Usage:
Status Control Module
Diagnostic Codes are displayed on the same LCD module as the service hours, engine rpm, battery voltage, engine oil pressure and engine oil temperature.
When a diagnostic code is present, an arrow on the display indicates which of the parameters mentioned previously is ACTIVEand a flashing diaG is displayed. If several faults are present, the diagnostic codes will be displayed in a numerical sequence. The diagnostic code can be cleared from the display by placing the Mode Control Switch (MCS to the OFF/RESETposition. Restart the engine to verify if the problem is still present.
Engine Supervisory System
To aid in the troubleshooting process and provide a history of observations, it is necessary to record all the available data from the ESS control system when a problem occurs. Data should be recorded from the Digital Diagnostic Tool (DDT), the Engine Control Module (ECM), the Computerized Monitoring System (CMS), the Status Control Module (SCM), the Caterpillar Ignition System (CIS) and the Pyrometers and any driven equipment monitoring system.
Use the Display Select toggle switch to check for diagnostic codes displayed by the ECM.
Flashingdiagnostic codes indicate that the engine was shut down due to an ESS operating parameter exceeding acceptable limits. A diagnostic code that is not flashingindicates that an alarm condition has occurred. The engine will not directly shut down due to an alarm condition.
NOTE: Toggling the Display Select switch will erase alarm (not-flashing) diagnostic codes and shutdown (flashing) diagnostic codes. Ensure each code occurrence is recorded prior to toggling the switch to the next display.
Diagnostic Code Introduction
Diagnostic Codes are used in the ESS Control System to alert and inform the operator of a system condition outside of the normal or expected operational limits. Diagnostic conditions are indicated with lamps an diagnostic codes to detail the condition. Most of the diagnostics on the ESS are detailed using a diagnostic code. Each diagnostic code consists of two elements, theComponentIdentifier (cid) and theFailureModeIndicator (FMI).
The CID, consisting of three digits, indicates the control system component where a diagnostic condition has been detected. Refer to ESS Component Identifies (CID) Table for more information.
The FMI, consisting of two digits, indicates the nature of the failure that has taken place. The combination of these three elements defining the specific type of problem. Refer to Failure Mode Identifies (FMI) Table for more information.
Example: 172-00
172 ... Component Identifier (CID) in this case it indicates the Air Temperature Sensor.
00... Failure Mode Identifier (FMI) in this case the failure mode is DATA VALID but above the normal operational range.
The interpretation of the diagnostic code (172-00) should be that the measured air temperature is too high. If a problem is indicated by a diagnostic code, it should be investigated and corrected as soon as possible.
Alarms
An alarm diagnostic code indicates an engine parameter has exceeded normal operation limits. This means the control system has detected engine operation outside of acceptable conditions or a failure of a component associated with the control system.
Continued operation outside of acceptable conditions may result in long term engine damage, poor performance or an engine shutdown without further warning.
Shutdowns
A shutdown diagnostic code (displayed by a flashing code) indicates and engine parameter, the engine operation, or a component failure makes continued operation of the engine unacceptable.
To troubleshoot an active diagnostic code, refer to the diagnostic code Cross-Reference to Functional Test Procedures in this section under the specific code number.
Diagnostic Indicators and Displays
The ESS Control System provides complete control of the engine operation, including the start/stop logic, governing, ignition timing control, air-to-fuel ratio control and engine protection.
The system provides engine status and diagnostic information on all of the control system aspects. The Caterpillar Ignition System (CIS), Status Control Module (SCM), Timing Control Module (TCM), Computerized Monitoring System (CMS) and a Engine Control Module (ECM) have LED's and/or a display area for indication diagnostic conditions.
The Caterpillar Ignition system (CIS) provides diagnostic information using LED indicators and a text message on the CIS remote display panel.
The SCM provides diagnostic information using six LED's and an LCD display. Problems detected by the Status Control will be indicated with a flashing LED and/or a diaG message on the LCD Display.
The ECM, TCM and CMS provide integrated diagnostics information. Using a communication link, diagnostic conditions are shared with the ECM.
The presence of ESS Control System diagnostic codes is indicated with the twelve red warning LED's on the CMS Module, the eight LED's on the TCM and the ECM alphanumeric display.
CMS Gauge Module
The CMS Gage Module has twelve warning LED's on the CMS Module, labeled F1 through F12, to indicate there are alarms or shutdowns. When a light is flashing, the details of the problem can be found by the code on the ECM display.
To clear a diagnostic code, which causes engine shutdown, the diagnostic code must be acknowledged and the MCS must be reset. Turn the Mode Control Switch (MCS) to the OFF/RESETposition. Diagnostic Codes which require an SCM reset will cause an additional diagnostic code "RST REQD"(reset required) to appear on the ECM.
The CMS warning lamp indicates the general type of problem, The Engine Control Module provides a diagnostic code with a detailed description of the specific problem. An LED along with a warning lamp on the CMS Module and Engine Control Module diagnostic code may also indicate some problems on the Timing Control Module (TCM).
Engine Control Module
The ECM has an alphanumeric display and eight LED's to detail the diagnostic condition.
01on the ECM display indicates a faulty ECM because of a ROM (read only memory) error. Replace the ECM.
02on the ECM display indicates a possible faulty incorrect or not programmed personality module. Check the connector to the personality module. If the problem persists, replace the personality module.
04on the ECM display indicates a faulty ECM because of Dual Port RAM error. Replace the ECM.
The eight LED's located next to its display, indicate the type of data available for display and the type of data currently on display. A solid LED indicates this type of information is currently on display. A flashing LED indicates this type of information is available but is not presently on display.
The alphanumeric display will show a CID-FMI diagnostic code if a problem has been detected. The diagnostic code consists of three digits and two digits. The combination of the numbers dictate a detailed description of the specific diagnostic found.
A flashing numeric code(CID-FMI) indicates the currently displayed diagnostic code caused the engine shutdown.
A solid numeric code(CID-FMI) indicates the currently displayed diagnostic code does not or did not cause the engine shutdown. It either indicates another problem, or the problem may be a result of the shutdown initiated by another diagnostic code.
Detonation Mixing Control Diagnostic Codes
Diagnostics Codes are used by the Detonation Mixing Control (DMC) System to alert the operator of a system problem and indicate its nature. The diagnostic codes may indicate a warning or shutdown condition.
Each diagnostic code is composed of two elements: a Component Identifier (CID) and a Failure Mode Identifier (FMI). The CID indicates the control system component where a fault condition has been detected. The FMI indicates the nature of the failure that has taken place. The combination of the CID and FMI indicates a specific type of failure. The Diagnostic Code Cross-Reference Chart, describes each valid combination of CID and FMI, and indicates the appropriate troubleshooting procedure that addresses each diagnostic code.
If a problem is indicated by a diagnostic code, it should be investigated and corrected as soon as possible.
DMC Diagnostic Indicators
Diagnostic Conditions on the DMC are sent to the ECM where they are displayed.
Detonation Sensor Diagnostics
The No Detonation Sensor Diagnostics (318-12 and 319-12) are reported by the TCM.
DMC Control Input Signals
The DMC Control Module requires a DC voltage power source for operation. From the supplied voltage, the DMC Control Module provides the regulated voltages needed to run the control and power the sensors.
NOTE: The DMC Control Module does not have any diagnostics for faults on the electrical power supply.
Power up Requirements
The power source must be capable of providing an instantaneous supply of 2 Amp at a minimum 18 VDC. Insufficient supply power at power-up may not operate the DMC Control.
Steady State Requirements
The power source must be capable of supplying 1 Amp at a minimum of 18 VDC following the initial control power-up.
Caterpillar Ignition System Diagnostic Messages
Diagnostic Faults
A diagnostic fault represents the most severe classification of problems with the CIS system. The presence of a diagnostic fault will inhibit the ignition from firing. When a fault is detected several things will occur:
- The ignition will stop firing.The alarm LED in the ignition unit will turn ON.The home status on the CIS Operator Interface Display will read "FAULT"and the bottom line will flash "VIEW DIAGNOSTICS".
Figure 4.9 - CIS Fault Indication
Diagnostic Warnings
A diagnostic warning represents the least severe classification of problems with the CIS. The ignition will continue to fire in the presence of a diagnostic warning. When a warning is detected several things will occur.
- The alarm LED in the ignition unit will turn ON.The home status on the CIS Operator Interface Display will read "WARNING"and the bottom line will flash "VIEW DIAGNOSTICS".
Figure 4.10 - CIS Warning Indication
When a Fault or a Warning is present, the operator can display the actual cause of the diagnostic on the CIS Operator Interface Display the following steps.
Accessing Diagnostic Codes
The ESS Control System diagnostic codes are provided on the ECM Display. The Display Select Switch,located on the front of the ESS Panel, is used to scroll through the current parameter data and any diagnostic codes. The scrolling order of information on the ECM display when the Mode Control Switch (MCS) is in the STARTposition is
- * Desired Engine Speed
- * Fuel Energy Content, then
- * Diagnostic Codes, in the order of occurrence.
- * Fuel Energy Content, then
After the final diagnostic code, the display returns to show Desired Engine Speed.
The diagnostic codes are accessed by scrolling past the Desired Engine Speed and the Fuel Energy Content displays using the Display Select Switch. If any of the ECM LED's are flashing, then the next display will show a diagnostic code. The display will show the first diagnostic code and the corresponding LED will be solid.
To continue scrolling through the diagnostic codes, toggle the Display Select Switchafter viewing each diagnostic code.
NOTE: The diagnostic code on the display may be cleared when the Display Select Switchis toggled. If the conditions of the problem persist, the code will return to the diagnostic list.
Diagnostic Codes Clear and Reset
Many of the diagnostic codes on the ESS Control System are alarm codes and will be cleared from the diagnostic list when the Display Select Switch is toggled and the conditions for the problem are no longer present. These diagnostic codes will be displayed on the ECM display as a solid message, versus flashing.
The diagnostic codes which do cause an engine shutdown require a system reset. The codes are displayed as a flashingmessage on the ECM display and cause a "RST REQD"(reset required) message to be displayed on the ECM. Turn the Mode Control Switch (MCS) to the OFF/RESETposition.
NOTE: Turning the Mode Control Switch to OFF/RESETwill clear ALLthe diagnostic codes from the control system. Acknowledge and clear ALLcodes before removing power from the system.
The diagnostic code will be cleared from the code list after being acknowledged and if the problem conditions are no longer present. When the four ECM LED's, on the right side, are not illuminated, no diagnostic codes are present.
If the problem conditions are still present when the Display Select Switch is toggled, the display will move to the next diagnostic code and light a solid LED for the code. The ECM will begin flashing the appropriate LED for the previous code to indicate that the diagnostic condition and code is still prevent and has not been acknowledged.
Always note and record each diagnostic code before clearing with the Display Select Switch.
1. From the "FAULT"or "WARNING"screen press the "DIAG"key in order to view the diagnostics.
2. Press the "DIAG"key again in order to see more diagnostics.
3. Press the "NEXT"key in order to see more diagnostic messages
4. Press the "ESC"key in order to exit.
5. After all of the diagnostics have been read the user can reset the warnings and faults by first pressing the "ESC"key in order to exit.
6. To clear the diagnostic codes from the CIS press the "RESET" key. When the "RESET" key is pressed the following will occur. All Warnings and Faults are cleared from memory. Temporary cylinder timing offsets will be inserted from the EPROM.
Failure Mode Identifiers (FMI)
The Failure Mode Identifier (FMI) indicates the nature of the failure that has taken place. The FMI list is adopted from SAE J1587 standard practice diagnostics. The information below shows all the SAE J1587 FMI codes and a general description of the diagnostic modifiers. For a detailed description of the failure mode detected for a particular device, check the diagnostic code Cross Reference chart and the prescribed troubleshooting procedure.
ESS Component Identifiers (CID)
A Component Identifier (CID) indicates the control subsystem is experiencing the event. The CID is a three-digit code assigned to each component or system condition. The valid CID for the ESS Control System are in numerical order with a description of the assigned component. The component description includes the physical device, any wiring between the device and the electronic control modules and the inputs or outputs of the control modules associated with the device.
Diagnostic Code Cross Reference by CMS Module Fault Lamp
The lamps on the CMS Module of the ESS Control Panel indicate a diagnostic condition exists which pertains to a particular part of the control system. The diagnostic code displayed on the Engine Control Module (ECM) will indicate the specific diagnostic detected. The CID-FMI diagnostic code is the result of a specific system device experiencing a problem or event. Troubleshooting procedures are cross-referenced according to the diagnostic code. Although the Diagnostic Description for a code describes the problem in terms of a particular feature of a device, the diagnostic can be the result of a problem in the system device, the wiring between the device and the electronic control modules, or the inputs or outputs of the control modules associated with the device. Each procedure includes an explanation of the interaction of the device to the engine control system operation.
Diagnostic Code Cross Reference By ECM Code
The lamp on the CMS Module of the ESS Control Panel indicate a diagnostic condition exists which pertains to a particular part of the control system. The diagnostics displayed on the Engine Control Module (ECM) indicate the specific diagnostic detected. The combined CID-FMI diagnostic code is the result of a specific system device experiencing a problem or event. Troubleshooting procedures are cross-referenced according in the following table by the CID-FMI diagnostic code. Although the Diagnostic Description for a code describes the problem in terms of a particular feature of a device, the diagnostic can be the result of a problem in the system device, the wiring between the device and the electronic control modules, or the inputs or outputs of the control modules associated with the device. Each procedure includes an explanation of the interaction of the device to the engine control system operation.
Status Control Module Diagnostic Codes
Diagnostic Codes are displayed on the same LCD module as the service hours, engine rpm, battery voltage, engine oil pressure and engine oil temperature.
When a diagnostic code is present, an arrow on the display indicates which of the parameters mentioned previously is active and a flashing diaG is displayed.
If several faults are present, the diagnostic codes will be displayed in numerical sequence. The diagnostic code can be cleared from the display by placing the Mode Control Switch (MCS) to the OFF/RESET position.
NOTE: Before attempting any repair of Functional Test procedures, record the diagnostic code and place the Mode Control Switch (MCS) to the OFF/RESET position. Restart the engine to verify if the problem is still present.
Caterpillar Ignition System Diagnostic Messages
Diagnostic Messages are displayed on the CIS remote panel. When a diagnostic message is present, the message "View Diagnostics" is displayed.
Wire Color Codes
Appended to the Wire Identification Code is a color code. The color code consists of two characters. There are currently 11 solid insulation colors used on Caterpillar products. Refer to color code table for the designations. A shielded wire is identified by a "CU" or "SH" instead of one of the eleven wire insulation colors.
NOTE: There are two basic wiring arrangements used on G3600 engines. The early engines used hard conduit on the engine and the engine mounted junction box terminals were labeled from 101 to 458. The later engines used individual flexible stainless steel harnesses and the junction box terminals were labeled from 610 to 958. The later version has been upgraded over time to include the Caterpillar Ignition System (CIS), Detonation Mixing Control (DMC), and the Hydrax actuators. The harnesses and junction box termination labels have remained essentially the same with necessary hardware additions and deletions. The schematics in this publication show only the later version terminal points. For the early versions reference the Electrical Schematics for termination points.
NOTE: For Generation III engines, refer to Schematic, SENR5083 (in-line) and Schematic, SENR5082 (VEE).
Wire Identification Codes
The G3600 Engine wiring is labeled with a four-character identification code followed by a two-character color code (example S121-WH). The identification code is designed to allow service personnel to quickly identify the function of the circuit. The first character is a letter that describes the type of circuit. The second character qualifies the identification. The third character further qualifies the identification. The fourth character is an instance number, to allow different labels for duplicate sensors.
