Can Not Reach Top Engine RPM

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 1 of 4 Shutdown SIS Previous Screen Product: PETROLEUM ENGINE Model: C-15 PETROLEUM ENGINE Z2C Configuration: C-15 Petroleum Engine Z2C00001-UP Can Not Reach Top Engine RPM SMCS - 1915-035 Note: If this problem occurs only under load, refer to, "Low Power/Poor or No Response to Throttle". i02274766 The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Probable Causes Diagnostic codes Event codes Programmable parameters Cold mode Altitude derate Throttle signal "Fuel Position" and/or "FRC Fuel Limit" Boost pressure sensor Fuel supply

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 2 of 4 Air inlet and exhaust system Accessory equipment Recommended Actions Diagnostic Codes and Event Codes Certain diagnostic codes and/or event codes may cause poor performance. Connect the Caterpillar Electronic Technician (ET) and check for active codes and logged codes. Troubleshoot any codes that are present before continuing with this procedure. Programmable Parameters Check the values of the following parameters on Cat ET: "Throttle Position Sensor" "Direct Fuel Control Mode" Determine the type of throttle that is used in the application. Program the parameters to match the type of throttle that is used. Refer to, "Throttle Position Sensor Circuit - Test" for more information. Note: The engine will have poor performance if the parameters are not programmed correctly. Cold Mode Use Cat ET to verify that the engine has exited cold mode. A status indicator will appear if the engine is operating in cold mode. This may limit engine speed. Altitude Derate The engine may be derated due to high elevation. Use Cat ET to check for an active engine derate on the status screens. Note: There are no event codes that are associated with the altitude derate. Throttle Signal View the status for the throttle position on the status screen of Cat ET. Operate the throttle from the LOW IDLE position to the HIGH IDLE position. The status should be approximately 0 percent at low idle and the status should be approximately 100 percent at high idle. If either indication is incorrect, refer to, "Throttle Position Sensor - Calibrate". Diagnostic codes that are related to the J1939 data link will prevent correct operation of the throttle if the throttle position is transmitted over the data link. If there is a problem with the data link, the engine will remain at low idle until the data link is repaired.

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 3 of 4 Boost Pressure Sensor, "Fuel Position", and/or "FRC Fuel Limit" 1. With the engine at full load, monitor "Fuel Position" and "Rated Fuel Limit" on the status screen. If "Fuel Position" does not equal "Rated Fuel Limit" then check the inlet manifold air pressure. 2. Verify that there are no active diagnostic codes that are associated with the boost pressure sensor or with the atmospheric pressure sensor. 3. Monitor boost pressure and atmospheric pressure on the status screen for normal operation. Note: Atmospheric pressure is not a default parameter on a status screen. You must manually select the parameter for the atmospheric pressure in order to monitor the atmospheric pressure sensor. Fuel Supply 1. Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines. If problems are found with the fuel lines, repair the lines and/or replace the lines. 2. Check the fuel tank for foreign objects which may block the fuel supply. 3. Check for air in the fuel. Refer to Systems Operation/Testing and Adjusting, "Air in Fuel - Test". 4. Purge trapped air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. 5. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold weather operation. 6. Check the fuel pressure. Refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test". If the fuel pressure is low, replace the fuel filters. If the fuel pressure is still low, check the following items: fuel transfer pump, fuel transfer pump coupling and fuel pressure regulating valve. Air Inlet and Exhaust System 1. Clean plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance Manual for instructions. 2. Check the air inlet and exhaust system for restrictions and/or for leaks. Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System". Accessory Equipment Check all accessory equipment for problems that may create excessive load on the engine. Repair any damaged components or replace any damaged components.

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 4 of 4 Thu Apr 8 08:09:25 CDT 2010

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 1 of 4 Shutdown SIS Previous Screen Product: PETROLEUM ENGINE Model: C-15 PETROLEUM ENGINE Z2C Configuration: C-15 Petroleum Engine Z2C00001-UP Engine Cranks but Will Not Start SMCS - 1000-035 i02121223 The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Probable Causes ECM personality module Electrical power to the Electronic Control Module (ECM) Remote shutdown switch Air shutoff circuit Starting motor solenoid or starting circuit Engine speed/timing sensors Electrical connections to the electronic unit injector Fuel supply Combustion problem Recommended Actions ECM Personality Module

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 2 of 4 If a new ECM has been installed on the engine, the engine will not start. The ECM will not communicate with the Caterpillar Electronic Technician (ET) until the correct personality module has been flashed into the ECM. 1. Verify that the following diagnostic is not active. 253-02 Personality Module mismatch If the code is active, access the "Winflash" and flash the correct version of the software. Electrical Power to the ECM 1. Turn the keyswitch OFF. 2. Check the positive battery and negative battery connections to the ECM. 3. Perform a pull test on positive battery wires and negative battery wires. 4. Check the negative battery connection on the ground stud. 5. Turn the keyswitch ON. 6. The warning lamps should illuminate for five seconds. If the warning lamp illuminates for five seconds, continue with this procedure. If the warning lamp does not illuminate for five seconds, refer to the diagnostic functional test, "Electrical Power Supply Circuit - Test". Remote Shutdown Switch Access the screen on Cat ET that displays the remote shutdown switch status. The remote shutdown switch status on Cat ET is called "User Shutdown". Table 1 "User Shutdown Status" Switch Status Measured Voltage at P61:27 ON Negative battery <0.9 VDC OFF Open circuit >10 VDC If the voltage is not in the proper range, refer to the diagnostic functional test, "Switch Circuits - Test". Air Shutoff Circuit Refer to the diagnostic functional test, "Air Shutoff System - Test" for additional information. Starting Motor Solenoid or Starting Circuit

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 3 of 4 1. Test the operation of the starting motor solenoid. 2. Check the engine wiring to the starting motor solenoid. 3. Test the operation of the starting motor. 4. Inspect the starter motor pinion and the flywheel ring gear for damage. Engine Speed/Timing Sensors Observe the engine speed on Cat ET while the engine is being cranked. This situation may require a direct hookup to the batteries in order to power Cat ET while the engine is cranking. Refer to Illustration 1 for the wiring diagram. Illustration 1 g00781203 If the engine is cranking and Cat ET displays 0 rpm, a problem exists in the circuits for the engine speed/timing sensors. Refer to the diagnostic functional test, "Engine Speed/Timing Sensor Circuit - Test". If an engine speed is present, check the sensor installation. If the sensor is not properly installed, the ECM may read engine speed, but the ECM cannot determine the tooth pattern. The ability for the ECM to read the tooth pattern is necessary to determine the cylinder position. Engine speed is present when engine speed is greater than 50 rpm. Refer to the diagnostic functional test, "Engine Speed/Timing Sensor Circuit - Test". Electrical connections to the electronic unit injector 1. Ensure that the electronic unit injector connector (J300/P300) is fully connected and free of corrosion. 2. Check for logged diagnostic codes that are related to the cylinder. Refer to the diagnostic functional test

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 4 of 4, "Injector Solenoid Circuit - Test" if diagnostic codes that are related to the cylinder are present. Check the Fuel Supply 1. Check the fuel level. 2. Monitor the exhaust for smoke while the engine is being cranked. If no smoke is present, there may be a problem with the fuel quality or there may be a problem with the fuel supply. 3. Check the fuel pressure. Refer to Testing and Adjusting, "Fuel System Pressure - Test". 4. Ensure that the fuel system has been primed. Refer to Testing and Adjusting, "Fuel System - Prime". 5. Check for fuel supply lines that are restricted. 6. Check the fuel filters. 7. If the temperature is below 0 C (32 F), check for solidified fuel (wax). Check for Combustion Problems Examples of conditions that may cause combustion problems are shown in the following list: Cold temperatures Injector misfiring Low compression Mechanical problem Valve lash settings Refer to Testing and Adjusting for more information on a particular problem. Thu Apr 8 08:12:11 CDT 2010

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 1 of 3 Shutdown SIS Previous Screen Product: PETROLEUM ENGINE Model: C-15 PETROLEUM ENGINE Z2C Configuration: C-15 Petroleum Engine Z2C00001-UP Engine Misfires, Runs Rough or Is Unstable SMCS - 1000-035 i02291647 The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Note: If the symptom is intermittent and the symptom cannot be repeated, refer to the diagnostic procedure, "Intermittent Low Power or Power Cutout". If the symptom is consistent and the symptom can be repeated, continue with this procedure. Probable Causes Diagnostic codes Programmable parameters Electrical connectors Cold mode Throttle signal Unit injectors Fuel supply Air inlet and exhaust system

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 2 of 3 Recommended Actions Note: If the symptom only occurs under certain operating conditions (high idle, full load, engine operating temperature, etc), test the engine under those conditions. the symptom under other conditions can give misleading results. Diagnostic Codes Check for active diagnostic codes on the Caterpillar Electronic Technician (ET). Troubleshoot any active codes before continuing with this procedure. Programmable Parameters Check the following parameters on Cat ET: "Throttle Position Sensor" "Desired Speed Input Configuration" "Direct Fuel Control Mode" Determine the type of throttle that is used in the application. Program the parameters to match the type of throttle that is used. Refer to the diagnostic functional test, "Throttle Position Sensor Circuit - Test" for more information. Note: If the parameters are not programmed correctly, then the engine will have poor performance. Electrical Connectors Check for the correct installation of the J1/P1 and J2/P2 connectors for the Electronic Control Module (ECM). Check the unit injector connectors. Refer to the diagnostic functional test, "Electrical Connectors - Inspect". Cold Mode Use Cat ET to verify that the engine has exited cold mode. Cold mode operation may cause the engine to run rough and the engine power may be limited. Throttle Signal Monitor throttle signal on Cat ET. Verify that the throttle signal is stable from the low idle position to the high idle position. Unit Injectors 1. Use Cat ET to determine if there are any active diagnostic codes for the unit injectors. 2. Perform the Injector Solenoid Test on Cat ET in order to determine if all of the injector solenoids are being energized by the ECM.

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 3 of 3 3. Perform the Cylinder Cutout Test on Cat ET in order to identify any misfiring cylinder(s). Refer to, "Injector Solenoid Circuit - Test" for information. Fuel Supply 1. Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines. If problems are found with the fuel lines, repair the lines and/or replace the lines. 2. Check the fuel tank for foreign objects which may block the fuel supply. 3. Check for air in the low pressure fuel supply system if any of the following procedures have been performed: Replacement of the fuel filters Service on the low pressure fuel supply circuit Replacement of unit injectors 4. Purge air from the low pressure fuel supply circuit. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the complete procedure. Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. 5. Check fuel quality. In temperatures below 0 C (32 F), check for solidified fuel (wax). Refer to Operation and Maintenance Manual for information on cold weather operation. 6. Check the fuel pressure during engine cranking. Check the fuel pressure after the fuel filter. Refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test" for the correct pressure values. If the fuel pressure is low, replace the fuel filters. If the fuel pressure is still low, check the following items: fuel transfer pump, fuel transfer pump coupling and fuel pressure regulating valve. Air Inlet and Exhaust System 1. Check for an air filter restriction. Clean plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance Manual. 2. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Testing and Adjusting, "Air Inlet and Exhaust System". Thu Apr 8 08:13:01 CDT 2010

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 1 of 2 Shutdown SIS Previous Screen Product: PETROLEUM ENGINE Model: C-15 PETROLEUM ENGINE Z2C Configuration: C-15 Petroleum Engine Z2C00001-UP Engine Stalls at Low RPM SMCS - 1915-035 i02291686 The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Probable Causes Unit injectors Fuel supply Accessory equipment Recommended Actions Unit Injectors 1. Check for correct installation of the J1/P1 and J2/P2 connectors for the Electronic Control Module (ECM). Check for correct installation of the connectors for the unit injectors. Refer to, "Electrical Connectors - Inspect". 2. Perform the "Injector Solenoid Test" with the Caterpillar Electronic Technician (ET) in order to determine if all of the injector solenoids are being energized by the ECM. 3. Perform the "Cylinder Cutout Test" with Cat ET in order to identify any injectors that might be misfiring. Refer to, "Injector Solenoid Circuit - Test" for the proper procedure.

C-15 Petroleum Engine Z2C00001-UP(SEBP4170-08) - Document Structure https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... Page 2 of 2 Fuel Supply 1. Check the pressure of the low pressure fuel system during engine cranking. Check the pressure while the engine is running. Refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test" for the correct procedure. 2. Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines. If problems are found with the fuel lines, repair the lines and/or replace the lines. 3. Check the fuel tank for debris which may block the fuel supply. 4. Check for air in the low pressure fuel supply system if any of the following procedures have been performed: Replacement of the fuel filters Service on the low pressure fuel supply circuit Replacement of unit injectors Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer to Systems Operation/Testing and Adjusting, "Air in Fuel - Test" for more information. NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again. 5. Purge air from the low pressure fuel supply circuit. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. 6. Check fuel quality. In temperatures below 0 C (32 F), check for solidified fuel (wax). Refer to Operation and Maintenance Manual for information on cold weather operation. Accessory Equipment Check all accessory equipment for problems that may create excessive load on the engine. Repair any damaged components or replace any damaged components. Thu Apr 8 08:13:39 CDT 2010

Page 1 of 3 Intermittent Engine Shutdown SMCS - 1000-035 i02291705 The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Note: Use this procedure only if the engine shut down completely and it was necessary to restart the engine. Probable Causes Active diagnostic codes or engine events Incorrect parameters for engine rating Poor electrical connections to the Electronic Control Module (ECM) Poor electrical connections to the unit injector connectors Faulty remote shutdown switch Tripped circuit breakers Fuel supply Faulty overspeed verify switch (if applicable) Note: If the problem only occurs under certain conditions such as high engine speed, full load or engine operating temperature, then perform the test under those operating conditions. Recommended Actions Active Diagnostic Codes or Engine Events Certain diagnostic codes and/or event codes may cause the engine to shutdown. Connect the Caterpillar Electronic Technician (ET) and check for active codes and/or for logged codes. Troubleshoot any codes

Page 2 of 3 that are present before continuing with this procedure. Incorrect Parameters for Engine Rating The engine may be shut down due to low pressure levels or other factors. Connect Cat ET and check for active shutdowns or diagnostic codes. If a shutdown is active, "Injection Disabled" will appear on Cat ET. An engine shutdown event will appear on a CAN J1939 device if the device is capable of displaying diagnostic codes. Poor Electrical Connections to the ECM 1. Check the associated wiring for the following conditions: damage, abrasion, corrosion and incorrect attachment. J1/P1 and J2/P2 ECM connectors J61/P61 Customer connector J401/P401 and J402/P402 Engine Speed/Timing Sensor connectors Refer to the diagnostic functional test, "Electrical Connectors - Inspect". 2. Check Cat ET for an active 168-02 "System Voltage intermittent/erratic". Check the battery connection at the J61 customer connector and the ECM connector. Perform a pull test on the pin locations at the ECM that are associated with the +Battery and the Battery connections. Refer to the diagnostic functional test, " Electrical Connectors - Inspect". Note: Aftermarket engine protection devices usually interrupt power to the ECM. Check for correct installation and for operation of aftermarket engine protection devices. It may be necessary to bypass aftermarket devices in order to continue testing. Poor Electrical Connections to the Unit Injector Connectors Check the J300/P300 valve cover connectors and associated wiring for the following conditions: damage, abrasion, corrosion and incorrect attachment. Refer to the diagnostic functional test, "Electrical Connectors - Inspect". Faulty Remote Shutdown Switch Access a status screen in Cat ET that displays the remote shutdown switch status. The remote shutdown switch status on Cat ET is called "User Shutdown". Table 1

Page 3 of 3 "User Shutdown Status" Switch Status Measured Voltage at P61-27 ON Negative battery <0.9 VDC OFF Open circuit >10 VDC If the voltage is not in the proper range, refer to the diagnostic functional test, "Switch Circuits - Test". Tripped Circuit Breakers Check the circuit breakers. The circuit breakers may exceed the trip point due to overheating. Reset the circuit breakers if the circuit breakers are tripped. Fuel Supply Check for a problem with the fuel supply and verify the fuel pressure. Verify that the fuel pressure sensor is installed. Refer to Systems Operation/Testing and Adjusting for additional information. Faulty Overspeed Verify Switch If an overspeed condition has occurred, the air shutoff solenoid(s) must be reset manually. Remove wire for the overspeed verify switch from the ECM connector and test again. If the problem goes away, there is a problem in the circuit for the overspeed verify switch. Refer to the diagnostic functional test, "Switch Circuits - Test". Thu Apr 8 08:14:35 CDT 2010

Page 1 of 3 Intermittent Low Power or Power Cutout SMCS - 1000-035 i02291707 The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Note: Use this procedure only if the engine does not shut down completely. Probable Causes Active diagnostic codes or engine events Incorrect throttle signal Poor electrical connections Fuel supply Recommended Actions Active Diagnostic Codes or Engine Events Certain diagnostic codes and/or event codes may cause poor performance. Connect the Caterpillar Electronic Technician (ET) and check for active codes and logged codes. Troubleshoot any codes that are present before continuing with this procedure. Incorrect Throttle Signal Connect Cat ET to the service tool connector. View the status for the throttle position on the status screen. Operate the throttle from the low idle position to the high idle position. The status should be 0 percent at low idle and the status should be 100 percent at high idle. If the status cannot operate in the full range, refer to the calibration procedure, "Throttle Position Sensor - Calibrate". Diagnostic codes that are related to the J1939 data link will prevent correct operation of the throttle if the throttle position is transmitted over the data link. If there is a problem with the data link, the engine will remain at low idle until the data link is repaired.

Page 2 of 3 Poor Electrical Connections 1. Inspect the battery wires from the ECM back to the battery compartment. Refer to the Electrical System Schematic. Inspect the wires and the power relay. Check the power and ground connections to the ECM. Refer to the diagnostic functional test, "Electrical Power Supply Circuit - Test" for more information. Fuel Supply 1. Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines. If problems are found with the fuel lines, repair the lines and/or replace the lines. 2. Check the fuel tank for foreign objects which may block the fuel supply. 3. Check for air in the low pressure fuel supply system if any of the following procedures have been performed: Replacement of the fuel filters Service on the low pressure fuel supply circuit Replacement of unit injectors Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer to Systems Operation/Testing and Adjusting, "Air in Fuel - Test" for more information. NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again. 4. Purge air from the low pressure fuel supply circuit. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. 5. Check fuel quality. In temperatures below 0 C (32 F), check for solidified fuel (wax). Refer to Operation and Maintenance Manual for information on cold weather operation. 6. Check the fuel pressure after the fuel filter while the engine is being cranked. Refer to Systems Operation/Testing and Adjusting, "Fuel Pressure - Test" for the correct pressure values. If the fuel pressure is low, replace the fuel filters. If the fuel pressure is still low, check the following items: fuel transfer pump, fuel transfer pump coupling and fuel pressure regulating valve. Thu Apr 8 08:15:09 CDT 2010

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Page 1 of 4 Low Power/Poor or No Response to Throttle SMCS - 1000-035 i02291711 The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Probable Causes Active diagnostic codes or engine events Incorrect engine rating Incorrectly programmed parameters Cold mode operation Poor electrical connections Incorrect status of PTO enable switch Incorrect status of intermediate speed switch Incorrect throttle signal Poor connections to the electronic unit injectors Fuel supply Turbocharger outlet pressure sensor (intake manifold air), rated fuel position and/or FRC fuel position Air inlet and exhaust system Recommended Actions Note: If the problem only occurs under certain conditions, test the engine under those conditions.

Page 2 of 4 Examples of certain conditions are high rpm, full load and engine operating temperature. the symptoms under other conditions can give misleading results. Active Diagnostic Codes or Engine Events Certain diagnostic codes and/or event codes may cause poor performance. Connect the Caterpillar Electronic Technician (ET) and check for active codes and for logged codes. Troubleshoot any codes that are present before continuing with this procedure. Incorrect Engine Rating Verify that the correct engine rating is being used for the application. Improperly Programmed Parameters Check the following parameters on Cat ET: Verify that the injector codes have been programmed properly. "Throttle Position Sensor" "Desired Speed Input Configuration" "Direct Fuel Control Mode" Determine the type of throttle that is used in the application. Program the parameters to match the type of throttle that is used. Refer to the diagnostic functional test, "Throttle Position Sensor Circuit - Test" for more information. Note: If the parameters are not programmed correctly, then the engine will have poor performance. Cold Mode Monitor the status screen on Cat ET in order to verify that the engine has exited cold mode. Poor Electrical Connections Check the associated wiring for damage, abrasion, corrosion or incorrect attachment on the following connectors: J1/P1 and J2/P2 ECM connectors, customer connector and throttle position sensor connector. Refer to, "Electrical Connectors - Inspect" for information. Incorrect Status of PTO Enable Switch Connect Cat ET and verify that the "PTO enable switch" is not engaged. Remove the wiring for the PTO enable switch and cycle the power to the ECM. Verify that the problem is still present. If the problem is still present, reattach the wires and continue to next step. If the problem is resolved, refer to the diagnostic functional test, "Switch Circuits - Test". Incorrect Status of Intermediate Speed Switch

Page 3 of 4 Connect Cat ET and verify that the intermediate speed switch is not engaged. Remove the wiring for intermediate speed and cycle power to the ECM. Verify that the problem is still present. If the problem is still present, reattach the wires and continue to next step. If the problem is resolved, refer to the diagnostic functional test, "Switch Circuits - Test". Incorrect Throttle Signal Connect Cat ET to the service tool connector. View the status for the throttle position on the status screen. Operate the throttle from the low idle position to the high idle position. The status should be approximately 0 percent at low idle and the status should be approximately 100 percent at high idle. If the status cannot operate in the full range, refer to the calibration procedure, "Throttle Position Sensor - Calibrate". Diagnostic codes that are related to the J1939 data link will prevent correct operation of the throttle if the throttle position is transmitted over the data link. If there is a problem with the data link, the engine will remain at low idle until the data link is repaired. Poor Connections to the Electronic Unit Injectors Inspect the J2/P2 ECM connector and the J300/P300 valve cover connector for proper connections. Refer to, " Electrical Connectors - Inspect". Connect Cat ET and cut out each cylinder in order to isolate the misfiring cylinder or cylinders. If the results are inconclusive, shut off half of the cylinders and repeat the cylinder cutout test on the active cylinders that are remaining in order to locate those cylinders that are missing. Refer to the diagnostic functional test, "Injector Solenoid Circuit - Test". Fuel Supply Check for a problem with the fuel supply and verify the fuel pressure. Verify that a fuel pressure sensor is installed on the engine. For further information, refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test". Turbocharger Outlet Pressure Sensor (Intake Manifold Air), Rated Fuel Position and/or FRC Fuel Position 1. With the engine at full load, monitor "Fuel Position" and "Rated Fuel Limit" on the status screen. If "Fuel Position" does not equal "Rated Fuel Limit", then check air inlet manifold pressure. 2. Verify that there are no active diagnostic codes that are associated with the turbocharger outlet pressure sensor (intake manifold air) or with the atmospheric pressure sensor. 3. Monitor air inlet manifold pressure and atmospheric pressure for normal operation on the status screen. Air Inlet and Exhaust System Check the air inlet and exhaust systems for restrictions and for leaks. Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect". Look for an indication of the warning lamp or restriction indicators that are tripped if the filters are equipped with these devices. These indicators are associated with plugged filters. Replace the plugged air filters or clean the plugged

Page 4 of 4 air filters per the guidelines for operation and maintenance. Repair any leaks that are found in the system. Thu Apr 8 08:15:33 CDT 2010

Page 1 of 4 Diagnostic Codes SMCS - 1900 Diagnostic Codes Diagnostic codes alert the operator that a problem in the electronic system has been detected. Diagnostic codes are also used by the service technician to identify the nature of the problem. Caterpillar Electronic Technician (ET) is a software program that is designed to run on a personal computer. The software can be used by the service technician in order to view the diagnostic code information for an ECM. Diagnostic codes may consist of the component identifier (CID), and the failure mode identifier (FMI). Component Identifier (CID) - The CID indicates the component that generated the code. For example, the CID number 1 identifies the fuel injector for the number one cylinder. Failure Mode Identifier (FMI) - The FMI indicates the type of failure. Suspect Parameter Number (SPN) - The SPN is a three digit code which is assigned to each component in order to identify data via the data link to the ECM. This is used on the diagnostics for the CAN data link. Refer to, "Diagnostic Code Cross Reference" for the complete list of the diagnostic codes and a description of each code. There is a troubleshooting procedure for every diagnostic code. Refer to, " With A Diagnostic Code". When a diagnostic code is activated, the Electronic Control Module (ECM) transmits information about the code over the J1939 data link. Some J1939 devices may display the code. However, the code will be displayed with a SPN-FMI code. Refer to, "Diagnostic Code Cross Reference" for a cross-reference between SPN-FMI codes and diagnostic codes. Do not confuse diagnostic codes with event codes. Event codes alert the operator that an abnormal operating condition such as low oil pressure or high coolant temperature has been detected. Refer to, " with an Event Code" for additional information on event codes. Illustration 1 is an example of the operating range of a sensor. i02769238 View Image

Page 2 of 4 Illustration 1 g01365757 Example of the typical operating range of a sensor (1) This area represents the normal operating range of the engine parameter. (2) In these areas, the engine is operating in an unsafe operating range of the monitored parameter. An event code will be generated for the monitored parameter. The sensor circuit does not have an electronic problem. Refer to,

Page 3 of 4 " with an Event Code" for additional information on event codes. (3) In these areas, the signal from the sensor is outside of the operating range of the sensor. The sensor circuit has an electronic problem. A diagnostic code will be generated for the sensor circuit. Active Diagnostic Codes An active diagnostic code represents a problem with the electronic control system. Correct the problem as soon as possible. When the ECM generates an active diagnostic code, the "Active Alarm" indicator ("Engine Control Alarm Status" on Cat ET) is activated in order to alert the operator. If the condition that generated the code is momentary, the message disappears from the list of active diagnostic codes. The diagnostic code becomes logged. Logged Diagnostic Codes When the ECM generates a diagnostic code, the ECM logs the code in permanent memory. The ECM has an internal diagnostic clock. Each ECM will record the following information when a code is generated: The hour of the first occurrence of the code The hour of the last occurrence of the code The number of occurrences of the code This information is a valuable indicator for troubleshooting intermittent problems. A code is cleared from memory when one of the following conditions occur: The service technician manually clears the code. The code does not recur for 100 hours. A new code is logged and there are already ten codes in memory. In this case, the oldest code is cleared. Some diagnostic codes may be easily triggered. Some diagnostic codes may log occurrences that did not result in complaints. The most likely cause of an intermittent problem is a faulty connection or damaged wiring. The next likely cause is a component failure. The least likely cause is the failure of an electronic module. Diagnostic codes that are logged repeatedly may indicate a problem that needs special investigation. Note: Always clear logged diagnostic codes after investigating and correcting the problem which generated the code.

Page 4 of 4 Thu Apr 8 08:16:03 CDT 2010

Page 1 of 4 Diagnostic Code Cross Reference SMCS - 1900 Problems with the electronic control system are reported via these types of codes: flash codes, diagnostic codes and event codes. For information on flash codes, refer to, "Flash Codes". For information on diagnostic codes, refer to, "Diagnostic Codes". For information on event codes, refer to, "Event Codes". Use Table 1 as a cross-reference between the various types of codes. Table 1 Cross Reference for Flash Codes i02292113 Flash Code Diagnostic or Event Code SPN/FMI Code Description of Code E443 1835-00 High Auxiliary Pressure E445 1836-00 High Auxiliary Temperature 545-05 545-05 Ether Start Relay open/short to +batt N/A 545-06 545-06 Ether Start Relay short to ground 1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt 1835-04 1835-04 Auxiliary Pressure Sensor short to ground 1836-08 1836-08 Auxiliary Temperature Sensor abnormal signal 13 174-03 174-03 Fuel Temperature open/short to +batt 174-04 174-04 Fuel Temperature short to ground 41-03 N/A 8 Volt DC Supply short to +batt 41-04 N/A 8 Volt DC Supply short to groundt

Page 2 of 4 262-03 620-03 5 Volt Sensor DC Power Supply short to +batt 21 262-04 620-04 5 Volt Sensor DC Power Supply short to ground 263-03 678-03 Digital Sensor Supply short to +batt 263-04 678-04 Digital Sensor Supply short to ground 24 100-03 100-03 Engine Oil Pressure open/short to +batt 100-04 100-04 Engine Oil Pressure short to ground 273-00 102-00 Turbo Outlet Pressure above normal 25 273-03 102-03 Turbo Outlet Pressure open/short to +batt 273-04 102-04 Turbo Outlet Pressure short to ground 26 27 274-03 108-03 Atmospheric Pressure open/short to +batt 274-04 108-04 Atmospheric Pressure short to ground 110-03 110-03 Engine Coolant Temperature open/short to +batt 110-04 110-04 Engine Coolant Temperature short to ground 28 91-13 91-13 Throttle Position calibration required 32 91-08 91-08 Throttle Position signal abnormal 320-02 190-02 Speed/Timing Sensor Loss of Signal 34 320-11 190-11 Speed/Timing Sensor mechanical failure 342-02 723-02 Loss of Secondary Engine Speed signal 342-11 723-11 Secondary Engine Speed Sensor mechanical failure 35 37 38 42 E004 0190-16 Engine Overspeed Shutdown E190 0190-00 Engine Overspeed Warning 94-03 94-03 Fuel Pressure open/short to +batt 94-04 94-04 Fuel Pressure short to ground 172-03 172-03 Intake Manifold Air Temp open/short to +batt 172-04 172-04 Intake Manifold Air Temp short to ground 22-13 N/A Timing Sensor calibration required

Page 3 of 4 261-13 228-13 Engine Timing calibration required E039 0100-18 Low Engine Oil Pressure Derate 46 E040 100-01 Low Engine Oil Pressure Shutdown E100 100-17 Low Engine Oil Pressure Warning 51 168-02 168-02 System Voltage intermittent/erratic 53 254-12 N/A Electronic Control Module Error 56 253-02 234-02 Personality Module mismatch 268-02 1111-02 Check Programmable Parameters 58 247-09 639-09 J1939 Data Link communications E015 110-16 High Engine Coolant Temperature Derate 61 E016 110-00 High Engine Coolant Temperature Shutdown E017 110-15 High Engine Coolant Temperature Warning E057 111-18 Low Engine Coolant Level Derate 62 E058 111-01 Low Engine Coolant Level Shutdown E059 111-17 Low Engine Coolant Level Warning E005 94-15 Fuel Filter Restriction Derate 63 E006 94-16 Fuel Filter Restriction Shutdown E095 94-00 Fuel Filter Restriction Warning E096 94-00 High Fuel Pressure 64 E025 172-16 High Inlet Air Temperature Derate E027 172-15 High Inlet Air Temperature Warning E054 174-16 High Fuel Temperature Derate 65 E055 174-00 High Fuel Temperature Shutdown E056 174-15 High Fuel Temperature Warning 72 73 1-11 651-11 Injector Cylinder #1 fault 2-11 652-11 Injector Cylinder #2 fault 3-11 653-11 Injector Cylinder #3 fault 4-11 654-11 Injector Cylinder #4 fault

Page 4 of 4 74 5-11 655-11 Injector Cylinder #5 fault 6-11 656-11 Injector Cylinder #6 fault Thu Apr 8 08:16:30 CDT 2010

Page 1 of 4 Diagnostic Code Cross Reference SMCS - 1900 Problems with the electronic control system are reported via these types of codes: flash codes, diagnostic codes and event codes. For information on flash codes, refer to, "Flash Codes". For information on diagnostic codes, refer to, "Diagnostic Codes". For information on event codes, refer to, "Event Codes". Use Table 1 as a cross-reference between the various types of codes. Table 1 Cross Reference for Flash Codes i02292113 Flash Code Diagnostic or Event Code SPN/FMI Code Description of Code E443 1835-00 High Auxiliary Pressure E445 1836-00 High Auxiliary Temperature 545-05 545-05 Ether Start Relay open/short to +batt N/A 545-06 545-06 Ether Start Relay short to ground 1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt 1835-04 1835-04 Auxiliary Pressure Sensor short to ground 1836-08 1836-08 Auxiliary Temperature Sensor abnormal signal 13 174-03 174-03 Fuel Temperature open/short to +batt 174-04 174-04 Fuel Temperature short to ground 41-03 N/A 8 Volt DC Supply short to +batt 41-04 N/A 8 Volt DC Supply short to groundt

Page 2 of 4 262-03 620-03 5 Volt Sensor DC Power Supply short to +batt 21 262-04 620-04 5 Volt Sensor DC Power Supply short to ground 263-03 678-03 Digital Sensor Supply short to +batt 263-04 678-04 Digital Sensor Supply short to ground 24 100-03 100-03 Engine Oil Pressure open/short to +batt 100-04 100-04 Engine Oil Pressure short to ground 273-00 102-00 Turbo Outlet Pressure above normal 25 273-03 102-03 Turbo Outlet Pressure open/short to +batt 273-04 102-04 Turbo Outlet Pressure short to ground 26 27 274-03 108-03 Atmospheric Pressure open/short to +batt 274-04 108-04 Atmospheric Pressure short to ground 110-03 110-03 Engine Coolant Temperature open/short to +batt 110-04 110-04 Engine Coolant Temperature short to ground 28 91-13 91-13 Throttle Position calibration required 32 91-08 91-08 Throttle Position signal abnormal 320-02 190-02 Speed/Timing Sensor Loss of Signal 34 320-11 190-11 Speed/Timing Sensor mechanical failure 342-02 723-02 Loss of Secondary Engine Speed signal 342-11 723-11 Secondary Engine Speed Sensor mechanical failure 35 37 38 42 E004 0190-16 Engine Overspeed Shutdown E190 0190-00 Engine Overspeed Warning 94-03 94-03 Fuel Pressure open/short to +batt 94-04 94-04 Fuel Pressure short to ground 172-03 172-03 Intake Manifold Air Temp open/short to +batt 172-04 172-04 Intake Manifold Air Temp short to ground 22-13 N/A Timing Sensor calibration required

Page 3 of 4 261-13 228-13 Engine Timing calibration required E039 0100-18 Low Engine Oil Pressure Derate 46 E040 100-01 Low Engine Oil Pressure Shutdown E100 100-17 Low Engine Oil Pressure Warning 51 168-02 168-02 System Voltage intermittent/erratic 53 254-12 N/A Electronic Control Module Error 56 253-02 234-02 Personality Module mismatch 268-02 1111-02 Check Programmable Parameters 58 247-09 639-09 J1939 Data Link communications E015 110-16 High Engine Coolant Temperature Derate 61 E016 110-00 High Engine Coolant Temperature Shutdown E017 110-15 High Engine Coolant Temperature Warning E057 111-18 Low Engine Coolant Level Derate 62 E058 111-01 Low Engine Coolant Level Shutdown E059 111-17 Low Engine Coolant Level Warning E005 94-15 Fuel Filter Restriction Derate 63 E006 94-16 Fuel Filter Restriction Shutdown E095 94-00 Fuel Filter Restriction Warning E096 94-00 High Fuel Pressure 64 E025 172-16 High Inlet Air Temperature Derate E027 172-15 High Inlet Air Temperature Warning E054 174-16 High Fuel Temperature Derate 65 E055 174-00 High Fuel Temperature Shutdown E056 174-15 High Fuel Temperature Warning 72 73 1-11 651-11 Injector Cylinder #1 fault 2-11 652-11 Injector Cylinder #2 fault 3-11 653-11 Injector Cylinder #3 fault 4-11 654-11 Injector Cylinder #4 fault

Page 4 of 4 74 5-11 655-11 Injector Cylinder #5 fault 6-11 656-11 Injector Cylinder #6 fault Thu Apr 8 08:16:30 CDT 2010

Page 1 of 1 CID 0001 FMI 11 Cylinder #1 Injector fault SMCS - 1290-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) is attempting to operate the injector. The ECM detects an open circuit or a short circuit in the circuit for the injector. If the cause of the diagnostic code is a problem in the common wire, two cylinders will be affected because of the shared common wire for the injectors. System Response: The ECM will log the diagnostic code. The ECM will continue to attempt to operate the injector after the code has been logged. The injector may not operate while the condition exists. Engine misfires Low power Test Step 1. Perform the following diagnostic procedure: Injector Solenoid Circuit - Test OK - STOP i03640720 Thu Apr 8 08:24:04 CDT 2010

Page 1 of 1 CID 0022 FMI 13 Timing Sensor calibration required SMCS - 1912-038 Conditions Which Generate This Code: The timing has not been calibrated since the Electronic Control Module (ECM) was installed or the calibration is out of the specification by more than four degrees. System Response: The ECM uses the default timing. The engine may run rough and/or the engine may emit white smoke in the exhaust. Test Step 1. Perform the following diagnostic procedure: Engine Speed/Timing Sensor - Calibrate OK - STOP i02048960 Thu Apr 8 08:24:29 CDT 2010

Page 1 of 1 CID 0041 FMI 03 8 Volt DC Supply short to +batt SMCS - 5574-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects all of the following conditions: The ECM has been powered for at least three seconds. The ECM reads signal voltage that is above 8.4 VDC for two seconds. System Response: The ECM will log the diagnostic code. The ECM flags all digital sensors as invalid data and all digital sensors are set to the respective default values. Low power Test Step 1. Perform the following diagnostic procedure: Digital Sensor Supply Circuit - Test OK - STOP i01942631 Thu Apr 8 08:24:48 CDT 2010

Page 1 of 1 CID 0041 FMI 04 8 Volt DC Supply short to ground SMCS - 5574-038 Conditions Which Generate This Code: The voltage level of the 8 volt supply is below normal. System Response: The Electronic Control Module (ECM) logs the diagnostic code. The ECM flags all digital sensors as invalid data and all digital sensors are set to the respective default values. The engine may experience low power. Test Step 1. Perform the following diagnostic procedure: Digital Sensor Supply Circuit - Test OK - STOP i02419278 Thu Apr 8 08:25:03 CDT 2010

Page 1 of 1 CID 0091 FMI 08 Throttle Position signal abnormal SMCS - 1913-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects an incorrect frequency on the throttle signal. System Response: The code is logged. The ECM flags the throttle position as invalid data and a default value of zero percent is used. The engine speed is limited to low idle. Test Step 1. Perform the following diagnostic procedure: Throttle Position Sensor Circuit - Test OK - STOP i02417388 Thu Apr 8 08:25:23 CDT 2010

Page 1 of 1 CID 0091 FMI 13 Throttle Position calibration required SMCS - 1913-038 Conditions Which Generate This Code: The duty cycle of the signal from the throttle that is connected to the primary throttle input is incorrect. System Response: The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags the throttle position as invalid data and a default value of zero percent is used. The engine speed is limited to low idle. Test Step 1. Perform the following diagnostic procedure: Throttle Position Sensor - Calibrate OK - STOP i02426246 Thu Apr 8 08:25:37 CDT 2010

Page 1 of 1 CID 0094 FMI 03 Fuel Pressure open/short to +batt SMCS - 1718-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) reads signal voltage that is above normal. System Response: The ECM will log the diagnostic code. The ECM flags fuel pressure as invalid data and a default value is used. There are no performance effects. Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short Circuit - Test OK - STOP i02424760 Thu Apr 8 08:25:57 CDT 2010

Page 1 of 1 CID 0094 FMI 04 Fuel Pressure short to ground SMCS - 1718-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) reads signal voltage that is below normal. System Response: The ECM will log the diagnostic code. The ECM flags fuel pressure as invalid data and a default value is used. There are no performance effects. Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short Circuit - Test OK - STOP i02424763 Thu Apr 8 08:26:36 CDT 2010

Page 1 of 1 CID 0100 FMI 03 Engine Oil Pressure open/short to +batt SMCS - 1924-038 Conditions Which Generate This Code: The signal voltage from the engine oil pressure sensor is above 4.8 VDC for at least eight seconds. System Response: The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags oil pressure as invalid data and a default value of 600 kpa (87 psi) is used. Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short Circuit - Test OK - STOP i02378792 Thu Apr 8 08:26:52 CDT 2010

Page 1 of 1 CID 0100 FMI 04 Engine Oil Pressure short to ground SMCS - 1924-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects a signal voltage that is below normal. System Response: The code is logged. The ECM flags oil pressure as invalid data and a default value is used. There are no performance effects. Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short Circuit - Test OK - STOP i02424648 Thu Apr 8 08:27:07 CDT 2010

Page 1 of 1 CID 0110 FMI 03 Engine Coolant Temperature open/short to +batt SMCS - 1906-038 Conditions Which Generate This Code: The signal voltage from the engine coolant temperature sensor is above normal. System Response: The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags coolant temperature as invalid data and a default value is used. The engine will not go into cold mode. The engine may misfire. The engine may experience reduced speed (rpm) and/or low power. Test Step 1. Perform the following diagnostic procedure: Engine Temperature Sensor Open or Short Circuit - Test OK - STOP i02427669 Thu Apr 8 08:27:21 CDT 2010

Page 1 of 1 CID 0110 FMI 04 Engine Coolant Temperature short to ground SMCS - 1906-038 Conditions Which Generate This Code: The signal voltage from the engine coolant temperature sensor is below normal. System Response: The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags coolant temperature as invalid data and a default value is used. The engine will not go into cold mode. The engine may misfire. The engine may experience reduced speed (rpm) and/or low power. Test Step 1. Perform the following diagnostic procedure: Engine Temperature Sensor Open or Short Circuit - Test OK - STOP i02427678 Thu Apr 8 08:27:40 CDT 2010

Page 1 of 1 CID 0168 FMI 02 System Voltage intermittent/erratic SMCS - 1401-038 Conditions Which Generate This Code: While the engine is running, the battery voltage drops below 9 VDC intermittently, or the battery voltage drops below 9 VDC three times in a seven second period. System Response: The Electronic Control Module (ECM) will log the diagnostic code. The engine may misfire and/or shutdown Test Step 1. Perform the following diagnostic procedure: Electrical Power Supply Circuit - Test OK - STOP i02458713 Thu Apr 8 08:27:55 CDT 2010

Page 1 of 1 CID 0172 FMI 03 Intake Manifold Air Temp open/short to +batt SMCS - 1921-038 Conditions Which Generate This Code: The signal voltage from the inlet air temperature sensor exceeds 4.9 VDC for eight seconds. System Response: The Electronic Control Module (ECM) logs the diagnostic code. The ECM flags Inlet air temperature as invalid data and a default temperature of 85 C (185 F) is used. Low power Test Step 1. Perform the following diagnostic procedure: Engine Temperature Sensor Open or Short Circuit - Test OK - STOP i02378820 Thu Apr 8 08:28:15 CDT 2010

Page 1 of 1 CID 0172 FMI 04 Intake Manifold Air Temp short to ground SMCS - 1921-038 Conditions Which Generate This Code: The signal voltage from the inlet air temperature sensor dropped below 0.2 VDC for eight seconds. System Response: The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags Inlet air temperature as invalid data and a default value of 85 C (185 F) is used. Low power Test Step 1. Perform the following diagnostic procedure: Engine Temperature Sensor Open or Short Circuit - Test OK - STOP i02378836 Thu Apr 8 08:28:37 CDT 2010

Page 1 of 1 CID 0174 FMI 03 Fuel Temperature open/short to +batt SMCS - 1922-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects signal voltage that is above normal. System Response: The ECM will log the diagnostic code. The ECM flags fuel temperature as invalid data and a default value is used. Low power Test Step 1. Perform the following diagnostic procedure: Engine Temperature Sensor Open or Short Circuit - Test OK - STOP i02385225 Thu Apr 8 08:28:53 CDT 2010

Page 1 of 1 CID 0174 FMI 04 Fuel Temperature short to ground SMCS - 1922-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects signal voltage that is below normal. System Response: The ECM will log the diagnostic code. The ECM flags fuel temperature as invalid data and a default value is used. There are no performance effects. Test Step 1. Perform the following diagnostic procedure: Engine Temperature Sensor Open or Short Circuit - Test OK - STOP i02424798 Thu Apr 8 08:29:12 CDT 2010

Page 1 of 1 CID 0247 FMI 09 J1939 Data Link communications i02490447 SMCS - 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has detected a loss of communications with the J1939 data link. Ensure that all flash files in the control system are current. System Response: The ECM will log the diagnostic code. The engine may not operate properly and/or the equipment may not have engine speed control. Test Step 1. Perform the following diagnostic procedure: CAN Data Link Circuit - Test OK - STOP

Page 1 of 2 CID 0253 FMI 02 Personality Module mismatch SMCS - 1902-038 Conditions Which Generate This Code: The flash file that is used for replacement is for a different engine family or for a different engine application. System Response: Caterpillar Electronic Technician (ET) will not be able to clear the code. The fuel injection system is disabled and the engine will not start. Test Step 1. Check the Part Number of the Flash File A. Restore the electrical power to the Electronic Control Module (ECM). B. Verify that the part number for the flash file agrees with the latest update that is available on Service Technician Workbench (STW), or on SIS Web. Expected Result: The correct flash file is installed in the ECM. OK - The correct flash file is installed in the ECM. Repair: The engine will not start until the 253-02 diagnostic code is cleared. Clearing this code requires factory passwords.acquire factory passwords. Clear the 253-02 diagnostic code. Return the engine to service. STOP Not OK - The correct flash file is not installed in the ECM. Repair: Flash program the ECM with the correct flash file. Refer to programming parameters, "Flash Programming". Verify that the problem is resolved. STOP i02428636

Page 2 of 2 Thu Apr 8 08:30:18 CDT 2010

Page 1 of 1 CID 0254 FMI 12 Electronic Control Module Error SMCS - 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has detected an internal fault. System Response: The ECM will log the diagnostic code. Engine power and engine performance may be affected. Any normal ECM function may be affected. Engine shutdown Test Step 1. Replace the ECM. Ensure that the new ECM serial number ends with the same two characters as the old ECM serial number. Refer to, "Replacing the ECM" before replacing the ECM. OK - STOP i02125661 Thu Apr 8 08:30:56 CDT 2010

Page 1 of 1 CID 0261 FMI 13 Engine Timing Calibration required SMCS - 1912-038 Conditions Which Generate This Code: The timing has not been calibrated since the Electronic Control Module (ECM) was installed or the calibration is incorrect. System Response: The ECM will log the diagnostic code. The ECM uses default timing. Engine misfires Low power Reduced engine speed White exhaust smoke Increased exhaust emissions Test Step 1. Perform the following diagnostic procedure: Engine Speed/Timing Sensor - Calibrate OK - STOP i02348802 Thu Apr 8 08:31:29 CDT 2010

Page 1 of 1 CID 0262 FMI 03 5 Volt Sensor DC Power Supply short to +batt SMCS - 5574-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects the following condition: The analog sensor supply voltage is greater than 5.2 VDC for one second. System Response: The ECM will log the diagnostic code. The ECM flags all analog sensors as invalid data and all analog sensors are set to the respective default values. Low power Test Step 1. Perform the following diagnostic procedure: 5 Volt Engine Pressure Sensor Supply Circuit - Test OK - STOP i02121647 Thu Apr 8 08:32:01 CDT 2010

Page 1 of 1 CID 0262 FMI 04 5 Volt Sensor DC Power Supply short to ground SMCS - 5574-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects the following condition: The analog sensor supply voltage is less than 4.8 VDC for one second. System Response: The ECM will log the diagnostic code. The ECM flags all analog sensors as invalid data and all analog sensors are set to the respective default values. Low power Test Step 1. Perform the following diagnostic procedure: 5 Volt Engine Pressure Sensor Supply Circuit - Test OK - STOP i02121649 Thu Apr 8 08:32:41 CDT 2010

Page 1 of 1 CID 0263 FMI 03 Digital Sensor Supply short to +batt SMCS - 5574-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects supply voltage that is above normal. System Response: The ECM will log the diagnostic code. The ECM flags all digital sensors as invalid data and all digital sensors are set to the respective default values. The engine may experience low power. Test Step 1. Perform the following diagnostic procedure: Digital Sensor Supply Circuit - Test OK - STOP i02461066 Thu Apr 8 08:33:20 CDT 2010

Page 1 of 1 CID 0263 FMI 04 Digital Sensor Supply short to ground SMCS - 5574-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects supply voltage that is below normal. System Response: The ECM will log the diagnostic code. The ECM flags all digital sensors as invalid data and all digital sensors are set to the respective default values. The engine may experience low power. Test Step 1. Perform the following diagnostic procedure: Digital Sensor Supply Circuit - Test OK - STOP i02461080 Thu Apr 8 08:33:54 CDT 2010

Page 1 of 1 CID 0268 FMI 02 Check Programmable Parameters SMCS - 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects that one or more of the programmable parameters have not been programmed. System Response: The diagnostic code is not logged. Any unprogrammed parameters are set to the default value. Engine performance may be affected. This is dependent on the unprogrammed parameters. Low power Test Step 1. Use Caterpillar Electronic Technician (ET) to reprogram the system configuration parameters. Refer to, "System Configuration Parameters" for additional information. A 0268-2 code is active - Repair: Identify the condition that is displayed beneath the code:if a programmable parameter is displayed, program that parameter with the correct value.if "Injector Code" is displayed, load the missing injector trim file into the ECM. STOP i02713570 Thu Apr 8 08:34:36 CDT 2010

Page 1 of 1 CID 0273 FMI 00 Turbo Outlet Pressure above normal SMCS - 1917-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects all of the following conditions: The outlet pressure of the turbocharger is greater than 200 kpa (29 psi). The engine speed is within 50 rpm of low idle for five seconds. The ECM has been powered for at least three seconds. System Response: The ECM will log the diagnostic code. The ECM flags turbocharger compressor outlet pressure as invalid data and a default value of 0 kpa (0 psi) is used. Low power Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short Circuit - Test OK - STOP i02071664 Thu Apr 8 08:34:56 CDT 2010

Page 1 of 1 CID 0273 FMI 03 Turbo Outlet Pressure open/short to +batt SMCS - 1917-038 Conditions Which Generate This Code: With an engine speed of zero rpm, the signal voltage for the turbocharger outlet pressure sensor exceeds 4.95 VDC for at least two seconds. System Response: The Electronic Control Module (ECM) logs the diagnostic code. The ECM flags the turbocharger outlet pressure as invalid data. A default value of 100 kpa (14.5 psi) is used. Low power Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short Circuit - Test OK - STOP i02378875 Thu Apr 8 08:35:22 CDT 2010

Page 1 of 1 CID 0273 FMI 04 Turbo Outlet Pressure short to ground SMCS - 1917-038 Conditions Which Generate This Code: The signal voltage for the turbocharger outlet pressure sensor falls below 0.5 VDC for two seconds. System Response: The Electronic Control Module (ECM) logs the diagnostic code. The ECM flags turbocharger outlet pressure as invalid data. A default value of 100 kpa (14.5 psi) is used. Low power Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short Circuit - Test OK - STOP i02378876 Thu Apr 8 08:35:36 CDT 2010

Page 1 of 1 CID 0274 FMI 03 Atmospheric Pressure open/short to +batt SMCS - 1923-038 Conditions Which Generate This Code: The signal voltage from the atmospheric pressure sensor is above 4.8 VDC for at least eight seconds. System Response: The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags atmospheric pressure as invalid data and a default value of 100 kpa (15 psi) is used. Low power Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short Circuit - Test OK - STOP i02281091 Thu Apr 8 08:35:51 CDT 2010

Page 1 of 1 CID 0274 FMI 04 Atmospheric Pressure short to ground SMCS - 1923-038 Conditions Which Generate This Code: The signal voltage from the atmospheric pressure sensor is below normal. System Response: The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags atmospheric pressure as invalid data and a default value is used. The engine may experience low power. Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short Circuit - Test OK - STOP i02473210 Thu Apr 8 08:36:05 CDT 2010

Page 1 of 1 CID 0320 FMI 02 Speed/Timing Sensor Loss of Signal SMCS - 1912-038 Conditions Which Generate This Code: The signal for the primary engine speed/timing sensor is intermittent or lost for less than one second. System Response: The Electronic Control Module (ECM) will use the secondary engine speed/timing sensor in order to determine engine speed. The ECM will log the diagnostic code. There may be a slight change in engine response when the ECM is switched to the secondary engine speed/timing sensor. Test Step 1. Perform the following diagnostic procedure: Engine Speed/Timing Sensor Circuit - Test OK - STOP i02085690 Thu Apr 8 08:36:20 CDT 2010

Page 1 of 1 CID 0320 FMI 11 Speed/Timing Sensor mechanical failure SMCS - 1912-038 Conditions Which Generate This Code: The signal for the primary engine speed/timing sensor is lost for more than one second. System Response: The Electronic Control Module (ECM) will use the secondary engine speed/timing sensor in order to determine engine speed. The ECM will log the diagnostic code. There may be a slight change in engine response when the ECM is switched to the secondary engine speed/timing sensor. Test Step 1. Perform the following diagnostic procedure: Engine Speed/Timing Sensor Circuit - Test OK - STOP i02085691 Thu Apr 8 08:36:36 CDT 2010

Page 1 of 1 CID 0342 FMI 02 Loss of Secondary Engine Speed signal SMCS - 1907-038 Conditions Which Generate This Code: The signal from the secondary engine speed/timing sensor is intermittent or lost for less than one second. System Response: The Electronic Control Module (ECM) will log the diagnostic code. Engine misfires during starting Engine shutdown Note: The engine will shut down only if the primary engine speed/timing sensor and the secondary engine speed/timing sensor fail. Test Step 1. Perform the following diagnostic procedure: Engine Speed/Timing Sensor Circuit - Test OK - STOP i02085693 Thu Apr 8 08:36:51 CDT 2010

Page 1 of 1 CID 0342 FMI 11 Secondary Engine Speed Sensor mechanical failure SMCS - 1907-038 Conditions Which Generate This Code: The signal for the secondary engine speed/timing sensor is lost for more than one second. System Response: The Electronic Control Module (ECM) will log the diagnostic code. Engine misfires during starting Engine shutdown Note: The engine will shut down only if the primary engine speed/timing sensor and the secondary engine speed/timing sensor fail. Test Step 1. Perform the following diagnostic procedure: Engine Speed/Timing Sensor Circuit - Test OK - STOP i02085697 Thu Apr 8 08:37:05 CDT 2010

Page 1 of 1 CID 0545 FMI 05 Ether Start Relay open/short to +batt SMCS - 4493-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects all of the following conditions: An open circuit or a short to +Battery condition is detected at the ether relay output for at least two seconds. The driver output is off. Battery voltage is greater than 9 VDC for the last two seconds. The ECM has been powered for at least three seconds. System Response: The ECM will log the diagnostic code. Ether injection is disabled. Hard starting Test Step 1. Perform the following diagnostic procedure: Ether Injection System - Test OK - STOP i01939089 Thu Apr 8 08:37:18 CDT 2010

Page 1 of 1 CID 0545 FMI 06 Ether Start Relay short to ground SMCS - 4493-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects all of the following conditions: The ECM has detected an open or a short to ground at the output for the ether relay for at least two seconds. The driver output is on. Battery voltage is greater than 9 VDC for the last two seconds. The ECM has been powered for at least three seconds. System Response: The ECM will log the diagnostic code. Ether injection is disabled. Hard starting Test Step 1. Perform the following diagnostic procedure: Ether Injection System - Test OK - STOP i01942702 Thu Apr 8 08:37:36 CDT 2010

Page 1 of 1 CID 1835 FMI 03 Auxiliary Pressure Sensor open/short to +batt SMCS - 5574-038-PX Conditions Which Generate This Code: The Electronic Control Module (ECM) detects a signal voltage that is above normal. System Response: The ECM logs the diagnostic code. The value of the auxiliary pressure is set to a default value. There are no performance effects. Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short Circuit - Test OK - STOP i02427110 Thu Apr 8 08:37:48 CDT 2010

Page 1 of 1 CID 1835 FMI 04 Auxiliary Pressure Sensor short to ground SMCS - 5574-038-PX Conditions Which Generate This Code: The Electronic Control Module (ECM) detects a signal voltage from the auxiliary pressure sensor that is below normal. System Response: The ECM logs the diagnostic code. The value of the auxiliary pressure is set to a default value. There are no performance effects. Test Step 1. Perform the following diagnostic procedure: Engine Pressure Sensor Open or Short Circuit - Test OK - STOP i02427111 Thu Apr 8 08:38:02 CDT 2010

Page 1 of 1 CID 1836 FMI 08 Auxiliary Temperature Sensor signal abnormal SMCS - 5574-038-TA Conditions Which Generate This Code: The Electronic Control Module (ECM) detects all of the following conditions: Either the duty cycle is greater than 95 percent or less than 5 percent for one second, or the sensor frequency is greater than 1000 Hz or less than 150 Hz for two seconds. There are no active diagnostic codes for the digital sensor supply (8 Volt DC). The ECM has been powered for at least three seconds. System Response: The ECM will log the diagnostic code. The auxiliary temperature will be set to a default value. None Test Step 1. Perform the following diagnostic procedure: Auxiliary Temperature Sensor Circuit - Test OK - STOP i02107196 Thu Apr 8 08:38:20 CDT 2010

Page 1 of 5 Event Codes SMCS - 1901 Event codes alert the operator that an abnormal engine operating condition such as low oil pressure or high coolant temperature has been detected. When the event code is generated, the event is active. Active Event Codes An active event code represents a problem with engine operation. Correct the problem as soon as possible. Active event codes are listed in ascending numerical order. The code with the lowest number is listed first. When certain event codes are activated, the Electronic Control Module (ECM) also generates a flash code that will be displayed on the diagnostic lamp. Refer to, "Diagnostic Code Cross Reference" for a cross-reference between event codes and flash codes. Illustration 1 is an example of the operating range of an oil temperature sensor. Do not use the Illustration to troubleshoot the oil temperature sensor. i02275527 View Image

Page 2 of 5 Illustration 1 g01139661 Example of the typical operating range of an oil temperature sensor (1) This area represents the normal temperature range for the engine oil. The normal output voltage of the sensor is between 0.2 VDC and 4.2 VDC. (2) In this area, the oil temperature above 107 C (225 F) is higher than normal. The output voltage of the sensor will

Page 3 of 5 generate an event code. The sensor does not have an electronic problem. (3) In these areas, the output voltage of the sensor is too high or too low. The voltage is outside of the normal range. The electronic problem will generate a diagnostic code. Refer to, " with a Diagnostic Code" for additional information on diagnostic codes. The following format is used for event codes: "EXXX (Y) Description of the event" The "E" means that the code is an event code. The "XXX" represents a numeric identifier for the event code. The "(Y)" represents a numeric identifier for the severity of the event. This is followed by a description of the event. Refer to the following example: "E004 (3) Engine Overspeed Shutdown" In this example, the number 3 indicates the severity of the event. The ECM has three levels of response to events: Warning (1) - This condition represents a serious problem with engine operation. However, this condition does not require a derate or a shutdown. Derate (2) - For this condition, the ECM reduces the engine's power in order to help prevent possible engine damage. Shutdown (3) - For this condition, the ECM shuts down the engine in order to help prevent possible engine damage. Responses to certain events may be programmed into the ECM. Refer to, "System Configuration Parameters". Logged Event Codes When the ECM generates an event code the ECM logs the code in permanent memory. The ECM has an internal diagnostic clock. The ECM will record the following information when an event code is generated: The hour of the first occurrence of the code The hour of the last occurrence of the code The number of occurrences of the code Logged events are listed in chronological order. The most recent event code is listed first. This information can be helpful for troubleshooting intermittent problems. Logged codes can also be used to review the performance of the engine. Clearing Event Codes

Page 4 of 5 A code is cleared from memory when one of the following conditions occur: The code does not recur for 100 hours. A new code is logged and there are already ten codes in memory. In this case, the oldest code is cleared. The service technician manually clears the code. Always clear logged event codes after investigating and correcting the problem which generated the code. For basic troubleshooting of the engine, perform the following steps in order to diagnose a malfunction: 1. Obtain the following information about the complaint from the operator: The event and the time of the event Determine the conditions for the event. The conditions will include the engine rpm and the load. Determine if there are any systems that were installed by the dealer or by the customer that could cause the event. Determine whether any additional events occurred. 2. Verify that the complaint is not due to normal engine operation. Verify that the complaint is not due to error of the operator. 3. Narrow the probable cause. Consider the operator information, the conditions of operation, and the history of the engine. 4. Perform a visual inspection. Inspect the following items: Fuel supply Oil level Oil supply Wiring Connectors Be sure to check the connectors. This is very important for problems that are intermittent. Refer to, "Electrical Connectors - Inspect".

Page 5 of 5 If these steps do not resolve the problem, identify the procedures in this manual that best describe the event. Check each probable cause according to the tests that are recommended. Thu Apr 8 08:38:40 CDT 2010

Page 1 of 1 E004 Engine Overspeed Shutdown SMCS - 7427-038 Conditions Which Generate This Code: Engine speed has exceeded the trip point for engine overspeed. System Response: The Electronic Control Module (ECM) will log the event. Caterpillar Electronic Technician (ET) displays "Injection Disabled" on the status screen. The engine is shutdown. The operator may be operating the engine incorrectly. The "Engine Overspeed" parameter may be incorrectly programmed for the application. Use Cat ET to view the parameter setting for engine overspeed. Refer to, "System Configuration Parameters" for the rpm range that is available for this parameter. Test Step 1. Interview the Operator Determine the events that caused the overspeed of the engine. Make corrections in order to prevent the overspeed from recurring. OK - STOP i02235554 Thu Apr 8 08:38:56 CDT 2010

Page 1 of 2 E005 Fuel Filter Restriction Derate SMCS - 1261-038 Conditions Which Generate This Code: The engine has been running for 60 seconds and the Electronic Control Module (ECM) has identified fuel pressure that is less than 225 kpa (33 psi) for 10 seconds. System Response: The ECM will log the event. Caterpillar Electronic Technician (ET) will display "Engine Derate" on any Cat ET status screen. The ECM derates the engine power by 17.5 percent per second. The maximum derate is 39 percent. The ECM will restore full power when the fuel pressure rises above 235 kpa (34 psi) for four seconds. The engine power is derated. Test Step 1. Replace the Fuel Filter A. Replace the engine's fuel filter. Prime the fuel system. Refer to the engine's Operation and Maintenance Manual for the correct procedure. B. Start the engine. Use Cat ET to check for another occurrence of the event. Expected Result: The event does not recur. OK - The event does not recur. Stop. NOT OK - The ECM is detecting an abnormal fuel pressure in the fuel system. Repair: Refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test" for information that relates to testing the fuel system. Stop. i02373037

Page 2 of 2 Thu Apr 8 08:39:11 CDT 2010

Page 1 of 2 E006 Fuel Filter Restriction Shutdown SMCS - 1261-038 Conditions Which Generate This Code: The engine has been running for 60 seconds and the Electronic Control Module (ECM) has identified a restriction of the fuel filter. System Response: The ECM will log the event. The Caterpillar Electronic Technician (ET) will display "No Engine Speed" on the status screen. The engine is shut down. This event code indicates a restriction in the fuel filter. Test Step 1. Replace the Fuel Filter A. Replace the engine's fuel filter. Prime the fuel system. Refer to the engine's Operation and Maintenance Manual for the correct procedure. B. Start the engine. Use Cat ET to check for another occurrence of the event. Expected Result: The event does not recur. OK - STOP Not OK - The ECM is detecting an abnormal fuel pressure in the fuel system. Repair: Refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test" for information that relates to testing the fuel system. STOP i02353654

Page 2 of 2 Thu Apr 8 08:39:27 CDT 2010

Page 1 of 2 E015 High Engine Coolant Temperature Derate SMCS - 1395-038-TA Conditions Which Generate This Code: The engine has been running for three minutes and the coolant temperature has exceeded the derate trip point for coolant temperature protection. System Response: The Electronic Control Module (ECM) will log the event. Caterpillar Electronic Technician (ET) displays "Engine Derate" on the status screen. The ECM will derate engine power by 12.5 percent. The ECM will derate engine power by a maximum of 25 percent for coolant temperatures that exceed 109 C (228 F). The engine power will be derated at a rate of one percent per second. Test Step 1. Check the Monitoring System Parameter The "High Engine Coolant Temperature" parameter may be incorrectly programmed. Use Cat ET to view the parameter setting for "High Engine Coolant Temperature". Ensure that the parameter setting is correct for the application of the engine. Expected Result: The "High Engine Coolant Temperature" parameter is programmed correctly. OK - An overheating condition exists for the engine. Repair: Refer to Systems Operation/Testing and Adjusting, "Cooling System - Check". STOP Not OK - The parameter is incorrectly programmed. Repair: Refer to, "System Configuration Parameters" for the temperature range that is available for the "High Engine Coolant Temperature" parameter.verify that the repair eliminates the problem. STOP i02235951

Page 2 of 2 Thu Apr 8 08:39:42 CDT 2010

Page 1 of 2 E016 High Engine Coolant Temperature Shutdown SMCS - 1395-038-TA Conditions Which Generate This Code: The engine has been running for three minutes and the coolant temperature has exceeded the shutdown trip point for coolant temperature protection. System Response: The Electronic Control Module (ECM) will log the event. The engine is shut down. Test Step 1. Check the Monitoring System Parameter The "High Engine Coolant Temperature" parameter may be incorrectly programmed. Use Caterpillar Electronic Technician (ET) to view the parameter setting for "High Engine Coolant Temperature". Ensure that the parameter setting is correct for the application of the engine. Expected Result: The "High Engine Coolant Temperature" parameter is programmed correctly. OK - The monitoring system parameter is programmed correctly. Repair: An overheating condition exists for the engine. Refer to Systems Operation/Testing and Adjusting, "Cooling System - Check". STOP Not OK - The parameter is incorrectly programmed. Repair: Refer to, "System Configuration Parameters" for the temperature range that is available for the "High Engine Coolant Temperature" parameter. Verify that the repair eliminates the problem. STOP i02291786

Page 2 of 2 Thu Apr 8 08:39:53 CDT 2010

Page 1 of 2 E017 High Engine Coolant Temperature Warning SMCS - 1395-038-TA Conditions Which Generate This Code: The engine has been running for three minutes and the coolant temperature has exceeded the warning trip point for coolant temperature protection. System Response: The Electronic Control Module (ECM) will log the event. Engine operation is not affected. Test Step 1. Check the Monitoring System Parameter The "High Engine Coolant Temperature" parameter may be incorrectly programmed. Use Caterpillar Electronic Technician (ET) to view the parameter setting for "High Engine Coolant Temperature". Ensure that the parameter setting is correct for the application of the engine. Expected Result: The "High Engine Coolant Temperature" parameter is programmed correctly. OK - An overheating condition exists for the engine. Repair: Refer to Systems Operation/Testing and Adjusting, "Cooling System - Check". STOP Not OK - The parameter is incorrectly programmed. Repair: Refer to, "System Configuration Parameters" for the temperature range that is available for the "High Engine Coolant Temperature" parameter. Verify that the repair eliminates the problem. STOP i02291787

Page 2 of 2 Thu Apr 8 08:40:07 CDT 2010

Page 1 of 2 E025 High Inlet Air Temperature Derate SMCS - 1050-038-TA Conditions Which Generate This Code: The inlet air system has exceeded the derate trip point for overtemperature protection. System Response: The Electronic Control Module (ECM) will log the event. Caterpillar Electronic Technician (ET) displays "Engine Derate" on the status screen. The ECM will derate engine power by three percent for an inlet air temperature of 80 C (176 F). The ECM will continue to derate engine power by an additional three percent for each 1 C (2 F) that is beyond the trip point. The ECM will derate engine power for a maximum of 20 percent. The engine power will be derated at a rate of one percent per second. The derate will be cancelled if the inlet air temperature drops below 79 C (174 F) for 20 seconds. Test Step 1. Check the Monitoring System Parameter The "High Intake Air Temperature" parameter may be incorrectly programmed. Use Cat ET to view the parameter setting for "High Intake Air Temperature". Ensure that the parameter setting is correct for the application of the engine. Expected Result: The "High Intake Air Temperature" parameter is programmed correctly. OK - There is a problem with the air inlet or the exhaust system. Repair: Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System". STOP Not OK - The parameter is incorrectly programmed. Repair: Refer to, "System Configuration Parameters" for the temperature range that is available for the "High Intake Air Temperature" parameter. Verify that the repair eliminates the problem.

Page 2 of 2 STOP Thu Apr 8 08:40:24 CDT 2010

Page 1 of 2 E027 High Inlet Air Temperature Warning SMCS - 1050-038-TA Conditions Which Generate This Code: The inlet air system has exceeded the warning trip point for overtemperature protection. System Response: The Electronic Control Module (ECM) will log the event. Engine operation is not affected. Test Step 1. Check the Monitoring System Parameter The "High Intake Air Temperature" parameter may be incorrectly programmed. Use Caterpillar Electronic Technician (ET) to view the parameter setting for "High Intake Air Temperature". Ensure that the parameter setting is correct for the application of the engine. Expected Result: The "High Intake Air Temperature" parameter is programmed correctly. OK - There is a problem with the air inlet or the exhaust system. Repair: Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System". STOP Not OK - The parameter is incorrectly programmed. Repair: Refer to, "System Configuration Parameters" for the temperature range that is available for the "High Intake Air Temperature" parameter. Verify that the repair eliminates the problem. STOP i02236416 Thu Apr 8 08:40:41 CDT 2010

Page 2 of 2

Page 1 of 2 E039 Low Engine Oil Pressure Derate SMCS - 1348-038-LP Conditions Which Generate This Code: The engine has been running for thirty seconds and the oil pressure has dropped below the derate trip point for low oil pressure protection. System Response: The Electronic Control Module (ECM) will log the event. Caterpillar Electronic Technician (ET) displays "Engine Derate" on the status screen. The ECM will derate engine power by 35 percent. Note: The derate will be cancelled if the engine oil pressure rises above 70 kpa (10 psi) for two seconds. There may be a problem with the engine lubrication system. Test Step 1. Check the Engine Oil Level A. Turn the keyswitch to the OFF position. B. Check the engine oil level. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check". Expected Result: The engine oil level is OK. OK - The engine oil level is OK. There may be a problem with the engine's lubrication system. Repair: Refer to Testing and Adjusting, "Engine Oil Pressure - Test". STOP Not OK - The engine oil level is low. Repair: Add engine oil to the proper level. Verify that the repair eliminates the problem.

Page 2 of 2 STOP Thu Apr 8 08:40:57 CDT 2010

Page 1 of 2 E040 Low Engine Oil Pressure Shutdown SMCS - 1348-038-LP Conditions Which Generate This Code: The engine has been running for thirty seconds and the oil pressure has dropped below the shutdown trip point for low oil pressure protection. System Response: The Electronic Control Module (ECM) will log the event. The engine is shut down. Test Step 1. Check the Engine Oil Level A. Turn the keyswitch to the OFF position. B. Check the engine oil level. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check". Expected Result: The engine oil level is OK. OK - The engine oil level is OK. There may be a problem with the engine's lubrication system. Repair: Refer to Testing and Adjusting, "Engine Oil Pressure - Test". STOP Not OK - The engine oil level is low. Repair: Add engine oil to the proper level. Verify that the repair eliminates the problem. STOP i02236634

Page 2 of 2 Thu Apr 8 08:41:15 CDT 2010

Page 1 of 3 E054 High Fuel Temperature Derate SMCS - 1250-038-TA Conditions Which Generate This Code: The fuel temperature has exceeded the derate trip point. System Response: Engine power is derated by 30 percent. i02291735 The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Test Step 1. Perform a Check of the Fuel Heater and Related Equipment A. If the engine is equipped with a fuel heater, perform a check of the fuel heater and thermostat. Expected Result: There are no problems with the fuel heater or the thermostat. OK - The fuel heater and the thermostat are OK. Proceed to Test Step 2. Not OK - A problem was found with the fuel heater or the thermostat. Repair: Repair the problem. Ensure that the repair eliminates the problem. STOP Test Step 2. Inspect the Fuel Return Line for Restrictions A. Inspect the fuel return line for restrictions. Check for collapsed fuel lines. Note: A restriction in the return fuel line will decrease fuel flow from the fuel manifold. The

Page 2 of 3 decrease in fuel flow will cause the fuel in the fuel manifold to increase in temperature. Expected Result: There are no problems with the fuel return lines. OK - The fuel return lines are OK. Proceed to Test Step 3. Not OK - A problem was found with the fuel return lines. Repair: Repair the problem. Ensure that the repair eliminates the problem. STOP Test Step 3. Check the Level of Fuel in the Fuel Tank A. Fuel is continuously cycled from the fuel tank through the fuel system back to the fuel tank. The quantity of fuel in the fuel tank may affect fuel temperature. If the quantity of fuel in the fuel tank becomes low, there may be insufficient volume to aid in the dissipation of heat. As a result, the fuel temperature will rise. Expected Result: The fuel level in the fuel tank is OK. OK - The fuel level in the tank is OK. Repair: Verify that the Caterpillar Electronic Technician (ET) is providing the correct fuel temperature. Check the actual fuel temperature. If the two temperatures are different, check the fuel temperature sensor for proper operation. Refer to the diagnostic functional test, "Engine Temperature Sensor Open or Short Circuit - Test". STOP Not OK - The fuel level was low. Repair: Check the fuel in the fuel tank for excessive heat. If necessary, add fuel to aid in dissipating heat from the fuel system. Ensure that the repair eliminates the problem. STOP Thu Apr 8 08:41:34 CDT 2010

Page 3 of 3

Page 1 of 3 E055 High Fuel Temperature Shutdown SMCS - 1250-038-TA Conditions Which Generate This Code: The fuel temperature has exceeded the shutdown trip point. System Response: The engine is shut down. i02291738 The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Test Step 1. Perform a Check of the Fuel Heater and Related Equipment A. If the engine is equipped with a fuel heater, perform a check of the fuel heater and thermostat. Expected Result: There are no problems with the fuel heater or the thermostat. OK - The fuel heater and the thermostat are OK. Proceed to Test Step 2. Not OK - A problem was found with the fuel heater or the thermostat. Repair: Repair the problem. Ensure that the repair eliminates the problem. STOP Test Step 2. Inspect the Fuel Return Line for Restrictions A. Inspect the fuel return line for restrictions. Check for collapsed fuel lines. Note: A restriction in the return fuel line will decrease fuel flow from the fuel manifold. The

Page 2 of 3 decrease in fuel flow will cause the fuel in the fuel manifold to increase in temperature. Expected Result: There are no problems with the fuel return lines. OK - The fuel return lines are OK. Proceed to Test Step 3. Not OK - A problem was found with the fuel return lines. Repair: Repair the problem. Ensure that the repair eliminates the problem. STOP Test Step 3. Check the Level of Fuel in the Fuel Tank A. Fuel is continuously cycled from the fuel tank through the fuel system back to the fuel tank. The quantity of fuel in the fuel tank may affect fuel temperature. If the quantity of fuel in the fuel tank becomes low, there may be insufficient volume to aid in the dissipation of heat. As a result, the fuel temperature will rise. Expected Result: The fuel level in the fuel tank is OK. OK - The fuel level in the tank is OK. Repair: Verify that the Caterpillar Electronic Technician (ET) is providing the correct fuel temperature. Check the actual fuel temperature. If the two temperatures are different, check the fuel temperature sensor for proper operation. Refer to the diagnostic functional test, "Engine Temperature Sensor Open or Short Circuit - Test". STOP Not OK - The fuel level was low. Repair: Check the fuel in the fuel tank for excessive heat. If necessary, add fuel to aid in dissipating heat from the fuel system. Ensure that the repair eliminates the problem. STOP Thu Apr 8 08:41:50 CDT 2010

Page 3 of 3

Page 1 of 3 E056 High Fuel Temperature Warning SMCS - 1250-038-TA Conditions Which Generate This Code: The fuel temperature is above the warning trip point. System Response: The event is logged. i02291742 The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Test Step 1. Perform a Check of the Fuel Heater and Related Equipment A. If the engine is equipped with a fuel heater, perform a check of the fuel heater and thermostat. Expected Result: There are no problems with the fuel heater or the thermostat. OK - The fuel heater and the thermostat are OK. Proceed to Test Step 2. Not OK - A problem was found with the fuel heater or the thermostat. Repair: Repair the problem. Ensure that the repair eliminates the problem. STOP Test Step 2. Inspect the Fuel Return Line for Restrictions A. Inspect the fuel return line for restrictions. Check for collapsed fuel lines. Note: A restriction in the return fuel line will decrease fuel flow from the fuel manifold. The

Page 2 of 3 decrease in fuel flow will cause the fuel in the fuel manifold to increase in temperature. Expected Result: There are no problems with the fuel return lines. OK - The fuel return lines are OK. Proceed to Test Step 3. Not OK - A problem was found with the fuel return lines. Repair: Repair the problem. Ensure that the repair eliminates the problem. STOP Test Step 3. Check the Level of Fuel in the Fuel Tank A. Fuel is continuously cycled from the fuel tank through the fuel system back to the fuel tank. The quantity of fuel in the fuel tank may affect fuel temperature. If the quantity of fuel in the fuel tank becomes low, there may be insufficient volume to aid in the dissipation of heat. As a result, the fuel temperature will rise. Expected Result: The fuel level in the fuel tank is OK. OK - The fuel level in the tank is OK. Repair: Verify that the Caterpillar Electronic Technician (ET) is providing the correct fuel temperature. Check the actual fuel temperature. If the two temperatures are different, check the fuel temperature sensor for proper operation. Refer to the diagnostic functional test, "Engine Temperature Sensor Open or Short Circuit - Test". STOP Not OK - The fuel level was low. Repair: Check the fuel in the fuel tank for excessive heat. If necessary, add fuel to aid in dissipating heat from the fuel system. Ensure that the repair eliminates the problem. STOP Thu Apr 8 08:42:06 CDT 2010

Page 3 of 3

Page 1 of 2 E057 Low Engine Coolant Level Derate SMCS - 1395-038-LO Conditions Which Generate This Code: The engine has been running for one minute and the coolant level is not being detected by the coolant level sensor. System Response: The Electronic Control Module (ECM) will log the event. The Caterpillar Electronic Technician (ET) displays "Engine Derate" on the status screen. The ECM will derate engine power by 35 percent. The engine power will be derated at a rate of one percent per second. Test Step 1. Check the Engine Coolant Level i02370276 Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. A. Check the coolant level of the engine. Refer to Operation and Maintenance Manual, "Cooling System Coolant Level - Check". Expected Result: The coolant level is OK. OK - The coolant is at the appropriate level. There may be a problem with the coolant level sensor. Repair: Test the operation of the coolant level sensor. Refer to, "Coolant Level Sensor Circuit - Test".

Page 2 of 2 STOP Not OK - The coolant level is low. Repair: Fill the cooling system with the appropriate coolant. Verify that the repair eliminates the problem. STOP Thu Apr 8 08:42:19 CDT 2010

Page 1 of 2 E058 Low Engine Coolant Level Shutdown SMCS - 1395-038-LO Conditions Which Generate This Code: The engine has been running for one minute and the coolant level is not being detected by the coolant level sensor. System Response: The Electronic Control Module (ECM) will log the event. Caterpillar Electronic Technician (ET) displays "Injection Disabled" on the status screen. The engine is shut down. Test Step 1. Check the Engine Coolant Level i02236801 Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. A. Check the coolant level of the engine. Refer tooperation and Maintenance Manual, "Cooling System Coolant Level - Check". Expected Result: The coolant level is OK. OK - The coolant is at the appropriate level. There may be a problem with the coolant level sensor. Repair: Test the operation of the coolant level sensor. Refer to, "Coolant Level Sensor Circuit - Test". STOP

Page 2 of 2 Not OK - The coolant level is low. Repair: Fill the cooling system with the appropriate coolant. Verify that the repair eliminates the problem. STOP Thu Apr 8 08:42:32 CDT 2010

Page 1 of 2 E059 Low Engine Coolant Level Warning SMCS - 1395-038-LO Conditions Which Generate This Code: The engine has been running for one minute and the coolant level is not being detected by the coolant level sensor. System Response: The Electronic Control Module (ECM) will log the event. Engine operation is not affected. Test Step 1. Check the Engine Coolant Level i02236927 Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. A. Check the coolant level of the engine. Refer tooperation and Maintenance Manual, "Cooling System Coolant Level - Check". Expected Result: The coolant level is OK. OK - The coolant is at the appropriate level. There may be a problem with the coolant level sensor. Repair: Test the operation of the coolant level sensor. Refer to, "Coolant Level Sensor Circuit - Test". STOP Not OK - The coolant level is low.

Page 2 of 2 Repair: Fill the cooling system with the appropriate coolant. Verify that the repair eliminates the problem. STOP Thu Apr 8 08:42:50 CDT 2010

Page 1 of 2 E095 Fuel Filter Restriction Warning SMCS - 1261-038 Conditions Which Generate This Code: The engine has been running for 60 seconds and the Electronic Control Module (ECM) has identified fuel pressure less than 250 kpa (36 psi) for 10 seconds. System Response: The ECM will log the event. The low fuel pressure warning will deactivate when the fuel pressure rises above 260 kpa (37 psi) for four seconds. Engine operation is not affected. Test Step 1. Replace the Fuel Filter A. Replace the engine's fuel filter. Prime the fuel system. Refer to the engine's Operation and Maintenance Manual for the correct procedure. B. Start the engine. Use Caterpillar Electronic Technician (ET) to check for another occurrence of the event. Expected Result: The event does not recur. OK - The event does not recur. Stop. NOT OK - The ECM is detecting an abnormal fuel pressure in the fuel system. Repair: Refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test" for information that relates to testing the fuel system. Stop. i02373025

Page 2 of 2 Thu Apr 8 08:43:05 CDT 2010

Page 1 of 2 E096 High Fuel Pressure SMCS - 1250-038-HQ Conditions Which Generate This Code: The engine has been running for 60 seconds and the fuel pressure exceeds the warning trip point for fuel system protection. System Response: The Electronic Control Module (ECM) will log the event. Engine operation is not affected. Test Step 1. Check for Diagnostic Codes A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. B. Turn the keyswitch to the ON position (engine off). C. Check for active diagnostic codes or logged diagnostic codes. Expected Result: No other codes are active or logged. OK - No other codes are active or logged. A mechanical problem exists in the low pressure fuel system. Repair: Refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test" for information that relates to testing the fuel system. STOP Not OK - There are diagnostic codes that are active or logged. Repair: Correct the other codes that are active or logged first. Refer to the appropriate topic in the " With a Diagnostic Code" section of this manual. Verify that the repair eliminates the problem. STOP i02237317

Page 2 of 2 Thu Apr 8 08:43:23 CDT 2010

Page 1 of 2 E100 Low Engine Oil Pressure Warning SMCS - 1348-038-LP Conditions Which Generate This Code: The engine has been running for thirty seconds and the oil pressure has dropped below the warning trip point for low oil pressure protection. System Response: The Electronic Control Module (ECM) will log the event. Engine operation will not be affected. Note: The warning will be cancelled if the engine oil pressure rises above 70 kpa (10 psi) for twenty seconds. Test Step 1. Check the Engine Oil Level A. Turn the keyswitch to the OFF position. B. Check the engine oil level. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check". Expected Result: The engine oil level is OK. OK - The engine oil level is OK. There may be a problem with the engine's lubrication system. Repair: Refer to Testing and Adjusting, "Engine Oil Pressure - Test". STOP Not OK - The engine oil level is low. Repair: Add engine oil to the proper level. Verify that the repair eliminates the problem. STOP i02237386

Page 2 of 2 Thu Apr 8 08:43:39 CDT 2010

Page 1 of 1 E190 Engine Overspeed Warning SMCS - 7427-038 Conditions Which Generate This Code: The trip point has been exceeded for engine overspeed protection. System Response: The Electronic Control Module (ECM) will log the event. Note: The warning will be cancelled if the engine rpm drops 200 rpm below the trip point that is programmed for this parameter. Engine operation is not affected unless engine speed exceeds the maximum governed engine speed. If the maximum engine speed is exceeded, the injection will be disabled until the engine speed drops below the maximum engine speed. The operator may be operating the engine incorrectly. The "Engine Overspeed" parameter may be incorrectly programmed for the application. Use Caterpillar Electronic Technician (ET) to view the parameter setting for engine overspeed. Refer to, "System Configuration Parameters" for the rpm range that is available for this parameter. Test Step 1. Interview the Operator Determine the events that caused the overspeed of the engine. Make corrections in order to prevent the overspeed from recurring. OK - STOP i02291765 Thu Apr 8 08:43:53 CDT 2010

Page 1 of 2 E443 High Auxiliary Pressure SMCS - 5095-038-AX Conditions Which Generate This Code: The Electronic Control Module (ECM) has detected an auxiliary pressure that is higher than the trip points that are programmed into the monitoring system. System Response: The ECM will log the code. i02121632 The level of response is determined by the monitoring system. There is no loss of performance if the monitoring system is programmed to "Warning". If the monitoring system is programmed to "Derate", the ECM will derate power by 25 percent. If the engine is programmed to "Shutdown", the engine will be shutdown. The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Test Step 1. Verify the Trip Points A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. B. Access the monitoring system on Cat ET. C. Verify that the trip points for auxiliary pressure are valid for the application. Expected Result: The trip points for the auxiliary pressure are valid. OK - The trip points are valid. Repair: There is a mechanical problem.

Page 2 of 2 STOP Not OK - The trip points are not valid. Repair: Program the trip points to the proper level.verify that the repair eliminates the problem. STOP Thu Apr 8 08:44:08 CDT 2010

Page 1 of 2 E445 High Auxiliary Temperature SMCS - 5095-038-AX Conditions Which Generate This Code: The Electronic Control Module (ECM) has detected an auxiliary temperature that is higher than the trip points that are programmed into the monitoring system. System Response: The ECM will log the code. i02121634 The level of response is determined by the monitoring system. There is no loss of performance if the monitoring system is programmed to "Warning". If the monitoring system is programmed to "Derate", the ECM will derate power by 25 percent. If the monitoring system is programmed to "Shutdown", the engine will be shutdown. The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Test Step 1. Verify the Trip Points A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. B. Access the monitoring system on Cat ET. C. Verify that the trip points for auxiliary temperature are valid for the application. Expected Result: The trip points for the auxiliary temperature are valid. OK - The trip points are valid. Repair: There is a mechanical problem.

Page 2 of 2 STOP Not OK - The trip points are not valid. Repair: Program the trip points to the proper level.verify that the repair eliminates the problem. STOP Thu Apr 8 08:44:23 CDT 2010