Port Temp Deviating Low .. 195E847 Cyl #7 Exhaust Port Temp Deviating Low .. 195E848 Cyl #8 Exhaust Port Temp Deviating Low .. 195E849 Cyl #9 Exhaust Port Temp Deviating Low .. 196E850 Cyl #10 Exhaust Port Temp DeviatingLow ................................................................... 196

E851 Cyl #11 Exhaust Port Temp DeviatingLow ................................................................... 197






Diagnostic Functional Tests

9Table of Contents

+5V Sensor Voltage Supply ................................ 200+8V Sensor Voltage Supply ................................ 212Air/Fuel Pressure Module ................................... 223Analog Sensor Signal ......................................... 230Choke Actuator Solenoid .................................... 240Combustion Sensor ............................................ 249Cylinder Firing Pulse ........................................... 256Desired Speed Input (4 - 20 mA) ........................ 271Detonation Sensors ............................................ 278ECM Output Circuit (Fuel Control) ...................... 292ECM Output Circuit (Prelubrication Oil Pump) .... 304ECM Output Circuit (Starting Motor) ................... 317ECM Status Indicator Output .............................. 327Electrical Power Supply ...................................... 334Engine Speed/Timing Sensor ............................. 341Fuel Actuator Solenoid ....................................... 348Ignition Transformers Primary Circuit .................. 357Ignition Transformers Secondary Circuit and SparkPlugs ................................................................. 368

Inspecting Electrical Connectors ........................ 372Integrated Combustion Sensing Module(ICSM) ............................................................... 377

Prelubrication System ......................................... 384PWM Sensor ....................................................... 389Thermocouple Test ............................................. 403Wastegate Solenoid ............................................ 413

Index SectionIndex ................................................................... 422

10Troubleshooting Section

Troubleshooting Section

Electronic Troubleshootingi01625280

System OverviewSMCS Code: 1901-038

Control SystemThe following components are included in thecontrol system:

Electronic Control Module (ECM)

Integrated Combustion Sensing Module (ICSM)

Gas Shutoff Valve (GSOV)

Prelube pump

Electrohydraulic actuator system

Starting system

Sensors for monitoring engine operation

The Engine Control Module (ECM) controls mostof the functions of the engine. The ECM monitorsvarious inputs from sensors in order to activaterelays, solenoids, etc at the appropriate levels. TheECM supports the following five primary functions:

Governing the engine

Controlling ignition

Controlling emissions

Start/stop control

Monitoring engine operation

The ECM does not have a removable personalitymodule. The software and maps are changed byusing ET to flash program a file.

Governing the EngineDesired engine speed is determined by the statusof the idle/rated switch, the desired speed input(analog voltage or 4 to 20 mA), and parameters thatare programmed into the software. Actual enginespeed is detected via a signal from the enginespeed/timing sensor. Parameters such as idle speedand governor gain can be programmed with ET.

The ECM monitors the actual engine speed. TheECM calculates the difference between the actualengine speed and the desired engine speed. TheECM controls the fuel actuator in order to maintainthe desired engine speed.

If the actual engine speed is less than the desiredengine speed, the ECM commands the fuel actuatorto move toward the open position in order toincrease the fuel flow.

Controlling IgnitionEach cylinder has an ignition transformer. Toinitiate combustion, the ECM sends a pulse ofapproximately 108 volts to the primary coil of eachignition transformer at the appropriate time and forthe appropriate duration. The transformer increasesthe voltage which creates a spark across the sparkplug electrode.

The ECM provides variable ignition timing thatis sensitive to detonation. Detonation sensorsmonitor the engine for excessive detonation. Theengine has one detonation sensor for each twoadjacent cylinders. The sensors generate data onvibration that is processed by the ECM in order todetermine detonation levels. If detonation reachesan unacceptable level, the ECM retards the ignitiontiming of the affected cylinder or cylinders. Ifretarding the timing does not limit detonation to anacceptable level, the ECM shuts down the engine.

Levels of detonation can be displayed by theMachine Information Display System (MIDS) on theremote control panel. Alternatively, the Cylinder XDetonation Level screen of ET can also be used.The X represents the cylinder number.

Controlling EmissionsThe ECM provides control of the air/fuel mixture forperformance and efficiency at low emission levels.The system includes the following components:combustion sensors, an Integrated CombustionSensing Module (ICSM) for each bank of cylinders,maps in the ECM, output drivers in the ECM, fuelactuator, air choke actuator, and exhaust bypassactuator (wastegate).


The desired air/fuel ratio is based on maps thatare stored in the ECM. The maps are specific fordifferent applications, engine speeds, and engineloads.

The engine load is calculated from the fuel flow. Forexample, zero fuel flow is zero load and fuel flow of100 cfm might be the rated load.

At loads that are less than 40 percent, the air/fuelratio is controlled by the air choke actuator which istrimmed by the exhaust port temperatures.

Each cylinder exhaust port has a thermocouplethat is monitored by an ICSM. The ICSM monitorsthe actual exhaust port temperatures for onebank of cylinders. The ICSM calculates anaverage exhaust port temperature for the bank ofcylinders. The ECM sends a map of the desiredexhaust port temperature to the ICSM. The ICSMcalculates the difference between the averageexhaust port temperature and the desired exhaustport temperature. The ICSM communicates theinformation to the ECM. The ECM controls the airchoke actuator in order to maintain the desiredexhaust temperature.

If the average exhaust temperature is too low, theECM commands the air choke actuator to movetoward the closed position in order to richen theair/fuel mixture. Combustion of the richer air/fuelmixture increases the exhaust port temperatures.

When the load reaches approximately 40 percent,the air/fuel ratio is controlled by the exhaust bypassactuator which is trimmed by the combustion burntime.

Combustion burn time The combustion burn timeis measured in each cylinder. Each cylinder has acombustion sensor. The pulse of the ignition starts atimer in the ICSM. The flame travels in the cylinderfrom the spark plug to the combustion sensor. TheICSM monitors the voltage across the combustionsensor. When the flame reaches the combustionsensor, the ionization that surrounds the sensorchanges the voltage. When the ICSM detects thechange of the sensors voltage, the ICSM stops thetimer. The combustion burn time is a method ofmeasuring the air/fuel ratio. A rich air/fuel mixtureprovides a faster combustion burn time. A leanair/fuel mixture provides a slower combustion burntime.

Each ICSM calculates an average combustion burntime for all of the cylinders in one bank. The ECMsends a map of the desired combustion burn timeto the ICSM. The ICSM calculates the differencebetween the average combustion burn time and thedesired combustion burn time. The ICSM sends afuel correction factor to the ECM. The ECM controlsthe exhaust bypass actuator in order to maintainthe desired combustion burn time.

A command for the desired inlet manifold airpressure is sent from the ECM to the exhaust bypassactuator. The actuator adjusts the inlet manifold airpressure in order to correct the combustion burntime.

If the average desired combustion burn time istoo fast, the ECM commands the exhaust bypassactuator to move toward the closed position in orderto lean the air/fuel mixture. Combustion of the leanerair/fuel mixture reduces the combustion burn time.

This is a continuous process during operationat loads that are greater than approximately 40percent.

Start/Stop ControlThe ECM contains the logic and the outputs forcontrol of engine prelubrication, starting, shutdown,and postlube. The customer programmable logicresponds to signals from the following components:mode control switch, emergency stop switch,remote start switch, data link, and other inputs.

To control the engine at the appropriate times, theECM provides +Battery voltage to the solenoids thatcontrol the prelube pump, the starting motor, andthe gas shutoff valve.

When the programmable logic determines thatthe prelubrication function is necessary, the ECMsupplies +Battery voltage to the solenoid for theprelube pump. The system is programmed toperform a postlube cycle during engine shutdown inorder to ensure that the turbocharger has adequatelubrication during shutdown.

When the programmable logic determines that it isnecessary to crank the engine, the ECM supplies+Battery voltage to the solenoid for the startingmotor. The ECM removes the voltage when theprogrammable crank terminate speed is reachedor when a programmable cycle crank time hasexpired.

The engine has an energize-to-run type of gasshutoff valve. When the programmable logicdetermines that fuel is required to start the engineor to run the engine, the ECM supplies +Batteryvoltage to the valves solenoid.

Monitoring Engine OperationThe ECM monitors both the engine operation andthe electronic system.

Problems with engine operation cause the ECMto generate an event code. The ECM can issue awarning or a shutdown for events. This depends onthe severity of the condition.


For example, a high pressure pump provideshydraulic pressure with oil for the electrohydraulicsystem. The oil supply is separate from the engineoil. The high pressure oil supply is monitored bya pressure switch. If the pressure drops below anacceptable level, the ECM generates an event codeand the ECM shuts down the engine.

An ICSM is installed on each side of the engine.Each ICSM monitors the combustion sensorsand the thermocouples for the cylinders and theturbocharger on that side of the engine. The ICSMsends signals regarding the parameters to theECM over the CAT Data Link. If any parameterexceeds the acceptable range, the ECM can initiatea warning or a shutdown.

For more information on monitoring of the engine,refer to Troubleshooting, Troubleshooting with anEvent Code and Systems Operation, ElectronicControl System Parameters.

Problems with the electronic system such asan open circuit produce a diagnostic code.For more information, refer to Troubleshooting,Troubleshooting with a Diagnostic Code.

i01626552

Electrical Connectors andFunctionsSMCS Code: 1408-038

Harness Wire IdentificationCaterpillar identifies different wires with elevendifferent solid colors. Table 1 lists the color codes ofthe wiring.

Table 1

Color Codes for WiringCode Color

BK Black

BR Brown

BU Blue

GN GreenGY GrayOR OrangePK Pink

PU Purple

RD Red

WH White

YL Yellow

In addition to the color, the entire length of eachwire is stamped with a specific circuit number thatis repeated on every 25 mm (1 inch) of the wire.The actual wires are identified on the schematic.

For example, a code of J011-RD on the schematicidentifies a red wire that is stamped with thecircuit number J011. This particular wire is theengine harness wire for the primary signal of thetransformer in the number one cylinder.

The schematic also identifies the size of the wire.The size or gauge of the wire is called the AmericanWire Gauge (AWG). Unless the schematic specifiesa different size, the wire is 16 AWG.


Terminal Box

g00842401Illustration 1Inside of the terminal box(1) 70-pin connectors (J2/P2) for the ECM(2) 70-pin connectors (J1/P1) for the ECM(3) Ground strap(4) Service tool connector (J7)(5) 16 amp circuit breaker (CB1)(6) 6 amp circuit breaker (CB2)(7) 70-pin connector (J3) for the customer

or the control panel

(8) Ignition wiring for the left side of theengine

(9) 70-pin connectors (J6/P6) for the sensorson the left side of the engine

(10) 70-pin connectors (J5/P5) for thesensors on the right side of the engine

(11) Ignition wiring for the right side of theengine

(12) 47-pin connector (J4) for the customeror the control panel

(13) Wiring for the electrical power


g00869099Illustration 2Front and bottom of the terminal box(9) 70-pin connectors (J6/P6) for the sensors on the left side of

the engine(10) 70-pin connectors (J5/P5) for the sensors on the right side

of the engine(12) 47-pin connector (J4) for the customer or the control panel(14) Emergency stop button

SensorsSensors provide information to the engine controlmodule and the integrated combustion sensingmodules. The information is used for monitoringengine operation. The information enables themodules to control the engine as efficiently aspossible over a wide range of operating conditions.

g00803846Illustration 3Front view(1) Jacket water outlet pressure sensor(2) Jacket water temperature sensor(3) Unfiltered engine oil pressure sensor(4) Engine oil temperature sensor(5) Filtered engine oil pressure sensor


g00825637Illustration 4Right side view near the front of the engine(1) Jacket water outlet pressure sensor(6) Detonation sensor(7) Jacket water inlet pressure switch(8) Crankcase pressure sensor

Note: There is one detonation sensor between eachpair or cylinders.

g00825893Illustration 5The inlet manifold air temperature sensor is installed in the inletair manifold between the two center cylinder heads on the rightside of the engine.(9) Inlet manifold air temperature sensor


g00825717Illustration 6Right side view near the rear of the engine(10) Connector for the electrohydraulic actuators pressure switch(11) Prelube oil pressure switch

g00825638Illustration 7Rear view(12) Fuel temperature sensor(13) Inlet air restriction switch (left)(14) Air/fuel pressure module(15) Inlet air restriction switch (right)(16) Engine speed/timing sensor


Integrated Combustion Sensing Module(ICSM)

g00843952Illustration 8Integrated Combustion Sensing Module (ICSM)

The engine has an Integrated Combustion SensingModule (ICSM) for each bank of cylinders. TheICSM monitors exhaust temperature sensorsand combustion sensors. The ICSM performscalculations with the data. The ICSM communicateswith the ECM via the CAT Data Link.

Exhaust temperatures are monitored for eachcylinder exhaust port, the inlet of the turbochargerturbine, and the outlet of the turbocharger turbine.

At loads that are less than 40 percent, the air/fuelratio is controlled according to the desired exhaustport temperature. The air choke actuator istrimmed according to the average exhaust porttemperatures.

The ICSM monitors the actual exhaust porttemperatures for one bank of cylinders. The ICSMcalculates an average exhaust port temperature forthe bank of cylinders. The ECM sends a map ofthe desired exhaust port temperature to the ICSM.The ICSM calculates the difference between theaverage exhaust port temperature and the desiredexhaust port temperature. The ICSM communicatesthe information to the ECM. The ECM controls theair choke actuator in order to maintain the desiredexhaust temperature.

When the load reaches approximately 40 percent,the air/fuel ratio is controlled by the exhaustbypass actuator which is trimmed according to thecombustion burn time.

Each ICSM calculates an average combustion burntime for all of the cylinders in one bank. The ECMsends a map of the desired combustion burn timeto the ICSM. The ICSM calculates the differencebetween the average combustion burn time and thedesired combustion burn time. The ICSM sends afuel correction factor to the ECM. The ECM controlsthe exhaust bypass actuator in order to maintainthe desired combustion burn time.

g00825730Illustration 9(17) Temperature sensor for the cylinder exhaust port(18) Temperature sensor for the exhaust after the turbocharger(19) Temperature sensor for the exhaust before the turbocharger(20) Combustion sensor

Note: For each cylinder, there is one temperaturesensor for the exhaust port (17) and one combustionsensor (20). For each turbocharger, there is onetemperature sensor for the exhaust after theturbocharger (18) and one temperature sensor forthe exhaust before the turbocharger (19).


i01626171

Electronic Service ToolsSMCS Code: 1901-038

Caterpillar Electronic Service Tools are designed tohelp the service technician:

Obtain data.

Diagnose problems.

Read parameters.

Program parameters.

Calibrate sensors.

The tools that are listed in Table 2 are required inorder to enable a service technician to perform theprocedures.


Table 2

Service ToolsPt. No. Description Functions

N/A Personal Computer (PC) This PC configuration is recommended:Intel Pentium II 333 mHz processor64 megabyte of RAM4.3 GB hard drive14X speed CD-ROM drive

N/A Personal Computer (PC) This PC configuration has the minimum requirements:IBM PC compatible 100 MHz processor32 megabyte of RAM10 MB of available hard drive spaceCD-ROM drive3.5" 1.44-MB floppy disk driveWindows NT or Windows 95RS232 port with 16550AF UARTVGA monitor or display

JERD2124 Version2001B

Software Single user license for ETIf a more recent version of this software is available, the morerecent version may be used.

JERD2129 Software Data subscription for all engines171-4401 Communication Adapter II (1) The communication adapter is connected between the PC (ET)

and the ECM.196-0055 Serial Cable As (1)(2) This cable connects the PC to the 171-4401 Communication

Adapter II.160-0141 Serial Cable As (2) This cable connects the PC to the 171-4401 Communication

Adapter II.207-6845 Adapter Cable As (1)(3) This cable connects the 171-4401 Communication Adapter II to

the 7X-1414 Data Link Cable As.7X-1701 Communication Adapter The communication adapter is connected between the PC (ET)

and the ECM.7X-1425 Serial Cable As This cable connects the PC (ET) to the 7X-1701 Communication

Adapter.139-4166 Adapter Cable As This cable connects the 7X-1701 Communication Adapter to the

7X-1414 Data Link Cable As.7X-1414 Data Link Cable As This cable connects the service tool connector on the engine

mounted terminal box to the 139-4166 Adapter Cable As.8T-8726 Adapter Cable As This is a breakout cable for use between the jacks and the plugs

of the sensors.

151-6320 Wire Removal Tool This tool is used for the removal of pins and sockets from Deutschconnectors and AMP connectors.

1U-5804 Crimp Tool This tool is used for work with CE electrical connectors.9U-7330 Digital Multimeter The multimeter is used for the testing and the adjusting of electronic

circuits.

7X-1710 Multimeter Probes The probes are used with the multimeter to measure voltage inwiring harnesses without disconnecting the harnesses.

5P-7277 Voltage Tester The tester is used to test for voltage in circuits, relays, bulbs, wires,and switches.

(1) This item is included in the 171-4400 Communication Adapter Gp.(2) Either the 160-0141 or the 196-0055 cable may be used.(3) Either the 160-0133 or the 207-6845 cable may be used.


Note: Either the 171-4401 Communication AdapterII or the 7X-1700 Communication Adapter Gp canbe used. However, the 7X-1700 CommunicationAdapter Gp is no longer serviced.

Electronic Technician (ET)The Caterpillar Electronic Technician (ET) isdesigned to run on a personal computer. ET candisplay the following information:

Parameters

Diagnostic codes

Event codes

Engine configuration

Status of the monitoring system

ET can perform the following functions:

Diagnostic tests

Sensor calibration

Flash downloading

Set parameters

Connecting ET with the 171-4401Communication Adapter IIThe battery supplies the communication adapterwith 24 VDC. Use the following procedure toconnect ET and the communication adapter to theengine.

1. Turn the engine control switch to the OFFposition.

g00694774Illustration 10(1) PC(2) 196-0055 Serial Cable or the 160-0141 Serial Cable(3) 171-4401 Communication Adapter II(4) 207-6845 Adapter Cable(5) 7X-1414 Data Link Cable

2. Connect cable (2) to the RS232 serial port ofPC (1).

3. Connect cable (2) to communication adapter (3).


5. Connect cable (4) to cable (5).

6. Connect cable (5) to the service tool connectorof the terminal box.

7. Turn the engine control switch to the ON position.The engine should be OFF. If ET and thecommunication adapter do not communicate withthe ECM, refer to Troubleshooting, ElectronicService Tool Will Not Communicate With ECM.

Connecting ET with the 7X-1701Communication AdapterThe battery supplies the communication adapterwith 24 VDC. Use the following procedure toconnect ET and the communication adapter to theengine.


1. Turn the engine control switch to the OFFposition.

g00694776Illustration 11(1) PC(2) 7X-1425 Serial Cable(3) 7X-1701 Communication Adapter(4) 139-4166 Adapter Cable(5) 7X-1414 Data Link Cable

2. Connect cable (2) to the RS232 serial port ofPC (1).



5. Connect cable (4) to cable (5).

6. Connect cable (5) to the service tool connectorof the terminal box.

7. Turn the engine control switch to the ON position.The engine should be OFF. If ET and thecommunication adapter do not communicate withthe ECM, refer to Troubleshooting, ElectronicService Tool Will Not Communicate With ECM.

i01653858

Engine Monitoring SystemSMCS Code: 1901-038

The ECM monitors the operating parameters ofthe engine. The ECM can initiate a warning or ashutdown if a specific engine parameter exceedsan acceptable range. The default settings for theparameters are programmed at the factory.

The status of the parameters can be viewed onthe Service/Monitoring System screen of ET. Thisscreen is also used to change the settings.

To accommodate unique applications and sites,some parameters may be reprogrammed with ET.The screens of ET provide guidance for changingtrip points. Use ET to perform the following activities:

Select the available responses.

Program the level for monitoring.

Program delay times for each response.

Note: Some parameters are protected by factorypasswords. Other parameters can be changed withcustomer passwords.

For instructions on using ET, refer to Users Manual,NEHS0679, Caterpillar Electronic Technician.

For information on the warnings and shutdowns,refer to Troubleshooting, Troubleshooting with anEvent Code.

For detailed information on system parameters thatcan be programmed and for recommendationsfor programming parameters, refer to SystemsOperation/Testing and Adjusting, RENR5908,Engine Monitoring System.

NOTICEChanging the parameters during engine operation cancause the engine to operate erratically. This can causeengine damage.

Unless the instructions are different, only changethe settings of the parameters when the engine isSTOPPED.


Programming Parametersi01625792

Programming ParametersSMCS Code: 1901-038

Programmable parameters enable the engine tobe configured to meet the requirements of theapplication. Two types of parameters can beprogrammed into the ECM: system configurationparameters and monitoring system parameters.

The CAT Electronic Technician (ET) is usedfor viewing the status of parameters and forprogramming parameters.

For more information on parameters, refer toTroubleshooting, Sytem Configuration Parametersand Troubleshooting, Engine Monitoring System.

i01409654

Customer PasswordsSMCS Code: 1901

Certain monitoring system parameters and systemconfiguration parameters may be protected withcustomer passwords. Use of the passwords helpsto prevent free access to the modification of theparameters. If the customer passwords are notprogrammed, all of the parameters are unprotected.

The customer passwords can be changed, ifnecessary. The customer passwords or a factorypassword is needed in order to change thecustomer passwords. If the customer passwordsare forgotten, factory passwords can be acquiredfrom Caterpillar.

After the customer passwords are entered, thepasswords are required in order to change certainparameters. Once the passwords are enteredsuccessfully, the passwords are not requestedagain until another screen is accessed or the datalink is interrupted.

This feature is enabled by programming twocustomer passwords. Use the following procedureto program the passwords. The same procedure isused to change the passwords:

1. Access the Service/Configuration screen ofthe ET.

2. Highlight the Customer Password #1 parameter.Click on the Change button in the lower rightcorner of the screen.

Note: Be sure to record the customer passwords.Store the passwords securely. The passwords canhave a maximum of eight characters. Alphanumericcharacters may be used. The passwords are casesensitive.

3. Enter the password in the Change ParameterValue dialog box and click on the OK button.

4. Highlight the Customer Password #2 parameter.Click on the Change button in the lower rightcorner of the screen.

5. Enter the password in the Change ParameterValue dialog box and click on the OK button.

The passwords are now programmed into thememory of the ECM.

Make a copy of Table 3 and record your passwords.Store the passwords securely.

Table 3

Customer PasswordsCustomer Password #1Customer Password #2

i01298784

Factory PasswordsSMCS Code: 1901-038

Factory level security passwords are required forclearing certain logged events and for changingcertain programmable parameters. Because of thepasswords, only authorized personnel can makechanges to some of the programmable items in theECM. When the correct passwords are entered, thechanges are programmed into the ECM.

Factory passwords are required to program thefollowing shutdowns:

Engine Overspeed

High Engine Oil Temperature

High Oil Filter Differential Pressure

Low Oil Filter Differential

High Jacket Water to Engine Oil TemperatureDifferential

The Enter Factory Passwords ET screen willdisplay the following parameters. To obtain theproper passwords, the information must be given toan authorized Caterpillar dealer:


Current ECM

Serial number of the service tool

Serial number of the engine

Serial number of the ECM

Diagnostic clock

Total Tattletale

Reason

The old interlock code is required to change theinterlock code on a used ECM. The passwords arecontrolled by Caterpillar. The passwords may onlybe obtained by an authorized Caterpillar dealer.

The passwords may only be used for oneprogramming session. After you exit the EnterFactory Passwords ET screen, a different set ofpasswords will be required before you can programthe ECM.

Factory passwords are not required for the first hourof operation for a new ECM. After the hour expires,factory passwords are required for some of theprogramming.

i01626337

Flash ProgrammingSMCS Code: 1901-038

Software is located in the flash memory of the ECMand the Integrated Combustion Sensing Module(ICSM). ET can be used to flash new software intothe ECM and the ICSM. The flash is accomplishedby transferring the data from ET to the modulevia data link wiring. The Software, JERD2124 orSoftware, JERD2129 is used.

Flash ProgrammingIf the slowest baud rate of ET is selected, flashprogramming can last up to 15 minutes. Be sure toset the baud rate to the fastest rate for your PC.

To select the baud rate, use the ETUtilities/Preferences. Select the Communicationstab and click on Advanced.... Then select thebaud rate from the Advanced CommunicationSettings menu and click the OK button.

If a communication error occurs, select a slowerbaud rate in order to improve the reliability.

1. Connect the ET to the service tool connector.

2. Turn the engine control switch to the STOPposition.

The ET will not flash if the engine control switchis in the OFF or START position.

3. Select WinFlash from the Utilities menu onthe ET.

WinFlash will try to detect an ECM.

4. When an ECM has been detected, the ECMSelector window will appear. Select theappropriate ECM and then select OK.

The Flash File Selection window will appear.

5. The flash files are located on a disk drive andin a directory. Select the correct disk drive andthe directory from Drives and Directories onthe ET.

A list of flash files will appear.

6. Select the correct file from the list of flash files.Read the Description and the File Info inorder to verify that the correct file is selected.Select Open.

7. Select the Begin Flash button in order toprogram the personality module.

When the flash is completed, this message willappear: Flash Completed Successfully.

8. Program the configuration parameters and themonitoring system parameters.

The parameters must be programmed in orderto ensure proper engine operation. Refer toTroubleshooting, Programming Parameters.

9. Start the engine and check for proper operation.

a. If a diagnostic code of 268-02 CheckProgrammable Parameters is generated,program any parameters that were not in theoriginal software.

b. Access the Configuration screen underthe Service menu in order to determinethe parameters that require programming.Look under the Tattletale column. All of theparameters should have a tattletale of 1 ormore. If a parameter has a tattletale of 0,program that parameter.


WinFlash Error MessagesIf 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.

i01653867

System ConfigurationParametersSMCS Code: 1901-038

The system configuration parameters must beprogrammed when the application is installed.Perform this programming before the initial enginestart-up. Incorrect programming of parametersmay lead to complaints about performance and/orto engine damage. Data from a gas analysis isrequired for determining the correct settings for thefuel quality and the specific gravity of the gas.

The status of the parameters can be viewed on theConfiguration screen of ET.

If the ECM is replaced, the appropriate parametersmust be copied from the old ECM. This can bedone with the Copy Configuration feature of ET.Alternatively, the settings can be recorded on paperand then programmed into the new module.

Table 4 is a list of the parameters that can beconfigured for G3600 Engines.

Table 4

Configuration Parameters for G3600 EnginesInformation for the ECM

Engine Serial NumberEquipment ID

Customer Password #1Customer Password #2Total Tattletale

Air/Fuel Ratio ControlFuel QualityGas Specific Gravity

Speed ControlLow Idle SpeedMinimum Engine High Idle SpeedMaximum Engine High Idle Speed

(continued)

(Table 4, contd)Configuration Parameters for G3600 Engines

Engine Accel. RateDesired Speed Input Configuration

GoverningGovernor Type SettingEngine Speed DroopGovernor GainGovernor StabilityGovernor CompensationAuxiliary Proportional Governor Gain 1Auxiliary Integral Governor Gain 1Auxiliary Derivative Governor Gain 1Choke GainChoke StabilityChoke CompensationWastegate GainWastegate StabilityWastegate Compensation

Start/Stop ControlDriven Equipment Delay TimeCrank Terminate SpeedEngine Purge Cycle TimeEngine Cooldown DurationCycle Crank TimeEngine Overcrank TimeEngine Speed Drop TimeEngine Pre-lube Time Out PeriodEngine PostLube Time Out Period

Monitoring and ProtectionHigh Inlet Air Temp Engine Load Set Point

For detailed information on the configurationparameters and for recommendations onprogramming of the parameters, refer to SystemsOperation/Testing and Adjusting, RENR5908,Electronic Control System Parameters.

For instructions on using ET, refer to Users Manual,NEHS0679, Caterpillar Electronic Technician.


NOTICEChanging the parameters during engine operation cancause the engine to operate erratically. This can causeengine damage.

Unless the instructions are different, only changethe settings of the parameters when the engine isSTOPPED.

i01522611

Factory Passwords WorksheetSMCS Code: 1901-038

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

Table 5

Factory Passwords WorksheetDealer CodeCustomers NameAddress

Telephone NumberInformation from the Enter Factory Passwords

Screen on ETET Serial NumberEngine Serial NumberECM Serial NumberDiagnostic Clock(1)

Total Tattletale

Reason CodeFactory Passwords

Factory Password (No. 1)Factory Password (No. 2)

(1) Do not obtain this information from the service meter.

i01626381

Replacing the ECMSMCS Code: 1901-038

The Electronic Control Module (ECM) contains nomoving parts. Before you replace an ECM, followthe troubleshooting procedures in this manual inorder to be sure that replacement of the ECM willcorrect the problem.

Verify that the suspect ECM is the cause of theproblem. Install a test ECM in place of the suspectECM. Transfer the software from the suspect ECMto the test ECM. Program all the parameters forthe test ECM in order to match the parameters ofthe suspect ECM. The parameters must match.Refer to the following test steps for details onprogramming the parameters.

If the test ECM resolves the problem, reconnectthe suspect ECM. Verify that the problem recurs. Ifthe problem recurs, replace the suspect ECM withthe test ECM.

Note: If the parameters cannot be read from thesuspect ECM, the parameters must be obtainedfrom records or from the factory.

Perform the following procedure to replace the ECM.

1. Use the Service/Copy Configuration/ECMReplacement function of the ET.

Save the file. You can select Load from ECM.You may also select the Print function in orderto obtain a paper copy of the parameter settings.

Note: Before you replace an ECM, record all of thelogged events.

a. Connect the ET with the communicationsadapter. Select the ET Service/CopyConfiguration/ECM Replacement from thepull-down menu.

The ET will load the configuration parametersand the monitoring system parameters of thesuspect ECM.

b. Select Load from ECM in the lower leftcorner of the ET screen. Select the suspectECM and select OK.

After the loading is complete, the ET willdisplay this message: The data has beensuccessfully loaded from the ECM. SelectOK.

c. Select File/Disconnect F8 from the pull-downmenu.

Note: Do not terminate the ET.

2. Replace the ECM.

a. Turn the engine control switch to theOFF/RESET position.


g00842215Illustration 12(1) ECM Connector P2(2) ECM Connector P1(3) 16 Amp Circuit Breaker(4) Mounting nut(5) Ground Strap

b. Switch the 16 Amp circuit breaker (1) for theECM to the OFF position.

c. Use a 4 mm Allen wrench to disconnectconnectors (P1) and (P2).

d. Remove mounting nut (2) in order todisconnect the ground strap (3). Remove thethree remaining mounting nuts.

Note: Rubber grommets behind the ECM are held inplace by the mounting studs. The grommets help toreduce vibration. The grommets may fall when theECM is removed. Be sure not to lose the grommets.

e. Remove the ECM from the terminal box.

3. Install the replacement ECM.

a. Use the mounting hardware to install thenew ECM. Use a mounting nut to fasten theground strap for the ECM to the upper leftmounting stud. Then install the other threemounting nuts.

Check the mounting hardware and theECM for correct installation. A correctlyinstalled ECM will move slightly on the rubbergrommets. If the ECM cannot move slightlyon the grommets, check that the washers,spacers, and grommets are positionedcorrectly.

b. Use a 4 mm Allen wrench to connect the P1and P2 connectors to the ECM. Tighten thescrews to a torque of 6 1 Nm (55 9 lb in).

4. Program the configuration parameters andthe monitoring system parameters into thereplacement ECM.

a. Switch circuit breaker (1) to the ON position.

b. Turn the engine control switch to the STOPposition.

c. Select File/Select ECM from the pull-downmenu.

d. Select the replacement ECM and click OK.

e. Select Service/Copy Configuration/ECMReplacement from the pull-down menu. ClickOK on the window.

f. Select Program ECM from the lower leftcorner of the screen. Select the replacementECM and click OK. If the correct ECM isshown, select Yes.

g. After the loading is complete, a window withthe message Programming Conflict Warningwill appear. Select OK.

h. A window with the message Program ECMResults will appear. Select OK.

Note: When you program a new ECM, factorypasswords are not required for the first hour ofoperation. After one hour, factory passwords arerequired for changing the parameters that arenormally protected with factory passwords.

i01626386

Replacing the ICSMSMCS Code: 1901-038

The Integrated Combustion Sensing Module (ICSM)contains no moving parts. Replacement of the ICSMcan consume much time. Before you replace anICSM, follow the troubleshooting procedures in thismanual in order to be sure that replacement of theICSM will correct the problem.

Use the following guidelines to verify that thesuspect ICSM is the cause of the problem:


Install a test ICSM in place of the suspect ICSM.Transfer the software from the suspect ICSM tothe test ICSM. Program all the parameters for thetest ICSM in order to match the parameters of thesuspect ICSM. The parameters must match. Referto the following steps for details on programmingthe parameters.

If the test ICSM resolves the problem, reconnectthe suspect ICSM. Verify that the problem recurs.If the problem recurs, replace the suspect ICSMwith the test ICSM.

Use the following procedure to replace the ICSM:

Note: If the parameters cannot be read from thesuspect ICSM, the parameters must be obtainedfrom records or from the factory.

1. Use the Service/Copy Configuration/ECMReplacement function of ET in order to transferthe software from the suspect ICSM.

You may also select the Print function in orderto obtain a paper copy of the parameter settings.

Note: Before you replace an ICSM, record all of thelogged events.

a. Connect ET with the communications adapter.Select Service/Copy Configuration/ECMReplacement from the pull-down menu.

ET will load the configuration parameters andthe monitoring parameters from the ECM.

b. Select Load from ECM in the lower leftcorner of the screen. Select the suspect ICSMand select OK.

After the loading is complete, ET willdisplay this message: The data has beensuccessfully loaded from the ECM. SelectOK.

c. Select File/Disconnect F8 from the pull-downmenu.

Note: Do not exit from ET.

2. Replace the ICSM.

a. Turn the engine control switch to theOFF/RESET position.

g00842289Illustration 1316 amp circuit breaker for the ECM

b. Switch the 16 amp circuit breaker for the ECMto the OFF position.

g00842252Illustration 14(1) 20 pin P72 connector(2) 14 pin P73 connector(3) Bolt

c. Disconnect P72 connector (1) and P73connector (2) from the ICSM. Remove fourbolts (3) in order to remove the cover.

Note: Rubber grommets for the ICSM are held inplace on the mounting studs. The grommets help toreduce vibration. The grommets may fall when theICSM is removed. Be sure not to lose the grommets.

Note: A ground strap is connected with one of themounting bolts.


g00842267Illustration 15(4) Connectors for the sensors(5) Mounting bolts(6) Ground strap

d. Disconnect connectors (4) for the sensorsfrom the ICSM. Remove four mounting bolts(5). Detach ground strap (6).

3. Install the replacement ICSM. Orient the 20 pinJ72 connector to the upward position.

a. Use the mounting hardware to install the newICSM. Be sure to install ground strap (6).

Check the mounting hardware and theICSM for correct installation. A properlyinstalled ICSM will move slightly on the rubbergrommets. If the ICSM cannot move slightlyon the grommets, check that the washers andgrommets are positioned correctly.

b. Connect connectors (4) for the sensors tothe ICSM.

c. Connect P72 connector (1) and P73 connector(2) to the ICSM.

d. Install the cover and four bolts (3).

4. Program the configuration parameters andthe monitoring system parameters into thereplacement ICSM.

a. Switch the 16 amp circuit breaker for the ECMON.

b. Turn the engine control switch to the STOPposition.

c. Select File/Select ECM from the pull-downmenu of ET.

d. Select the Replacement ICSM and clickOK.

e. Select Service/Copy Configuration/ECMReplacement from the pull-down menu. ClickOK on the window.

f. Select Program ECM from the lower leftcorner of the screen. Select the replacementICSM and click OK.

g. After the loading is complete, a window withthe message Programming Complete willappear. Select OK.

Note: When you program a new ICSM, factorypasswords are not required. Also, the ICSM doesnot require calibration.

i01681543

Troubleshooting Data SheetSMCS Code: 1901-038

To help troubleshoot a gas engine, complete theinformation in Table 6. Be sure to include the unitsof measurement.


Table 6

Data Sheet for TroubleshootingCustomer and installationEngine model and driven equipmentEngine serial number ApplicationServicehours

Compressionratio

Altitude Fuel Qualitysetting (LHV)

FuelLHV

Fuelmethane number

Fuelrate

Pressure to the gasregulator

Fuelflow

Airflow

Brand of oiltype of oil

Enginerpm

Percentload

Detonationlevel

Airrestriction

Inlet manifold air pressure Inlet manifold air temperature Actual air/fuel ratioDesired air/fuel ratioDesired burn time

leftEngine oil pressure Turbocharger exhausttemperature

rightExhaust stackpressure

Exhaust stacktemperature

% O2 PPM of NOx PPM of CO Brand of exhaustanalyzer

(1) (3) (5) (7) (9) (11) (13) (15)Cylinder exhaustport tempera

Date post:	17-Oct-2015
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