Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
August 2005
Troubleshooting
3406E, C-10, C-12, C-15, C-16 and C-18
On-highway Engines
W1A1-Up (Engine)
CPD1-Up (Engine)
EGH1-Up (Engine)
1MM1-Up (Engine)
CJP1-Up (Engine)
MDP1-Up (Engine)
MEP1-Up (Engine)
2KS1-Up (Engine)
2WS1-Up (Engine)
3CS1-Up (Engine)
6NZ1-Up (Engine)
7CZ1-Up (Engine)
i01658146
Table of Contents 0001-11 Cylinder #1 Injector current fault (72) ... 101
0002-11 Cylinder #2 Injector current fault (72) ... 101
0003-11 Cylinder #3 Injector current fault (73) ... 102
0004-11 Cylinder #4 Injector current fault (73) ... 102
Troubleshooting Section 0005-11 Cylinder #5 Injector current fault (74) ... 103
0006-11 Cylinder #6 Injector current fault (74) ... 103
Electronic Troubleshooting
0022-11 Primary to Secondary Engine Speed Signal
System Overview .................................................... 5
Calibration (42) ................................................. 103
Electronic Service Tools ........................................ 16
0022-13 Engine Speed Signal Calibration Not
Replacing the ECM ............................................... 18
Performed (42) .................................................. 105
Sensors and Electrical Connectors ....................... 19
0030-08 PTO Throttle signal invalid (29) ............ 105
Engine Wiring Harness Diagram .......................... 26
0030-13 PTO Throttle out of calibration (29) ...... 105
Vehicle Wiring Harness Diagram .......................... 28
0041-03 8 Volt Supply voltage high (21) ............. 106
0041-04 8 Volt Supply voltage low (21) .............. 106
Programming Parameters
0043-02 Key Switch Fault (71) ........................... 107
Programming Parameters ..................................... 30
0052-11 Air Inlet Shutoff Shutdown (00) ............. 107
Test ECM Mode .................................................... 30
0054-05 Auxiliary Output #06 current low (66) ... 107
Customer Passwords ............................................ 31
0054-06 Auxiliary Output #06 current high (66) .. 108
ECM Date/Time Stamped Information .................. 31
0055-05 Auxiliary Output #07 current low (67) ... 108
ECM Snapshot ...................................................... 32
0055-06 Auxiliary Output #07 current high (67) .. 108
Factory Passwords ............................................... 33
0064-12 Secondary Engine Speed loss of signal
Factory Passwords Worksheet ............................. 34
(34) .................................................................... 109
Flash Programming .............................................. 34
0071-00 Idle Shutdown Override (01) ................. 109
Service Information Report ................................... 35
0071-01 Idle Shutdown (47) ................................ 110
0071-14 PTO Shutdown (47) ............................... 110
Customer Specified Parameters
0084-00 Vehicle Overspeed Warning (41) ........... 110
Customer Specified Parameters ........................... 36
0084-01 Vehicle Speed loss of signal (31) .......... 111
Customer Specified Parameters Table ................. 62
0084-02 Vehicle Speed signal invalid (36) ........... 111
Customer Specified Parameters Worksheet ......... 68
0084-08 Vehicle Speed signal out of range (36) .. 112
0084-10 Vehicle Speed signal rate of change
System Configuration Parameters
(36) ..................................................................... 112
System Configuration Parameters ........................ 72
0084-14 Quick Stop Occurrence ......................... 112
0091-08 Throttle Position Invalid (32) .................. 113
Troubleshooting without a Diagnostic Code
0091-13 Throttle Position out of calibration (28) .. 113
Can Not Reach Top Engine RPM ......................... 73
0100-01 Low Oil Pressure Warning (46) .............. 113
Can Not Reach Vehicle Speed Limit ..................... 74
0100-03 Oil Pressure voltage high (24) ............... 117
Check Engine Lamp or Warning Lamp Is
0100-04 Oil Pressure voltage low (24) ................ 117
Malfunctioning ..................................................... 76
0100-11 Very Low Oil Pressure (46) .................... 118
Cooling Fan Is Always ON .................................... 76
0102-00 Excessive Boost Pressure .................... 121
Cruise Control, Idle, or PTO Can Not Be Set ....... 78
0102-03 Boost Pressure voltage high (25) ......... 121
Driver Questionnaire ............................................. 80
0102-04 Boost Pressure voltage low (25) ........... 122
Driver Questionnaire Response ............................ 81
0105-00 High Intake Manifold Air Temperature
ECM Will Not Accept Factory Passwords ............. 82
Warning (64) ..................................................... 122
Electronic Service Tool Will Not Communicate with
0105-03 Intake Manifold Air Temperature voltage
ECM .................................................................... 82
high (38) ............................................................ 123
Engine Cranks but Will Not Start .......................... 83
0105-04 Intake Manifold Air Temperature voltage low
Engine Misfires, Runs Rough or Is Unstable ........ 85
(38) .................................................................... 123
Engine Retarder (Compression Brake) Will Not Turn
0105-11 Very High Intake Manifold Air Temperature
ON ....................................................................... 86
(64) .................................................................... 124
Engine Vibration ................................................... 87
0108-03 Barometric Pressure voltage high (26) .. 124
Engine Will Not Crank ........................................... 88
0108-04 Barometric Pressure voltage low (26) .. 124
Excessive Black Smoke ........................................ 89
0110-00 High Coolant Temperature Warning
Excessive Fuel Consumption ............................... 90
(61) .................................................................... 125
Excessive White Smoke ....................................... 91
0110-03 Coolant Temperature voltage high
Intermittent Cruise Control, Idle, or PTO Kickout .. 92
(27) .................................................................... 125
Intermittent Engine Shutdown ............................... 93
0110-04 Coolant Temperature voltage low (27) .. 126
Intermittent Low Power or Power Cutout .............. 94
0110-11 Very High Coolant Temperature (61) ..... 126
Low Power/Poor or No Response to Throttle ....... 96
0111-01 Low Coolant Level Warning (62) ........... 126
Poor Acceleration or Response ............................ 98
0111-02 Coolant Level signal invalid (12) ........... 127
0111-03 Coolant Level voltage high (12) ............ 128
Troubleshooting with a Diagnostic Code
0111-04 Coolant Level voltage low (12) .............. 128
Diagnostic Codes ................................................ 100
0111-11 Very Low Coolant Level (62) ................. 128
No Diagnostic Code Detected (55) ..................... 101
0121-05 Low/High Retarder current low (14) ...... 129
4 RENR2238-09
Table of Contents
0121-06 Low/High Retarder current high (14) .... 130 Ignition Key Switch Circuit and Battery Supply Circuit
0122-05 Med/High Retarder current low (14) ..... 130 - Test ................................................................. 259
0122-06 Med/High Retarder current high (14) .... 130 Ignore Brake/Clutch Switch Circuit - Test ........... 264
0168-01 Low ECM Battery Power (17) ............... 131 Injector Solenoid Circuit - Test ............................ 267
0168-02 ECM Battery Power Intermittent (51) .... 131 Multi-Torque - Test .............................................. 279
0171-03 Ambient Air Temperature voltage high .. 131 Neutral Switch Circuit - Test ................................ 280
0171-04 Ambient Air Temperature voltage low ... 132 Powertrain Data Link Circuit - Test ..................... 287
0171-11 Ambient Air Temperature Data Lost ...... 132 PTO Engine RPM Set Speed (Input A and Input B)
0174-00 High Fuel Temperature Warning (65) ... 132 Circuit - Test ...................................................... 295
0174-03 Fuel Temperature voltage high (13) ...... 133 PTO Shutdown Timer - Test ................................ 299
0174-04 Fuel Temperature voltage low (13) ....... 133 PTO Shutdown Timer - Test ................................ 301
0190-00 Engine Overspeed Warning (35) .......... 133 PTO Switch Circuit - Test .................................... 303
0190-12 Primary Engine Speed loss of signal PTO Switch ON Lamp Circuit - Test ................... 313
(34) .................................................................... 134 Remote PTO Accelerator Position Sensor Circuit -
0191-07 Transmission Not Responding (68) ...... 134 Test ................................................................... 317
0224-11 Theft Deterrent Active (00) ................... 134 Retarder (Compression Brake) Solenoid Circuit -
0224-14 Theft Deterrent Active with Engine Cranking Test ................................................................... 324
(00) .................................................................... 135 Service Brake Pedal Position (Switch 1) Circuit -
0231-02 J1939 Data Incorrect (58) ..................... 135 Test ................................................................... 334
0231-11 J1939 Data Link Fault (58) ................... 136 Service Brake Pedal Position (Switch 2) Circuit -
0231-12 J1939 Device Not Responding ............. 136 Test ................................................................... 339
0232-03 5 Volt Supply voltage high (21) ............. 136 Starting Aid Output Circuit - Test ........................ 344
0232-04 5 Volt Supply voltage low (21) .............. 137 Starting Aid Switch Circuit - Test ......................... 348
0246-11 Brake Pedal Switch #1 Fault ................. 137 Tachometer Circuit - Test .................................... 352
0247-11 Brake Pedal Switch #2 Fault ................. 137 Torque Limit Switch Circuit - Test ........................ 356
0249-11 J1922 Data Link Fault (58) ................... 138 Two Speed Axle Switch Circuit - Test ................. 360
0252-11 Engine Software Incorrect (59) ............. 138 Vehicle Speed and Speedometer Circuit - Test .. 364
0253-02 Check Customer or System Parameters Warning Lamp Circuit - Test ................................ 373
(56) .................................................................... 139
0253-11 Check Transmission Customer Parameters Calibration Procedures
(56) .................................................................... 139 Engine Speed/Timing Sensor - Calibrate ............ 379
Injector Code - Calibrate ..................................... 381
Diagnostic Functional Tests Vehicle Speed Circuit - Calibrate ........................ 382
5 Volt Engine Pressure Sensor Supply Circuit -
Test ................................................................... 140 Index Section
Accelerator Pedal (Throttle) Position Sensor Circuit -
Test ................................................................... 145 Index ................................................................... 386
Air Inlet Shutoff Circuit - Test .............................. 153
ATA (SAE J1587 / J1708) Data Link Circuit -
Test ................................................................... 159
Auxiliary Brake Circuit - Test ............................... 165
Check Engine Lamp Circuit - Test ...................... 169
Clutch Pedal Position Switch Circuit - Test ......... 173
Coolant Level Sensor Circuit - Test .................... 178
Cooling Fan Circuit and A/C High Pressure Switch
Circuit - Test ...................................................... 188
Cruise Control Switch Circuit - Test .................... 202
Diagnostic Enable Switch Circuit - Test .............. 209
Eaton Top 2 Transmission Circuit - Test ............. 212
ECM Memory - Test ............................................ 219
Electrical Connectors - Inspect ........................... 222
Engine Pressure Sensor Open or Short Circuit -
Test ................................................................... 226
Engine Running Output Circuit - Test ................. 233
Engine Shutdown Output Circuit - Test ............... 236
Engine Speed/Timing Sensor Circuit - Test ........ 239
Engine Temperature Sensor Open or Short Circuit -
Test ................................................................... 247
Fan Override Switch Circuit - Test ...................... 253
Idle Shutdown Timer - Test ................................. 256
RENR2238-09 5
Troubleshooting Section
The Rated Fuel Limit is a limit that is based on Customer Parameters And Engine Speed
the power rating of the engine and engine rpm. Governing
The Rated Fuel Limit is similar to the rack stops
and the torque spring on a mechanically governed A unique feature with electronic engines is customer
engine. The Rated Fuel Limit provides the power specified parameters. These parameters allow the
curves and the torque curves for a specific engine vehicle owner to fine tune the ECM for engine
family and a specific engine rating. All of these limits operation. Fine tuning the ECM for engine operation
are determined at the factory. These limits are in allows the vehicle owner to accommodate the typical
the Personality Module and these limits cannot be usage of the vehicle and the power train of the
changed. vehicle.
g00628178
Engine Monitoring
Illustration 1
(1) TC reference Caterpillar provides a factory installed engine
(2) Speed-timing signal monitoring system. The Caterpillar engine monitoring
(3) Electrical current to injector solenoid
(4) Injection pressure curve
system monitors engine oil pressure, coolant
temperature, intake manifold air temperature, and
Note: The signals and the timing of Illustration 1 are coolant level (optional device). Optional devices are
not to scale. OEM installed.
For example, if DERATE mode was selected, the This response is identical to the response when the
engine will derate engine power and vehicle speed. system is in the WARNING mode.
The engine will derate engine power and vehicle
speed if the coolant temperature sensor, the oil The DERATE mode alters the engine performance
pressure sensor or the coolant level sensor detects when any of the following conditions exist:
conditions that exceed acceptable limits.
• Oil pressure becomes Very Low Oil Pressure.
An excessive intake manifold air temperature will not
derate the engine. Also, an excessive intake manifold • Coolant level becomes Very Low Coolant Level.
air temperature will not shut down the engine.
• Coolant temperature becomes High Coolant
Caterpillar Engine Monitoring Temperature.
• High Coolant Temperature The SHUTDOWN mode will shut down the engine
when any of the following conditions exist:
• High Intake Manifold Air Temperature
• Oil pressure becomes Very Low Oil Pressure.
• Low Oil Pressure
• Coolant level becomes Very Low Coolant Level.
DERATE Operation
• Coolant temperature becomes Very High Coolant
If the system is programmed to DERATE, the ECM Temperature.
causes the warning lamp to turn ON. The warning
lamp does not flash. Also, the ECM begins flashing
the check engine lamp. The flashing check engine
lamp indicates that a problem has been detected by
the engine monitoring system.
8 RENR2238-09
Troubleshooting Section
g00628179 g00628189
Illustration 2 Illustration 5
Graph of engine monitoring coolant temperature Graph of engine monitoring coolant level
(1) Start or Restart warning derate (1) Warning derate
(2) The maximum rate will not exceed 10 percent per second. (2) The maximum rate will not exceed 10 percent per second.
(3) Shutdown (3) Shutdown
g00628181
Illustration 3
C-10 and C-12 Graph of engine monitoring coolant temperature
(1) Shutdown
g00628190
Illustration 6
Graph of engine monitoring coolant level time
(1) Start or Restart warning tripped
(2) Shutdown
g00628184
Illustration 4
3406E, C-15, C-16 and C-18 Graph of engine monitoring coolant
temperature
(1) Shutdown
RENR2238-09 9
Troubleshooting Section
g00732031 g00628192
Illustration 7 Illustration 9
C-10 and C-12 Graph of low oil pressure for OCT99 and newer 3406E, C-15, C-16 and C-18 Graph of low oil pressure
Personality Modules
(1) Low oil pressure
(1) Low Oil Pressure (2) Very low oil pressure
(2) Very Low Oil Pressure
g00628193
Illustration 10
Graph of Very low oil pressure start-up or restart
(1) Warning derate
(2) Shutdown
• The ECM is indicating an active code at the “PTO Time” and “PTO Fuel” are logged when the
present time. engine rpm is set by the use of the cruise switches
and the engine is operating under some load. Also,
Diagnostic Event Codes “PTO Time” and “PTO Fuel” are logged when the
PTO On/Off Switch is in the ON position and vehicle
Diagnostic event codes are used to indicate that speed is within the range of the “PTO Vehicle Speed
some operational problem has been detected in the Limit” Parameter.
engine or in the truck by the ECM. Usually, this does
not indicate an electronic malfunction. “Idle Time” and “Idle Fuel” can include operating time
when all of the following conditions are met:
The ECM also provides an ECM date/time clock that
is used to time stamp the following diagnostic event • When engine speed is set by using the cruise
codes: switches and the vehicle speed is within the range
of the “Idle Vehicle Speed Limit” Parameter.
• 84-00 Vehicle Overspeed Warning
• The engine is not operating under a load.
• 84-14 Quick Stop Occurrence
Fuel Information can be displayed in US Gallons or
• 100-11 Very Low Oil Pressure liters.
• 105-11 Very High Intake Manifold Air Temperature “Total Fuel” is the total amount of fuel that is
consumed by the engine during operation.
• 110-11 Very High Coolant Temperature
“Total Max Fuel” is the maximum amount of fuel that
• 111-11 Very Low Coolant Level could have been consumed by the engine during
operation.
• 190-00 Engine Overspeed Warning
“Average Load Factor” provides relative engine
Refer to Troubleshooting, “Troubleshooting with a operating information. “Average Load Factor”
Diagnostic Code” for a listing of all of the diagnostic compares actual engine operation information to
codes. the maximum engine operation that is available.
“Average Load Factor” is determined by using
“Total Max Fuel”, “Idle Fuel”, and “Total Fuel”. All of
ECM Lifetime Totals these parameters are available on Cat ET. These
parameters are available within the menu for “Current
The ECM maintains total data of the engine for the Totals”.
following parameters:
• “Total Time” (Engine Hours) Trip Data That Is Stored In The ECM
• “Total Distance” The Trip data allows the tracking of engine operation
by the vehicle owner over intervals that are defined
• “PTO Time” and “PTO Fuel” by the vehicle owner. Two types of Trip Data are
stored in the ECM, Driver Trip Data and Fleet Trip
• “Idle Time” and “Idle Fuel” Data. All of the Trip Data is stored in memory and
the Trip Data is maintained through the Unswitched
• “Total Fuel” Battery Lines when the ignition switch is OFF. An
internal battery will maintain this information while the
• “Total Max Fuel” Unswitched Battery Lines are disconnected.
• Overall Fuel Economy Cat ET calculates the percentage of time that is spent
in each of the engine rpm or vehicle speed ranges.
• Driving Fuel Economy Custom Data is available. Custom Data allows the
recording of engine parameters that are specified by
• Idle Time the vehicle owner. The ECM records the Custom
Data.
• Idle Fuel
A reset of the Fleet Trip Data which includes the Fleet
• Percent Idle Time Trip Segment, the Histograms, and the Custom Data
can be done in several ways. The following tools can
• PTO Time be used to reset the Fleet Trip Data:
The following list defines the options for Variable 1 of Fuel Correction Factor
the basic program:
A Fuel Correction Factor is available for fine
• “Engine Hours” tuning the calculations for fuel consumption. The
Fuel Correction Factor is protected by Customer
• “Distance Traveled” Passwords. The Fuel Correction Factor enhances
the accuracy of the calculation for fuel consumption.
• “Fuel Burned” Altering the Fuel Correction Factor does not affect
data that is already stored in the ECM. Altering
• “Occurrences” the Fuel Correction Factor only affects data that is
stored in the ECM after the Fuel Correction Factor
Refer to the following list for information regarding is entered.
the options that are available for Variable 2 and
Variable 5. Note: The Fuel Correction Factor should be adjusted
by the use of a long interval, data from the fuel tank
Variables 3, 4, 6, and 7 define the minimum range and recorded data in the ECM.
and the maximum range of variables 2 and 5.
Quick Stop Rate
• Engine RPM
A Customer Parameter is available in order to
• Vehicle Speed record the Quick Stop occurrences. The Parameter
determines the rate of change in vehicle speed that
• Fuel Rate is used by the ECM in order to record a Quick Stop
Event Code and a Quick Stop Snapshot. Refer to
• Load Factor Troubleshooting, “ECM Snapshot”.
• Cruise • PM2
The ECM also uses the Engine Oil Capacity. A larger “Secure Idle” is another Theft Deterrent Feature.
engine oil capacity provides a longer maintenance This allows the driver to bring the engine to an idle
interval. The Engine Oil Capacity is programmed into condition. The driver then enters the password. The
the ECM in liters or quarts. If the PM1 is programmed engine will remain at low idle until the password is
to the Manual mode, the owner can program the re-entered. If the engine is shutdown, a password will
ECM in the owner’s specific maintenance interval. be required to go above low idle after start-up.
The maintenance interval can be programmed to the
owner’s specific interval that is based on mileage or Fleet Information Software (FIS)
time. The interval for the PM2 and the interval for
the Cooling System Clean/Flush are established by The Caterpillar Fleet Information Software (FIS) is
the factory. another method that can be used to review the trip
information. The entire Fleet Trip Segment, which
CAT ID includes the following elements of data can be
accessed with the Caterpillar FIS:
The Caterpillar Driver Information Display (CAT ID)
is available to provide engine operating information • Histograms
to the driver. The Driver Trip Segment, the Fleet Trip
Segment, and the Maintenance Indicator data can be • Custom Data
viewed. However, the Fleet Trip Histograms and the
Custom Data cannot be viewed from the display. • Information that is tagged by the ID code
The CAT ID provides the ability to enter an ID code • Information that is tagged by the state of travel
for a driver in order to divide the Fleet Trip Segment
for two drivers. If the driver enters the information Maintenance Indicator information can also be
regarding the state of travel, the Fleet Trip Segment accessed by the use of the Caterpillar FIS.
can be tagged by the state of travel.
When the Caterpillar FIS downloads the information,
The CAT ID can be used in order to tag portions of the Caterpillar FIS also resets the ECM in order to
the Fleet Trip Segment into two ID codes. The CAT ID prepare the ECM for the next trip. The information
can also be used in order to tag portions of the Fleet can be downloaded to a computer with the Caterpillar
Trip Segment into the state of travel. The ID code and FIS program, or the information can be downloaded
the information regarding the state of travel cannot to an Argo Mobile Data Tool (MDT). The Argo Mobile
be viewed from the display. Only the Caterpillar Fleet Data Tool (MDT) is then connected to a computer in
Information Software (FIS) can view this information. order to download the information.
The ability to reset any of these parameters is
dependent on Customer Parameters in the ECM. Driver Reward Feature
The CAT ID will also display engine operating The Driver Reward Feature automatically adjusts the
parameters such as engine rpm, coolant temperature, VSL as a reward to the driver for operating a truck
boost pressure and many other parameters. in a manner that meets the truck engine owner’s
specifications. Several parameters are monitored
The CAT ID will also display engine diagnostic codes. in order to evaluate a driver’s operating technique.
The CAT ID will also display a brief text description Weighting factors are applied to the parameters that
of the diagnostic codes. reflect the operating techniques that are desired and
the operating techniques that are expected. If the
An available feature of the CAT ID is the Theft operating techniques meet the owner’s specifications
Deterrent. The Theft Deterrent allows the driver or the operating techniques exceed the owner’s
to input a password prior to shutdown. The Theft specifications, the VSL is automatically increased as
Deterrent will prevent the engine from restarting until a reward. The VSL will decrease when the operating
the password is successfully entered. The CAT ID techniques do not meet the owner’s specifications.
must have the version of software that is capable of
supporting this feature. The CAT ID can be used to monitor parameters that
affect the Driver Reward, which allows the driver to
An “Auto-Enable” option is available as a Theft adjust the operating techniques, as required.
Deterrent on Personality Modules which are dated
OCT99 and newer. If this option is selected, the Theft
Deterrent Feature will automatically be activated
when the engine is shut down. The driver must input
the correct password in order to start the engine.
RENR2238-09 15
Troubleshooting Section
With this system, the customer can remotely extract Refer to Troubleshooting, “Customer Specified
the following information from the ECM: Parameters”.
• Cruise control
16 RENR2238-09
Troubleshooting Section
i02182997 • Parameters
Electronic Service Tools • Diagnostic codes
SMCS Code: 0785 • Engine rating history
S/N: W1A1-Up
• Driver and fleet trip segments
S/N: CPD1-Up
• Histograms
S/N: EGH1-Up
S/N: 1MM1-Up
• Custom data
Table 2 Note: Items (2), (3), and (4) are part of the 171-4400
Required Electronic Service Tools for
Communication Adapter II Gp.
the Use of Cat ET
Use the following procedure to connect Cat ET and
Part Description the Communication Adapter II.
Number
Caterpillar Electronic Technician 1. Turn the keyswitch to the OFF/RESET position. If
the keyswitch is not placed in the OFF/RESET
JERD2124 “Electronic Technician Program” (Cat ET) position, the engine may start.
“Electronic Technician Truck Engine Data
JERD2125 2. Connect cable (2) between the “COMPUTER”
Subscription”
end of communication adapter (3) and the RS232
or
serial port of PC (1).
“Electronic Technician Engine/Machine
JERD2129
Data Subscription” 3. Connect cable (4) between the “DATA LINK” end
of communication adapter (3) and the service tool
171-4400(1) Communication Adapter II Gp
connector.
237-7547(2) Adapter Cable As
(1) The 7X-1700 Communication Adapter Gp may also be used.
4. Turn the keyswitch to the ON position. If Cat
(2) The 237-7547 Adapter Cable As is required to connect to the ET and the communication adapter do not
USB port on computers that are not equipped with a RS232 communicate with the Engine Control Module
serial port. (ECM), refer to Troubleshooting, “Electronic
Service Tool Will Not Communicate With ECM”.
Note: For more information regarding the use of
Cat ET and the PC requirements for Cat ET, refer to
the documentation that accompanies your Cat ET
Optional Service Tools
software. Table 3
2. If the test ECM repairs the problem, reconnect 2. If the test ECM repairs the problem, reconnect
the suspect ECM. Verify that the problem returns the suspect ECM. Verify that the problem returns
when the suspect ECM is reconnected. when the suspect ECM is reconnected.
3. Select the ECM Replacement Feature under the 3. Obtain customer parameters from the failed ECM.
“Service/Copy Configuration” menu and load the
parameters from the failed ECM. a. Obtain the customer passwords and record the
customer passwords. If the customer (owner)
4. Temporarily connect the new ECM by connecting has lost the passwords or if the customer
both ECM connectors. Do not mount the ECM on has forgotten the passwords, proceed to
the engine yet. Troubleshooting, “Customer Passwords” for
more details.
5. Flash program the personality module into the
new ECM if the personality module is not already b. Access the “Configuration” screen on Cat ET
installed. The new ECM is shipped with a blank and record the customer parameters from
personality module. the ECM that is being replaced. If the ECM
does not communicate with Cat ET, obtain the
6. Use the ECM replacement feature on the required parameter list from the OEM.
Caterpillar Electronic Technician (Cat ET) in order
to program the new ECM. c. Use the Troubleshooting, “Customer Specified
Parameters Worksheet” to record the customer
7. Enter the value for the “Rating Number” parameter parameters.
into the new ECM.
d. Record the injector codes. The injector codes
8. Check for active codes. Program any required can be found in the “Injector Codes Calibration”
parameters that have not been programmed. in “Calibrations” under the “Service” menu on
Cat ET. Refer to Troubleshooting, “Injector
Note: On initial powerup of a new ECM, the Code - Calibrate” for more information.
parameter “Rating Number” must be programmed
to avoid activating a 253-02 Check Customer Or 4. Record ECM lifetime totals.
System Parameters.
a. Use the Troubleshooting, “Customer Specified
9. If 22-13 Engine Speed Signal Calibration Not Parameters Worksheet (Current Totals
Performed is not active, install the new ECM on Worksheet)” in order to record the old “ECM
the engine. Otherwise, perform a timing calibration Current Totals”.
first.
5. Temporarily connect the new ECM by connecting
both ECM connectors. Do not mount the ECM to
the engine until the timing calibration has been
performed.
7. Obtain factory passwords when the passwords d. Program the injector codes on Cat ET. Select
are required. the following screens in order: “Service”,
“Calibrations”, “Injector Codes Calibration”.
Note: The following parameters can be programmed Refer to Troubleshooting, “Injector Code -
on a new ECM without factory passwords: “Full Calibrate” for more information.
Load Setting (FLS)”, “Full Torque Setting (FTS)”,
and “Engine Serial Number”. System configuration e. Select the following screens in order to calibrate
parameters must be entered before the customer the engine timing: “Service”, “Calibrations”, and
specified parameters are entered. If customer “Timing Calibration”. Calibrate the timing. Refer
parameters are entered before the system to Troubleshooting, “Engine Speed/Timing
configuration parameters, the total tattletale will Sensor - Calibrate” for the proper procedure.
change. It will then be necessary to obtain another
set of factory passwords in order to change system 10. Install the new ECM on the engine.
configuration parameters.
i01907619
8. Perform the following operations.
Note: On initial powerup of a new ECM, the following J300/P300 Injector Solenoid Harness
parameters must be programmed to avoid activating J400/P400 Timing Calibration Probe
253-02 Check Customer Or System Parameters:
“Full Load Setting (FLS)”, “Full Torque Setting J401/P401 Primary Engine Speed/Timing
(FTS)”, “Vehicle Speed Calibration” (ppm), “Rating Sensor
Number”, “Engine Serial Number”, and “Injector J402/P402 Secondary Engine Speed/Timing
Codes Calibration”. Sensor
J403/P403 Accelerator Pedal Position Sensor
a. Access the “Configuration” screen on Cat
ET. Enter the following parameters that are
recorded on the worksheet: “Full Load Setting
(FLS)”, “Full Torque Setting (FTS)”, and
“Engine Serial Number”.
g00995055
Illustration 13
RENR2238-09 21
Troubleshooting Section
Diagram of components
g00992601
Illustration 14
Left side view (typical example)
22 RENR2238-09
Troubleshooting Section
g00992610
Illustration 15
Top view (typical example)
RENR2238-09 23
Troubleshooting Section
3406E Engine
g00995059
Illustration 16
Left side view (typical example)
24 RENR2238-09
Troubleshooting Section
g00995060
Illustration 17
Right side and front views (typical example)
RENR2238-09 25
Troubleshooting Section
g00992613
Illustration 18
Left side view and top view (typical example)
26 RENR2238-09
Troubleshooting Section
i01907629
g00995478
Illustration 19
28 RENR2238-09
Troubleshooting Section
i01248643
g00665578
Illustration 20
30 RENR2238-09
Troubleshooting Section
i02305595
ECM Snapshot
SMCS Code: 0785
i02278907 • The Full Load Setting (FLS) was changed per the
factory’s instructions.
Service Information Report
Be as specific as possible.
SMCS Code: 0336
Recommendations
Customer’s Complaint
Obtain as much information from the customer
as possible. Investigate any written information
that is available and document any information
that is gathered from the customer. The following
information is of particular importance:
Be as specific as possible.
Cause of Failure
Comments on the cause of failure should include
the number of diagnostic codes that were logged.
Comments should also indicate if the code was an
active code. Indicate the source of the problem. Also
indicate the method that was used to discover the
problem. Examples of the methods that were used to
discover the problem could be one of the following
methods:
Be as specific as possible.
Repair Procedure
Comments on the repair procedure should include
the following types of information:
• Time of change
i01914146
“Multi-Torque Ratio”
This parameter is used to select the desired
Multitorque trip point. Multitorque ratings allow
the engine to provide additional torque, additional
horsepower, and torque when the transmission
is operating in higher gear. The additional torque
allows the truck to crest a hill without downshifting
and increases fuel economy. The “Multi-Torque”
feature also helps to reduce wear. The trip point is
determined by a ratio of engine speed versus vehicle
speed. The three programmable options represent
the different trip point values that are listed below.
Table 6
Table 7
Table 11 Table 14
Minimum Maximum Default Minimum Maximum Default
0 6.550 Not Programmed 12.0 PPR 500.0 PPR 113.0 PPR
Table 12
“Low Speed Range Axle Ratio”
Minimum Maximum Default
204 km/h 204 km/h The “Low Speed Range Axle Ratio” must be
48 km/h (30 mph) programmed when a “Two-Speed Axle On/Off
(127 mph) (127 mph)
Switch” is used by the ECM to adjust the “Vehicle
Speed Calibration”. When a two-speed axle is used,
“VSL Protection” the change in gear ratios from the high speed range
to the low speed range alters the calibration of the
The “VSL Protection” is the maximum engine rpm vehicle speed signal. Since the vehicle speed signal
when there is a problem with the vehicle speed signal has been altered, a calibration adjustment is required
that is detected by the ECM. The ECM limits the to ensure that the ECM driven speedometer and the
engine to this engine rpm when the ECM senses information that is stored in the ECM correctly reflect
no vehicle speed signal, and a load on the engine. the actual vehicle speed. This parameter should be
This is a feature that is used to prevent tampering by programmed to the “Low Speed Range Axle Ratio”.
running without a Vehicle Speed input to the ECM. This parameter only requires programming when the
“Two-Speed Axle Switch” parameter is enabled. The
Note: When this parameter is programmed to 2120 “Two-Speed Axle Switch” Parameter is enabled when
rpm, the ECM disables 84-01 Loss Of Vehicle Speed the parameter is programmed to J1/P1:7, J1/P1:47,
Signal (31) and 84-10 Vehicle Speed Rate of Change J1/P1:6, or J1/P1:46.
(36) and the “VSL Protection” may be exceeded by
disconnecting the Vehicle Speed Sensor. Table 16
Minimum Maximum Default
Table 13
Minimum Maximum Default 1.00 19.99 1.00
“Tachometer Calibration”
The “Tachometer Calibration” is used by the ECM
to translate the engine speed signal into revolutions
per minute for a tachometer. The “Tachometer
Calibration” is programmed in pulses per revolution
(PPR). The programmable range is from 12.0 PPR to
500.0 PPR in 0.1 PPR increments.
40 RENR2238-09
Troubleshooting Section
Table 19
g00631045 g00631048
Illustration 22 Illustration 23
Coast and latch of engine retarder mode
Note: When the vehicle speed drops below the
Engine Retarder Minimum Vehicle Speed and the
“Engine Retarder Minimum VSL Type”
parameter is programmed to the Hard limit, the
The “Engine Retarder Minimum VSL Type” defines engine retarder turns off. When the vehicle speed
drops below the Engine Retarder Minimum Vehicle
the use of the “Engine Retarder Minimum Vehicle
Speed and the parameter is programmed to the Soft
Speed” parameter. The “Engine Retarder Minimum
VSL Type” provides the following two options: limit, the Engine retarder remains on.
Table 22 Table 24
Minimum Maximum Default Minimum Maximum Default
204 km/h 0 km/h (0 mph) 8 km/h (5 mph) 3 km/h (2 mph)
0 km/h (0 mph) 0 km/h (0 mph)
(127 mph)
Note: This parameter only affects the Factory “Soft Cruise Control”
installed engine retarder (compression brake). This
parameter does not affect an auxiliary braking device “Soft Cruise Control” provides a 8 km/h (5 mph)
or Brakesaver. operating range around the cruise control set speed
in order to provide a smoother cruise control. “Soft
The actual level of braking is limited by the settings Cruise Control” controls the cruise speed within the
of the retarder switch. For example, the retarder will following range:
not come on if the retarder is switched off.
• 4 km/h (2.5 mph) below the set vehicle speed at
If Soft Cruise Control is programmed to YES, the full load
retarder will not come on until the vehicle speed
is 5 km/h (3 mph) above the cruise set speed. An • 4 km/h (2.5 mph) above the set vehicle speed at
Electronic Service Tool will change an attempt to no load
program 2 km/h (1 mph) or 3 km/h (2 mph) for this
parameter to 5 km/h (3 mph) if Soft Cruise Control
is programmed to YES.
Table 23
Table 26 Table 29
Alternative Default Minimum Maximum Default
No Yes 600 rpm TEL rpm TEL rpm
Table 30
“Idle Parameters” Minimum Maximum Default
Table 35 Table 37
Minimum Maximum Default Alternative Default
Low Idle rpm PTO TEL rpm 0 rpm Yes No
“PTO Engine RPM Set Speed Input B” “Maximum PTO Enable Speed”
NOV99 and newer software NOV01 and newer software
The ECM controls this engine rpm. This control Note: This parameter is not available on engine
occurs when the “PTO ON/OFF” circuit and the “PTO serial numbers W1A1-Up, MDP1-Up, and MEP1-Up.
Engine RPM Set Speed Input B” switch is on and the
“PTO Engine RPM Set Speed A” switch is off. The This parameter specifies the maximum engine speed
RPM can be programmed to operate from Low Idle for the engagement of the PTO mode. The PTO
up to the “PTO Top Engine Limit” RPM. While the mode will engage when the engine rpm is equal to
engine is operating at this set speed, all other inputs the programmed limit or less than the programmed
for speed control are ignored except for the “PTO limit. This parameter is only available when the “PTO
Engine RPM Set Speed A”. The inputs for speed Configuration” is programmed to “Cab Switches”,
control that are ignored include the Cab Throttle “Remote Switches”, or “Remote Throttle”.
switch, the Remote Throttle switch, the Set/Accel
switch, and the Resume/Decel switch. This feature Table 38
can also be used in conjunction with the “PTO to Set Minimum Maximum Default
speed” feature for multiple speed PTO operation.
This feature can also override the “PTO to Set speed” Low Idle rpm TEL rpm TEL rpm
feature for multiple speed PTO operation.
Note: The “PTO Configuration” parameter must be • If the parameter is programmed to “Top Engine
Limit” (TEL), the engine will operate to the
programmed to Cab Switches, Remote switches,
programmed “Top Engine Limit”.
or Remote Throttle and the “PTO Engine RPM Set
Speed Input B” parameter must be programmed to a
dedicated switch input (J1/P1:6, J1/P1:46, J1/P1:58, • If the parameter is programmed to “PTO TEL”, the
engine will operate to the programmed “PTO Top
or J1/P1:60) for this feature to function.
Engine Limit”.
Table 36
Note: “PTO Configuration” must be programmed
Minimum Maximum Default to Cab Switches for this parameter to take effect.
Low Idle rpm PTO TEL rpm 0 rpm If “PTO Configuration” is programmed to Remote
Switches or Remote Throttle, the ECM will always
ignore the Cab Throttle when the “PTO On/Off” circuit
“PTO to Set Speed” is on.
Table 41
Minimum Maximum Default
270 N·m 3400 N·m 3400 N·m
(200 lb ft) (2500 lb ft) (2500 lb ft)
g00671143
Illustration 26
“PTO Shutdown Timer Maximum RPM” Graph
Table 43
Table 46
“Top Engine Limit” (TEL)
Minimum Maximum Default
5 km/h (3 mph) 48 km/h (30 mph) 5 km/h (3 mph) OCT99 and older software
Table 52
Alternative Default
Yes No
Table 53
Minimum Maximum Default
600 rpm 750 rpm 600 rpm
“Transmission Style”
This parameter indicates the type of transmission
configuration that is installed in the vehicle to the
ECM. This parameter is used by the ECM to read the
signals from the following devices:
• Automatic Option 1
• Automatic Option 2
• Automatic Option 3
RENR2238-09 49
Troubleshooting Section
Table 54
Table 56
“Top Gear Minus Two Ratio”
Alternative Default The “Top Gear Minus Two Ratio” identifies the third
Yes No highest gear ratio for an Eaton Top 2 Transmission.
For example, eighth gear for an Eaton Super
10 Top 2 transmission is Top Gear Minus Two.
“Top Gear Ratio” The programmable range is 0.000 to 3.750 in
0.001 increments. The default is 0.000. Refer
The “Top Gear Ratio” identifies the highest gear to “Gear Ratios for Eaton Top 2 Transmission”
ratio for an Eaton Top 2 Transmission. For example, for programmable values for each Eaton Top 2
tenth gear for an Eaton Super 10 Top 2 transmission transmission.
is the Top Gear. The programmable range is 0.000
to 3.750 in 0.001 increments. The default is 0.000. Note: This parameter must be precisely programmed
Refer to “Gear Ratios for Eaton Top 2 Transmission” to three decimal places to ensure the proper
for programmable values for each Eaton Top 2 operation of the Eaton Top 2 and Caterpillar engine
transmission. drive train in the top two gears.
50 RENR2238-09
Troubleshooting Section
Table 65 Table 66
−40 °C (−40 °F) 49 °C (120 °F) 49 °C (120 °F) −40 °C (−40 °F) 49 °C (120 °F) 49 °C (120 °F)
52 RENR2238-09
Troubleshooting Section
“A/C Switch Fan On-Time” This parameter is used to determine the voltage trip
point. Below this trip point, the Battery Monitor and
The input 11 to the ECM can be used for the the Engine Speed Control System will automatically
connection of a normally closed high pressure A/C elevate engine idle in order to maintain ideal battery
switch. The ECM has a built-in timer. The timer is system voltage. This feature is used to promote
used to prevent excessive cycling of the cooling additional battery life. The engine idle will only
fan clutch due to successive cycling of the A/C be increased if the vehicle is stopped and the
switch. Programming this parameter to 0 disables the transmission is out of gear. If these conditions are
function. Programming depends on the refrigerant, not met, the engine idle will not be adjusted. This
and the design of the air conditioning system as well feature will not function when the engine is operating
as the use of the signal input. Program the timer to in dedicated PTO mode (“PTO On/Off” switch in the
1 second for the connection of this input to another ON position).
system. Programming the timer to 1 second also
provides a time delay. This feature requires the “Fan The recommended setting is 12.2 Volts for a 12 Volt
Control Type” to be programmed to the On/Off or the system, and 24.5 Volts for a 24 Volt system.
“Three-Speed Fan”.
Note: This feature requires the installation of a
Table 67 Neutral Switch on J1/P1. This is terminal 62 (Input
Minimum Maximum Default 12). Engine speed will only be elevated when the
transmission is in Neutral.
1 second 600 seconds 0 seconds
Table 70
This parameter provides a programmable delay Note: NOV01 and newer software does not allow
after provisions to turn on the engine retarder or the the “Engine Monitoring Mode” to be programmed to
engine brake are met. “Off” except on engine serial numbers W1A1-Up,
MDP1-Up, and MEP1-Up.
Table 69
Table 71
Minimum Maximum Default
Alternative Default
0 seconds 3 seconds 0 seconds
Derate Off
Shutdown Warning(1)
“Smart Idle Parameters” (1) This is for NOV01 and newer software except engine serial
numbers W1A1-Up, MDP1-Up, and MEP1-Up.
“Battery Monitor and Engine Control Voltage”
Table 80
Alternative Default
Yes No
“PM 1 Reset”
g00629908
Illustration 28 This parameter determines the driver’s access for
resetting the PM 1 (Maintenance) after the PM 1
OLD FCF – Fuel Correction Factor in ECM has been performed. Maintenance Indicator Mode
cannot be programmed to “OFF” for the “PM 1 Reset”
TANK – Actual Fuel Economy parameter to take effect.
RENR2238-09 55
Troubleshooting Section
Table 86
When this parameter is used with a “Theft Deterrent
Password”, this parameter prevents the engine from ECM Snapshot Frame Data
starting unless the password has been entered via Engine rpm Vehicle Speed
the dash display of the CAT ID. Before the operator Throttle Position Cruise Status
can use the feature of Theft Deterrent of the CAT Clutch Switch Brake Switch
ID, the system must be turned on. In order to turn
on the theft deterrent, a service tool must be used
to program the parameter for the theft deterrent to The most recent Quick Stop Snapshot is stored in
“YES”. The operator must first enter the password the ECM memory. When a Quick Stop Event occurs
before the engine is shut off. This will enable the the ECM replaces the old Quick Stop Snapshot
system. Enabling the system prevents the engine with the new Quick Stop Snapshot. The ECM also
from starting without re-entering the password on the logs a diagnostic event code for each “Quick Stop
next attempted start. Occurrence”. The ECM stores a maximum of 255
occurrences.
Table 84
Table 87
Alternative Default
Alternative Default
Yes, Auto-Enable(1) No
5 kilometers per hour
(1) NOV99 and newer software per second ( 3 miles per
0 kilometers per hour
hour per second) to 24
per second (0 miles per
kilometers per hour per
hour per second)
second (15 miles per
hour per second)
56 RENR2238-09
Troubleshooting Section
Note: Programming the “Quick Stop Rate” too low “Input Selections”
will cause an excessive number of Quick Stop Event
Codes. A vehicle without a load or a trailer will be “Fan Override Switch”
able to stop much more quickly than a vehicle with
a heavy load. If too many Quick Stop Event Codes Four input connections can be used in order to
are being logged, the “Quick Stop Rate” should be connect the “Fan Override Switch”. The “Fan
increased. This will improve the detection of the Override Switch” can be programmed to the following
exceptions when the exceptions occur. ECM pins:
MAR99 and newer software The Input 5 to the ECM can be used to connect
an “Ignore Brake/Clutch Switch”. The “Ignore
“Driver Reward” is a feature that allows a truck owner Brake/Clutch Switch” is used for applications that
to place emphasis on certain factors for desired require the mobile use of the vehicle with a set PTO
operating habits. If the vehicle is operated in a engine set rpm that does NOT require the Brake or
manner that exceeds the owner’s specifications, the the Clutch to disengage the engine’s PTO operation.
maximum vehicle speed limit can be automatically This parameter (“Ignore Brake/Clutch Switch”) must
increased to a specified value as a reward to the be programmed to J1/P1:47 to enable this feature.
driver. The “Driver Reward Enable” parameter Table 91
provides a means in order to disable the “Driver
Reward” feature. This parameter also provides a Alternative Default
means in order to lock out the “Driver Reward” J1/P1:47 None
feature. An Electronic Service Tool is used for those
areas with regulations that require a fixed maximum
Vehicle Speed Limit.
Table 89
Alternatives Default
Disabled Enabled
RENR2238-09 57
Troubleshooting Section
Alternative Default
J1/P1:7 None
“Remote PTO Resume Switch”
The J1939 data link and input 3 can be used to
“Diagnostic Enable” connect the “Remote PTO Resume Switch”. The
“Remote PTO Resume Switch” is used when the
The J1939 data link and input 7 can be used “PTO Configuration” is programmed to Remote
to connect the “Diagnostic Enable”. Diagnostic Switches and the “PTO On/Off” switch is in the ON
flash codes can be prompted by the use of the position.
“Diagnostic Enable”. To initiate the flash codes,
Table 96
depress the momentary “Diagnostic Enable” until
the Check Engine Lamp begins to flash. Refer to Alternative Default
Troubleshooting, “Diagnostic Codes” for additional
J1939 - Body Controller
information regarding flash codes. J1939 - Cab Controller
J1/P1:60
J1939 - Instrument Cluster
Table 93
None
Alternative Default
J1/P1:46 “PTO Engine RPM Set Speed Input A”
J1939 - Body Controller
None
J1939 - Cab Controller NOV99 and newer software
J1939 - Instrument Cluster
The “PTO Engine RPM Set Speed Input A” switch
“PTO On/Off Switch” can be connected to any one of the following
locations: J1/P1:6, J1/P1:46, J1/P1:58, J1/P1:60,
NOV01 and newer software and J1939 data link. If the “PTO Engine RPM Set
Speed Input A” parameter is programmed to the
Note: This parameter is not available on engine corresponding switch input option, the switch is used
serial numbers W1A1-Up, MDP1-Up, and MEP1-Up. to control engine speed during PTO operation. The
“PTO Configuration” parameter must be programmed
This parameter allows the connection of a “PTO to Cab Switches, Remote Switches or Remote
On/Off Switch” using either the J1939 data link or Throttle and the “PTO Engine RPM Speed Input A”
J1/P1:56. parameter must be programmed to a valid speed.
Table 94 Table 97
The “PTO Engine RPM Set Speed Input B” switch “Two-Speed Axle Switch”
can be connected to any one of the following
locations: J1/P1:6, J1/P1:46, J1/P1:58, J1/P1:60, The J1939 data link and input 6 to the ECM is used to
and J1939 data link. If the “PTO Engine RPM Set connect the “Two-Speed Axle On/Off Switch”. When
Speed Input B” parameter is programmed to the a two-speed axle is used, the change in gear ratios
corresponding switch input option, the switch is used from the high speed range to the low speed range
to control engine speed during PTO operation. The alters the calibration of the vehicle speed signal.
“PTO Configuration” parameter must be programmed When this parameter is programmed to J1/P1:6 or
to Cab Switches, Remote Switches or Remote J1939 and the switch is in the ON position the ECM
Throttle and the “PTO Engine RPM Speed Input B” automatically adjusts the vehicle speed calibration.
parameter must be programmed to a valid speed. This will ensure that the ECM driven speedometer
and the information that is stored in the ECM correctly
Table 98 reflect the actual vehicle speed. The “High Speed
Alternatives Default Range Axle Ratio” and “Low Speed Range Axle
Ratio” must also be programmed for this feature to
J1/P1:6 function correctly.
J1/P1:46
None
J1/P1:58 Table 100
J1/P1:60
Alternative Default
J1/P1:6
“Starting Aid On/Off Switch” J1939 - Body Controller
None
J1939 - Cab Controller
OCT99 and newer software J1939 - Instrument Cluster
Alternatives Default
J1/P1:6
“Cruise Control Set/Resume Switch”
J1/P1:7
None The “Cruise Control Set/Resume” input circuits
J1/P1:46
J1/P1:47 are available for the connection of a cruise
control set/resume switch. This parameter can be
programmed to J1/P1:35 & 44 or J1939. If the
parameter is set to J1/P1:35 & 44, the Set input
should be connected to J1/P1:35 and the Resume
input should be connected to J1/P1:44. This switch
is used in conjunction with the Cruise Control On/Off
Switch to perform the following functions:
• Enable the Diagnostic Flash Codes on the Check “Retarder Off/Low/Medium/High Switch”
Engine Lamp.
The input for the “Retarder Solenoid Low/Hi Switch”
When the “PTO Configuration” is programmed to Cab and the input for the “Retarder Solenoid Med/Hi
Switches, the “Cruise Control Set/Resume Switch” is Switch” are available for the connection of a selector
also used with the “PTO On/Off” switch to control the switch for the engine retarder solenoid. The Retarder
engine rpm in PTO Mode. Switch can be connecting by the use of the J1939
data link or using J1/P1:23 & 40. If J1/P1:23 & 40 is
Table 102 used, the Low/Hi Input should be connected to ECM
Alternative Default Connector J1/P1:23 and the Med/Hi Input should
be connected to ECM Connector J1/P1:40. This
J1939 - Body Controller switch controls the operation of the Engine Retarder
J1939 - Cab Controller J1/P1:35 & 44 Solenoids.
J1939 - Instrument Cluster
Table 105
Table 107
Alternative Default
J1/P1:66
60 RENR2238-09
Troubleshooting Section
The ECM can also be configured to receive vehicle “Engine Shutdown Output”
speed information from the ABS system via the
J1939 data link. The ABS system must be capable of The Output 2, Output 3 or Output 4 is available
supporting the “J1939 High Resolution Wheel Speed for the connection of an Engine Shutdown Output
Broadcast Message”. The “Vehicle Speed Input” Relay that is used to shut down the vehicle electrical
must be programmed to “J1939-ABS”. system after the idle timer has expired. The “Engine
Shutdown Output” can be programmed to J1/P1:10,
Note: The “J1939-ABS” option is only available with J1/P1:12 or J1/P1:13. The “Engine Shutdown Output”
NOV01 and newer Personality Modules. This option comes on after the engine runs for more than 3
is not available for engine serial numbers W1A1-Up, seconds. The “Engine Shutdown Output” turns off
MDP1-Up, and MEP1-Up. when the engine rpm is at least 100 rpm below the
low idle rpm for more than 3 seconds.
Table 108
Table 110
Alternative Default
Alternative Default
J1939 - ABS
J1/P1:32 & 33 J1/P1:10
J1939 - Trans
J1/P1:12 None
J1/P1:13
“Auxiliary Brake”
The Auxiliary Brake Output is for use with a
BrakeSaver or other Aftermarket braking devices.
The Output 3 is available for the connection of an
auxiliary Brake Relay. This parameter (“Auxiliary
Brake”) must be programmed to J1/P1:12. Operation
of the auxiliary brake and the relay is inhibited during
undesirable engine operating conditions. The time
period of fueling the engine is an undesirable engine
operating condition.
RENR2238-09 61
Troubleshooting Section
Injector Codes
Injector Codes are etched on each injector. The
Injector Codes can be viewed from the electronic
service tool and the injector codes can be changed
from the electronic service tool. The technician must
select the Service screen, the Calibration screen and
the Injector Codes Calibration screen in order to view
the injector codes. Also, the technician must select
the Service screen, the Calibration screen and the
Injector Codes Calibration screen in order to change
the injector codes. The injector code must match the
code on the corresponding injector. When an injector
is replaced, reprogram the new code for the new
injector.
i01907620
Customer Specified
Parameters Table
SMCS Code: 1901
Table 117
Table for Customer Specified Parameters
“Parameter” Available Range or Options Default
“Selected Engine Rating”
“Rating Number” Dependent on engine power Unavailable
“Multitorque Ratio” Unavailable (Standard Ratings)
“MT-1”, “MT-2”, or “MT-4” “MT-4” (Multi-Torque)
(Multi-Torque Ratings)
“ECM Identification Parameters”
“Vehicle ID” 17 Digits
Available characters are dependent all zeroes
on the service tools.
“Security Access Parameters”
“ECM Wireless Communication Enable” “Yes”
“No”
“No”
“Vehicle Speed Parameters”
“Vehicle Speed Calibration” 2485 to 93226 PPKM
8696 PPKM (14000 PPM)
(4000 to 150000 PPM)
“Vehicle Speed Cal (J1939 - Trans)” 0 to 6500 Not Programmed
“Vehicle Speed Cal (J1939 - ABS)” 0 to 6.550 Not Programmed
“Vehicle Speed Limit” 48 to 204 km/h (30 to 127 mph) 204 km/h (127 mph)
“VSL Protection” 1300 to TEL rpm TEL rpm
“Tachometer Calibration” 12.0 to 500.0 pulses per revolution 113.0 pulses per revolution
“Soft Vehicle Speed Limit” “Yes”
“No”
“No”
“Low Speed Range Axle Ratio” 1.00 to 19.99 1.00
“High Speed Range Axle Ratio” 1.0 to 9.9 1.00
(continued)
RENR2238-09 63
Troubleshooting Section
(continued)
66 RENR2238-09
Troubleshooting Section
Table 126
Timer Parameters
“Idle Shutdown Time”
“Idle Shutdown Timer
Maximum RPM”
“Allow Idle Shutdown
Override”
“Minimum Idle Shutdown
Outside Temp”
“Maximum Idle Shutdown
Outside Temp”
“A/C Switch Fan On-Time”
“Fan with Engine Retarder
in High Mode”
“Engine Retarder Delay”
Table 127
Table 134
Table 132
Output Selections
Driver Reward
“Engine Running Output”
“Driver Reward Enable”
“Engine Shutdown Output”
“Auxiliary Brake”
“Starting Aid Output”
“Air Inlet Shutoff Relay
Control”
“Fan Control Type”
“PTO Active Output”
RENR2238-09 71
Troubleshooting Section
Table 135
Customer Passwords
“Customer Password #1”
“Customer Password #2”
Table 136
Data Link Parameters
“Power train Data Link”
Injector Codes
Table 137
Injector Codes
Injector Code (1)
Injector Code (2)
Injector Code (3)
Injector Code (4)
Injector Code (5)
Injector Code (6)
Can Not Reach Top Engine • “Top Engine Limit” Engines with software
prior to DEC 02
RPM
• “VSL Protection”
SMCS Code: 1915-035
• “PTO Top Engine Limit” with the PTO On/Off
Switch turned ON.
Probable Causes
Note: If this problem occurs under load, refer to
• “PTO Vehicle Speed Limit” with the PTO
On/Off Switch turned ON.
Troubleshooting, “Low Power/Poor or No Response
to Throttle”. d. Set each parameter to the parameter’s
maximum value one at a time and determine
The probable root causes are listed in order below: whether the problem is corrected.
• Diagnostic codes 3. Check Cold Mode operation.
• Customer specified parameters (normal operation) Note: This is normal operation if the problem occurs
only after start-up in cold weather.
• Cold mode
a. Monitor Cat ET in order to verify that the engine
• Accelerator pedal position sensor has progressed from Cold Mode.
• Vehicle speed signal “Cold Mode” is indicated in the upper corner
of any status screen.
• Fuel supply
4. Check the accelerator pedal position sensor.
• Power train data link
a. Use the Cruise/Idle On/Off Switch to put the
• Air intake and exhaust system engine in idle mode.
b. Check for active diagnostic codes and/or • The engine is stable by using idle mode to
logged diagnostic codes. control the engine rpm.
Certain diagnostic codes will limit the engine • The engine is unstable by using the
speed. accelerator pedal position sensor.
c. Troubleshoot all active diagnostic codes before If the status of the accelerator pedal position
continuing with this procedure. sensor is unstable, refer to Troubleshooting,
“Accelerator Pedal (Throttle) Position Sensor
2. Check customer specified parameters. Circuit - Test”.
a. Verify that the complaint is not normal operation 5. Monitor the vehicle speed signal. Ensure the
(programmed parameter). accuracy of the vehicle speed signal by comparing
the vehicle speed signal to the actual vehicle
b. Access the “Configuration” screen on Cat ET. speed.
a. Monitor the exhaust for smoke while the engine Probable Causes
is being cranked.
The probable root causes are listed in order below:
If no smoke is present, there may be a problem
with the fuel quality or there may be a problem • Diagnostic codes
with the fuel supply.
• Customer specified parameters (normal operation)
b. Check the fuel quality.
• Cold mode
c. Check the fuel pressure.
• Electronic system problem
d. Ensure that the fuel system has been primed.
• Fuel supply
e. Check for air in the fuel system.
• Air intake system or exhaust system
f. Check for fuel supply lines that are restricted.
• Leakage in air-to-air aftercooler core
g. Check the fuel filters . Refer to Testing and
Adjusting for more information on the fuel Recommended Actions
system. Also refer to Truck Application and
Installation Guide, LEBT5109. 1. Check for diagnostic codes.
h. If the temperature is below 0 °C (32 °F), check a. Connect the Caterpillar Electronic Technician
for solidified fuel (wax). (ET) to the data link connector.
7. Check the “Powertrain Data Link”. Ensure that the b. Turn the key switch to the ON position.
power train data link is not limiting the power.
c. Check for active diagnostic codes and logged
a. Monitor the “Powertrain Data Link” status diagnostic codes.
screen while the vehicle is experiencing
problems. Certain diagnostic codes will limit the vehicle
speed to 45 mph.
If the “Powertrain Data Link” status screen
indicates that the “Powertrain Data Link” is d. Troubleshoot all diagnostic codes before
limiting the power or the rpm, verify that this continuing with this procedure.
is not normal operation. If this is not normal
operation, refer to the vehicle OEM for repairs. 2. Check customer specified parameters.
8. Air intake and exhaust system a. Verify that the complaint is not due to normal
operation (programmed parameter).
a. Clean plugged air filters or replace plugged air
filters. Refer to the Operation and Maintenance b. Access the “Configuration” screen on Cat ET.
Manual.
c. Check the following parameters:
b. Check the air intake and the exhaust system
for restrictions and/or leaks. Refer to Testing • “Vehicle Speed Limit”
and Adjusting for more information.
• “Soft Vehicle Speed Limit”
• “Lower Gears Engine RPM Limit”
• “Intermediate Gears Engine RPM Limit”
RENR2238-09 75
Troubleshooting Section
• “Gear Down Protection Engine RPM Limit” When the engine is OFF, the boost pressure
should be 0 kPa (0 psi).
• “VSL Protection”
b. Monitor the status of the accelerator pedal
• “Top Engine Limit” position sensor. Operate the engine at high idle
with the vehicle in Neutral.
• Incorrect programming of the Vehicle Speed
calibration (ppm). If the engine can not reach the programmed
“Top Engine Limit”, check the duty cycle for the
• “PTO Top Engine Limit” with the PTO On/Off accelerator pedal position sensor in order to
Switch turned ON. ensure that the duty cycle is within calibration
(75 to 90 Percent at high idle).
• “Maximum PTO Vehicle Speed” with the
PTO On/Off Switch turned ON. If the accelerator pedal position is unstable,
check the duty cycle of the accelerator pedal
d. Set each parameter to the parameter’s position sensor. Check the duty cycle by slowly
maximum value one at a time and determine operating the accelerator pedal in order to
whether the problem is corrected. verify that the duty cycle is within calibration.
The accelerator pedal position sensor is
Note: The “Soft Vehicle Speed Limit” will not allow within calibration when both of the following
the vehicle to achieve the programmed VSL under conditions are met:
all engine load conditions. Programming the “Soft
Vehicle Speed Limit” to NO may be required to • 10 to 22 percent at low idle
eliminate the complaint.
• 75 to 90 percent at high idle
3. Check cold mode operation.
Also, ensure that the duty cycle changes as the
Note: This is normal operation if the problem occurs pedal position changes.
only after start-up in cold weather.
If a problem with the accelerator pedal position
a. Check the status screen on Cat ET. sensor is suspected, refer to Troubleshooting,
“Accelerator Pedal (Throttle) Position Sensor
“Cold Mode” is indicated in the upper corner of Circuit - Test”.
any status screen when cold mode is active.
Note: If the engine exceeds the “Top Engine Limit”,
4. Check for an electronic system problem. the “Top Engine Limit with Droop” is programmed to
YES.
a. Monitor the fuel position, the “Rated Fuel Limit”,
and the “FRC Fuel Limit”. 6. Monitor the vehicle speed signal. Ensure the
accuracy of the vehicle speed signal by comparing
While the vehicle is operating under full load, the vehicle speed signal to the actual vehicle
the parameters should meet the following speed.
conditions:
If the vehicle speed is greater than the VSL,
• The fuel position is equal to the “Rated Fuel the Power is limited. If a problem is discovered,
Limit”. refer to Troubleshooting, “Vehicle Speed and
Speedometer Circuit - Test”.
• The fuel position is less than the “FRC Fuel
Limit”. 7. Check the “Powertrain Data Link”. Ensure that the
SAE J1939 Powertrain Data Link is not limiting
If the fuel position is equal to the “Rated Fuel the power.
Limit” and the fuel position is less than the
“FRC fuel Limit”, the electronics are operating a. Monitor the “Powertrain Data Link” status
correctly. Go to Step 6. screen while the vehicle is experiencing
problems.
5. If the fuel position is not equal to the “Rated Fuel
Limit” and/or the fuel position is not less than the If the “Powertrain Data Link” status screen
“FRC Fuel Limit”, perform the following tests in indicates that the “Powertrain Data Link” is
order: limiting the power or the rpm, verify that this
is not normal operation. If this is not normal
a. When the engine is OFF, turn the key switch operation, refer to the vehicle OEM for repairs.
to the ON position. Check the boost pressure
on Cat ET. 8. Check the fuel supply.
76 RENR2238-09
Troubleshooting Section
a. Monitor the exhaust for smoke while the engine Check the Circuit for the Warning Lamp
is being cranked.
Refer to Troubleshooting, “Warning Lamp Circuit -
If no smoke is present, there may be a problem Test”.
with the fuel quality or there may be a problem
with the fuel supply. Check the Systems on the Power Train
b. Check the fuel quality.
Data Link
A system that is connected to the power train data link
c. Check the fuel pressure.
may be illuminating the lamp. These systems include
d. Ensure that the fuel system has been primed. the brakes, the transmission, and/or the cab control.
9. Check the air intake system for restrictions or Cooling Fan Is Always ON
leakage. Check the exhaust system for restrictions
or leakage. Refer to Testing and Adjusting, “Air SMCS Code: 1350-035
Inlet and Exhaust System - Inspect”.
• Problem with the lamp circuit a. Inspect the ECM Vehicle Harness Connector
J1/P1. Check for a wire that goes into terminal
• A system on the power train data link 13 (Output 4) and/or terminal 11 (Output 5).
b. Turn the ignition key to the ON position while d. If the parameter is programmed to “Continuous”
the engine is OFF. the cooling fan will run continuously while the
engine is in PTO mode.
c. Connect the Caterpillar Electronic Technician
(ET). 3. Check the A/C High Pressure Switch circuit.
d. Access the parameter for the “Fan Control a. Connect ET to the cab data link connector.
Type”.
b. Access the status screen for the “A/C Fan
Ensure that the parameter for the “Fan Control Input”.
Type” is programmed to On/Off control for
an On/Off fan or ensure that the parameter If the status screen for the “A/C Fan Input”
for the “Fan Control Type” is programmed to indicates that the “A/C Fan Input” is Disabled,
Three-Speed Fan control for a three-speed fan. the ECM is not programmed to use the signal
input for the A/C High Pressure Switch. The
If the fan is an On/Off fan, proceed to Step 1.e. ECM will not turn the fan ON because of a
high A/C Pressure. The problem is in the OEM
If the fan is a three-speed fan, proceed to Step Vehicle system.
1.h.
If the status screen for the “A/C Fan Input”
e. Access the “On/Off Cooling Fan” test. indicates that the “A/C Fan Input” is OFF, ON or
COUNTING, the ECM is programmed to turn
f. Ensure that any fan override switches on the the fan ON because the A/C High Pressure
dash are in the OFF position. Switch circuit is open. If the status screen
for the “A/C Fan Input” indicates OFF, ON or
g. Listen for the solenoid and/or the relay to click COUNTING, proceed to Step 3.c.
as the test is activated and deactivated.
c. Start the engine. Allow the engine to idle. Watch
If the solenoid and/or the relay is clicking, the the Electronic Service Tool Status screen that
ECM and the circuit to the solenoid and/or the indicates the status of the “A/C Fan Input”.
relay are operating correctly.
If the status screen indicates OFF at any time
If the solenoid and/or the relay are not clicking, and the fan is still ON, the A/C High Pressure
refer to Troubleshooting, “Cooling Fan Circuit Switch circuit is operating correctly. The
and A/C High Pressure Switch Circuit - Test”. problem is in the OEM Vehicle system.
h. Access the “Three-Speed Fan Slip Output” test. If the status screen indicates ON and/or
COUNTING, the ECM is turning the fan ON
i. Listen for the Slip Solenoid to click as the test because the A/C High Pressure Switch circuit
is activated and deactivated. is open. Refer to Troubleshooting, “Cooling
Fan Circuit and A/C High Pressure Switch
If the Slip Solenoid is clicking, the ECM and Circuit - Test”.
the circuit to the Slip Solenoid are operating
correctly. 4. Check the Manual Fan Override Switch.
If the Slip Solenoid is not clicking, refer to a. Connect ET to the cab data link connector.
Troubleshooting, “Cooling Fan Circuit and A/C
High Pressure Switch Circuit - Test”. b. Access the parameter for the “Fan Override
Switch”.
2. Check the “PTO Activates Cooling Fan” parameter.
c. Check the parameter for the “Fan Override
Note: If the problem occurs in PTO mode, continue Switch”. Ensure that the Fan Override Switch
with this step. If the problem does not occur in PTO is programmed to one of the options for Input
mode, skip this step. Selections.
a. Connect ET to the cab data link connector. If the parameter is programmed to one of the
four available outputs, check the input for
b. Access the configuration parameters on ET. the Fan Override Switch. The four available
options for Input Selections are the following
c. Check the “PTO Activates Cooling Fan” connections:
parameter.
• J1/P1:6
78 RENR2238-09
Troubleshooting Section
Probable Causes If the cruise control pause switch was the cause
of the last kickout, the cruise control pause switch
The probable root causes are listed below: may be preventing normal operation of the cruise
control.
• Customer specified parameters (normal operation) a. Check the position of the cruise control pause
switch. If the switch is in the ON position, the
• Cruise control pause switch switch will prevent normal operation of the
cruise control. Change the switch to the OFF
• On/Off switch for cruise control and idle control position. Verify that the repair eliminates the
problem.
• PTO on/off switch
b. If the cruise control pause switch is in the OFF
• Set/resume switch position and the switch is still causing the
cruise kickout, the switch is bad or the wiring
• Circuit for service brake switch is shorted.
• Transmission neutral switch circuit c. Check the switch for proper operation. If the
switch is bad, replace the switch. If the switch
• Clutch switch circuit is working, the wiring is probably shorted. Refer
to Troubleshooting, “Electrical Connectors -
• Vehicle speed circuit Inspect”.
• Adaptive cruise control 3. When the PTO is set with a dedicated PTO On/Off
switch, use Cat ET to check the Configuration.
Recommended Actions Check the following parameters:
4. Connect Cat ET to the data link connector. Check f. Check the vehicle speed while the vehicle is
the status screen for the following controls: being driven in order to determine that the
vehicle speed that is indicated by Cat ET
• On/Off switch for cruise control and idle control does not vary significantly from the vehicle
speed that is indicated by the speedometer.
• PTO on/off switch Possible root causes for problems with the
vehicle speed circuit could be an incorrect
• Set/Resume switch Vehicle Speed Calibration or an intermittent
speed signal. If the problem is not apparent,
• Circuit for service brake switch refer to Troubleshooting, “Vehicle Speed and
Speedometer Circuit - Test”.
• Transmission neutral switch
5. Check the adaptive cruise control for proper
• Clutch switch operation.
i02127473
Driver Questionnaire
SMCS Code: 0336
Table 139
Ask the driver to answer the following questions before attempting to repair an intermittent problem, or a problem with
symptoms but no diagnostic codes. Use this and the response guideline to these questions on the next page.
Questions Yes Comments
1. Ask the driver if the check engine lamp turned on during the problem or
if the check engine lamp turned on after the problem.
The check engine lamp stays on for the following time period:
2. Ask the driver for the number of occurrences for this problem.
Ask the driver to duplicate the problem if the problem can be duplicated in
less than one hour.
3. Ask the driver if other shops have worked on the same problem.
If the answer is yes, ask the names of the shops. Also ask for the time
period for the work that was performed.
4. Ask the driver if the engine completely shut down. Ask the driver if the
restart required the use of the key switch.
Ask the driver for the waiting period before the driver could restart the
engine after the shutdown.
5. Ask the driver if the engine had a hesitation, a speed burp or a misfire
without a complete shutdown.
6. Ask the driver if the radio, dash gauges or lights momentarily turn off
during an occurrence of the problem.
Ask the driver if there are any other observations about the truck’s
components.
7. Ask the driver if the problem occurs only at specific engine loads.
Ask the driver for additional details.
8. Ask the driver if the problem occurs at a specific engine operating
temperature.
If the problem occurs at a specific engine operating temperature, record
the engine temperature.
9. Ask the driver if the problem occurs only at specific outside
temperatures or temperature ranges.
If the problem occurs only at specific outside temperatures or temperature
ranges, record the outside temperature or temperature range.
10. Ask the driver if the problem occurs during any other specific
conditions.
11. Ask the driver if the problem occurs at a specific vehicle speed.
If the problem occurs at a specific vehicle speed, record the vehicle
speed.
12. Ask the driver if the vehicle kicked out of cruise control mode, idle
mode or PTO mode.
13. Ask the driver if the problem occurs during the use of the accelerator.
During this time, the engine is not in cruise control mode or PTO mode.
14. Ask the driver if the problem occurs at a specific engine rpm.
If the problem occurs at a specific engine rpm record the engine rpm.
RENR2238-09 81
Troubleshooting Section
i02127475
Driver Questionnaire
Response
SMCS Code: 0336
Table 140
1. If the check engine lamp turned on there will be a logged diagnostic code. Refer to Troubleshooting, “Troubleshooting with
a Diagnostic Code” in order to determine if the driver’s indicated symptoms agree with the symptoms that are associated
with the diagnostic code. If the driver’s symptoms do not match the symptoms of the diagnostic code, troubleshooting the
diagnostic code will not correct the problem. Review the snapshots that are associated with each diagnostic code in order to
determine the operating conditions of the engine during the occurrence of the problem. Try to duplicate these conditions. If
there are not any logged diagnostic codes check the battery connections for the Engine Control Module (ECM). Refer to
Troubleshooting, “Ignition Key Switch Circuit and Battery Supply Circuit - Test”.
2. If the problem is easily repeatable, take the vehicle for a test drive while Caterpillar Electronic Technician (ET) is
connected to the data link connector. Note the conditions when the problem occurs. The operator should be prepared to
take snapshot data by using Cat ET or the cruise control set/resume switches. Ensure that you operate the vehicle after
correcting the problem. During vehicle operation, duplicate the operating conditions before releasing the vehicle in order to
verify that the problem has been corrected.
3. If the vehicle has been to other shops for the same problem, call the other shops in order to determine the type of work that
has been done. Avoid replacing the same components again, unless you are absolutely sure that the components are the
problem. If a component has recently been changed, it is unlikely that the component will fail again.
4. Troubleshoot the reason that the engine will not start. Repair the reason that the engine does not start. When you repair
the reason that the engine did not start you should repair the reason that the engine shut down. If the engine shut down
completely, check the ECM battery connections, the ground connections, the fuel system, the fuel, the primary engine
speed/timing sensor and the secondary engine speed/timing sensor. If the engine will not restart, refer to Troubleshooting,
“Engine Cranks but Will Not Start”.
5. If the problem is easily repeatable, refer to Troubleshooting, “Engine Misfires, Runs Rough or Is Unstable”.
If the problem is not easily repeatable, refer to Troubleshooting, “Intermittent Low Power or Power Cutout”.
6. If other devices on the vehicle are affected, something is wrong with the vehicle wiring. Refer to Troubleshooting, “Ignition
Key Switch Circuit and Battery Supply Circuit Test” for information on inspecting the ECM battery connections.
7. Operate the engine under similar load conditions. Check the low pressure fuel lines for restrictions. Also check the
fuel/water separator and the fuel tanks for foreign objects that are blocking the fuel supply.
8. Operate the engine at this temperature. Attempt to duplicate the problem.
9. When possible, troubleshoot the problem in this temperature range.
10. If the problem seems to occur during the rain or a washing, thoroughly inspect the connectors for moisture. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
11. If the problem occurs at a specific vehicle speed, check the parameters that affect vehicle speed in order to verify that the
parameters are programmed close to the vehicle speed of the occurrence of the problem. Check the following parameters:
“Vehicle Speed Limit”
“VSL Protection”
“Low Cruise Control Speed Set Limit”
“High Cruise Control Speed Set Limit”
“Idle Vehicle Speed Limit”
“PTO Vehicle Speed Limit”
“Engine/Gear Speed Limit”
Set each parameter to the maximum value one at a time and verify that the problem is corrected.
12. If the vehicle kicks out of cruise control mode, idle mode or PTO mode and it can be duplicated, check the status screen
on the electronic service tool. Check the status of the “Cruise Kickout”, the “Idle Kickout” or the *PTO Kickout*. If the problem
can not be duplicated, inspect the vehicle speed circuit, the service brake circuit and the clutch switch circuit and switch
adjustment, the circuit for the neutral switch and the circuits for the cruise/idle/pto switches, as required.
13. Check for logged diagnostic codes that are associated with the accelerator pedal position sensor. Refer to
Troubleshooting, “Accelerator Pedal (Throttle) Position Sensor Circuit - Test”.
14. If the problem occurs at a specific engine rpm, check the “VSL Protection”, the “Idle rpm Limit”, the “Top Engine Limit”, the
“PTO Top Engine Limit” and the Progressive Shift Parameters. These parameters are programmable. Set each parameter
to the maximum value one at a time and verify that the problem is corrected.
82 RENR2238-09
Troubleshooting Section
i02319575 i02319609
• Wires and terminals are properly installed into the 3. Turn the key switch ON.
connector.
4. Connect Cat ET.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for additional information. This may solve the communication problem.
Electrical Power Supply to the Service Engine Cranks but Will Not
Tool Connector
Start
Verify that battery voltage is present between
terminals A and B of the service tool connector. If the SMCS Code: 1000-035
communication adapter is not receiving power, the
communication adapter’s display will be blank. Probable Causes
Cat ET and Related Hardware • Key switch
In order to eliminate Cat ET and the related hardware • Communications between the Electronic Control
as the problem, connect Cat ET to a different engine. Module (ECM) and the Caterpillar Electronic
If the same problem occurs on a different engine, Technician (ET)
check Cat ET and the related hardware in order to
determine the cause of the problem. • Aftermarket engine protection devices
If the ECM is not receiving battery voltage, the ECM • Unit injectors
will not communicate. Check the electrical power to
the ECM. Refer to Troubleshooting, “Ignition Key • ECM
Switch Circuit and Battery Supply Circuit - Test”.
• Engine speed/timing signal
Override Switches • Theft deterrent
Verify that there are no aftermarket devices that are • Fuel supply
preventing battery voltage from reaching the ECM.
• Combustion problem
Some type of override switch is interrupting the power
to the ECM if the following conditions are true:
Check the Key Switch Ensure that the J300/P300 connector is fully
connected and ensure that the J300/P300 connector
Connect Cat ET to the data link connector. Access is free of corrosion. Check for logged diagnostic
the status for “Ignition Key Switch”. Slowly cycle codes that are related to the injectors. Refer to
the key switch ON and OFF while the status for Troubleshooting, “Injector Solenoid Circuit - Test”.
“Ignition Key Switch” is being monitored. The status
should indicate the state of the switch. If the ECM Perform the “Injector Solenoid Test” on Cat ET in
will not communicate and the key switch is in the order to determine if all of the injector solenoids
ON position, refer to “Check Aftermarket Engine are being energized by the ECM. Refer to
Protection Devices”. Troubleshooting, “Injector Solenoids” for additional
information.
Note: If the Engine Shutdown Output feature is used,
the status for “Ignition Key Switch” may indicate that Check the Engine Software
the switch is ON even though the key switch is turned
to the OFF position. 1. Verify that Cat ET is connected to the service
tool. For instructions on programming the
Check the Communications Between the latest flash file, refer to Troubleshooting, “Flash
Programming”.
ECM and Cat ET
2. Ensure that 252-11 Incorrect Engine Software is
1. Verify that Cat ET is connected to the data link not active. If the diagnostic code is present, refer
connector. to Troubleshooting, “ECM Memory - Test”.
2. If Cat ET indicates that the ECM will not
communicate, refer to Troubleshooting, Check the ECM
“Electronic Service Tool Will Not Communicate
with ECM” and to “Check Aftermarket Engine If the ECM is still suspected of being the problem,
Protection Devices”. temporarily connect a test ECM. This will help
determine whether the original ECM is the problem.
3. If the ECM communicates go to “Check the ECM”.
Check the Engine Speed/Timing Signal
Note: A new ECM does not have a flash file.
The engine will not start and the engine will not 1. Observe the engine rpm on Cat ET while the
communicate with Cat ET until the correct flash file engine is being cranked.
has been installed. Refer to Troubleshooting, “Flash
Programming”. Note: This may require Cat ET to be powered directly
by the vehicle batteries or by a separate power
Check Aftermarket Engine Protection source. If this is necessary, use the 167-9225
Harness (Service Tool Adapter). Connect the
Devices harnesses 70–pin connector to the ECM J1
connector. Connect the harnesses 9–pin connector
These devices usually interrupt power to the ECM to the adapter for the Cat ET service tool . Connect
and the ECM will not communicate with Cat ET. the red cable clamp to the +Battery terminal. Connect
Check for the correct installation of the aftermarket the clamp for the black cable to the −Battery terminal.
engine protection device. Verify that the ECM is
receiving battery voltage. 2. If Cat ET displays 0 rpm and the engine is
cranking, there is a problem in the circuit for
Check the Electrical Power Supply to the the engine speed/timing sensors. Refer to
ECM Troubleshooting, “Engine Speed/Timing Circuit
- Test”.
Verify that the ECM is receiving battery voltage
when the key switch is turned ON. Refer to 3. If an engine rpm is present, check the sensor
Troubleshooting, “Ignition Key Switch Circuit and installation. If the sensor is not properly installed,
Battery Supply Circuit - Test”. the sensor may read RPM but the sensor may not
be able to sense the tooth pattern. The ability to
sense the tooth pattern is necessary to determine
the crankshaft position. Engine rpm is present
when the engine rpm is 50 rpm or more.
RENR2238-09 85
Troubleshooting Section
SMCS Code: 1000-035 b. Check the fuel quality. Refer to Testing and
Adjusting, “Fuel Quality - Test”. Also refer to the
Probable Causes Truck Performance and Driveability Diagnostic
Guide, LEBT3477.
The probable root causes are listed in order below:
c. Check the fuel pressure. Refer to Testing and
Adjusting, “Fuel System Pressure - Test”.
Note: If the problem is intermittent and the problem
can not be duplicated, refer to Troubleshooting,
“Intermittent Low Power or Power Cutout”.
86 RENR2238-09
Troubleshooting Section
d. Ensure that the fuel system has been primed. If the signal from the primary engine speed/timing
Refer to Testing and Adjusting, “Fuel System sensor is lost intermittently, the engine may
- Prime”. misfire. The misfiring may occur when the
signal source becomes the secondary engine
e. Check for fuel supply lines that are restricted. speed/timing sensor. Ensure that the primary
engine speed/timing sensor is properly installed.
f. Check the fuel filters. Also, ensure that the wiring is not damaged or
pulled too tightly. This may cause an intermittent
g. If the temperature is below 0 °C (32 °F), check connection. Also, ensure that the crankshaft gear
for solidified fuel (wax). and the timing plate are not damaged. Refer to
the following publication for additional information:
h. Check for air in the fuel system. Refer to Troubleshooting, “Engine Speed/Timing Sensor
Testing and Adjusting, “Air in Fuel - Test”. Circuit - Test”
3. If the problem does not occur during cruise control, 6. Check the secondary engine speed/timing sensor.
check the accelerator pedal position sensor.
If the signal for the secondary engine speed/timing
a. Use the Cruise/Idle On/Off Switch to put the sensor is lost during engine start-up, additional
engine in idle mode. time may be required to start the engine. The
engine may also misfire during this time until the
b. Vary the engine rpm with the Set/Resume ECM determines the proper firing order. Refer to
switches. Troubleshooting, “Engine Speed/Timing Circuit
- Test”.
If both of the following conditions are met,
connect Cat ET and monitor the status of the
i02376490
accelerator pedal position sensor.
Engine Retarder (Compression
• The engine is stable by using idle mode to
control the engine rpm. Brake) Will Not Turn ON
• The engine is unstable by using the SMCS Code: 1129-035
accelerator pedal position sensor.
Probable Causes
If the status of the accelerator pedal position
sensor is unstable, refer to Troubleshooting,
“Accelerator Pedal (Throttle) Position Sensor
• Programmable parameters
Circuit - Test”.
• Engine retarder switches
4. Check the “Power train Data Link”. Ensure that
the SAE J1922 or the SAE J1939 Power train
• Accelerator pedal position sensor
Data Link is not limiting the power.
• Clutch switch
a. Connect Cat ET to the data link connector.
• PTO on/off switch
b. Monitor the “Power train Data Link” status
screen while the vehicle is experiencing Recommended Actions
problems.
Check the Programmable Parameters
If the “Power train Data Link” status screen
indicates that the “Power train Data Link” is Use the Caterpillar Electronic Technician (ET) to
limiting the power or the rpm, verify that this check the following parameters while the engine is
is not normal operation. If this is not normal not running:
operation, refer to the vehicle OEM for repairs.
Engine Retarder Mode – If the engine retarder
5. Check the primary engine speed/timing sensor. mode is programmed to “Latch” or to “Coast”, the
engine retarder will not activate unless the service
brake pedal is depressed. If the engine retarder
mode is programmed to “Manual”, service brakes are
not required to activate the engine retarder.
RENR2238-09 87
Troubleshooting Section
“Engine Retarder Minimum Vehicle Speed” – The Check the Clutch Switch
engine retarder will not turn on below the value that
is programmed for this parameter. Use Cat ET to monitor the status of the clutch switch.
“Engine Retarder Minimum Vehicle Speed Monitor the status of the clutch switch while you
Type” – When vehicle speed drops below the operate the clutch pedal. Depress the pedal and
“Engine Retarder Minimum Vehicle Speed” and this release the pedal several times.
parameter is programmed to “Hard Limit” the engine
retarder turns off. When vehicle speed drops below The status of the clutch switch should indicate that
the “Engine Retarder Minimum Vehicle Speed” and the clutch pedal is being depressed and released.
this parameter is programmed to “Soft Limit” the When the clutch pedal is depressed the status should
engine retarder remains on. indicate ON. When the clutch pedal is released the
status should indicate OFF. If the status of the clutch
“Engine Retarder Delay” – This parameter switch does not correspond to the position of the
provides a programmable delay after the conditions clutch pedal, refer to Troubleshooting, “Clutch Pedal
that turn on the engine retarder are met. Position Switch Circuit - Test”.
• Loose fasteners, damaged fasteners, and missing • Components in the starting circuit
fasteners
• Flywheel ring gear
• Loose mounts or broken mounts
• Transmission
• Loose brackets or broken brackets
• PTO
Start the engine. Run the engine through the entire
idle speed range. Inspect the components again. • Engine accessory
Repair any faulty components. Replace parts, if
necessary. • Hydraulic cylinder lock
Verify that all of the crankshaft pulley bolts are Recommended Actions
installed.
Check the Batteries
Check the Clutch Disc
Check the charge on the vehicle’s batteries.
Run the engine through the entire idle speed range Charge the batteries, if necessary. Refer to Special
while the clutch is disengaged. Instruction, SEHS7633, “Battery Test Procedure”.
If the vibrations are reduced, there is a balance Load test the batteries. Refer to Special Instruction,
problem with the clutch disc or the clutch disc is out SEHS9249, “Use of 4C-4911 Battery Load Tester for
of alignment. Repair the clutch disc or replace the 6, 8 and 12 Volt Lead Acid Batteries”.
clutch disc.
Check the Starting Circuit
Check the Air Compressor
1. Check the wiring to the starting motor solenoid.
Remove the air compressor. Refer to the engine’s Refer to the vehicle’s electrical schematic.
Disassembly and Assembly manual for the correct
procedure. 2. Check the engine start switch and the engine start
relay for electrical power.
Run the engine through the entire idle speed
range. If the vibration is eliminated, replace the air 3. Check the starting motor cables. If the starting
compressor. motor cables are corroded, remove the starting
motor cables and clean the starting motor cables.
Use a Vibration Meter to Isolate the
Cause of the Vibration 4. Test the operation of the starting motor.
Further analysis requires the use of a vibration Check the Flywheel Ring Gear
meter. Any meter that can accurately measure the
displacement of the vibration and the frequency of Inspect the flywheel ring gear for damage.
the vibration is sufficient. Refer to Special Instruction,
SEHS7914, “Troubleshooting Vibration In Vehicular Check the Transmission
Equipment” for additional information. This Special
Instruction describes the internal engine components Verify that the driveline moves freely.
and components of the drive train that can cause
excessive vibration.
Check the PTO
Recommended Actions • The Fuel Position is less than the FRC Fuel
Limit.
Perform the following diagnostic procedures in order:
If the Fuel Position is equal to the Rated Fuel
1. Check the Air Inlet System for restrictions Limit and the Fuel Position is less than the
or leakage. Check the Exhaust System for FRC Fuel Limit, the Electronics are operating
restrictions or leakage. Refer to Testing and correctly. Go to Step 7.
Adjusting, “Air Inlet and Exhaust System -
Inspect”.
90 RENR2238-09
Troubleshooting Section
6. If the Fuel Position is not equal to the Rated Fuel 8. Check the “Power train Data Link”. Ensure that
Limit and/or the Fuel Position is not less than the SAE J1922 or the SAE J1939 Power train
the FRC Fuel Limit, perform the following tests Data Link is not limiting the power.
in order:
a. Connect an Electronic Service Tool.
a. Connect an Electronic Service Tool.
b. Monitor the “Power train Data Link” Status
b. When the engine is OFF, turn the Ignition Key screen while the vehicle is experiencing
Switch to the ON position. Check the boost problems.
pressure on an Electronic Service Tool Status
Screen. If the “Power train Data Link” Status screen
indicates that the “Power train Data Link” is
When the engine is OFF, the boost pressure limiting the power or the rpm, verify that this
should be 0 kPa (0 psi). is not normal operation. If this is not normal
operation, refer to the vehicle OEM for repairs.
c. Monitor the status of the Accelerator Pedal
Position Sensor. Operate the engine at high 9. Check the ECM or the Personality Module.
idle with the vehicle in Neutral.
a. Connect an Electronic Service Tool.
If the engine can not reach the programmed
“Top Engine Limit”, check the Accelerator Pedal b. Verify that the correct Personality Module has
Position Duty Cycle in order to ensure that the been installed.
Accelerator Pedal Position Duty Cycle is within
calibration (75 to 90 Percent at high idle). Refer to Troubleshooting, “ECM Memory -
Test”.
If the accelerator pedal position is unstable,
check the Accelerator Pedal Position Duty
i02310928
Cycle. Check the Accelerator Pedal Position
Duty Cycle by slowly operating the accelerator
pedal in order to verify that the Accelerator
Excessive Fuel Consumption
Pedal Position Sensor is within calibration. SMCS Code: 1250-035
The Accelerator Pedal Position Sensor is
within calibration when both of the following
conditions are met: Probable Causes
• 10 to 22 percent at low idle • Vehicle operation
7. Monitor the vehicle speed signal. Ensure the Use the Caterpillar Electronic Technician to check the
histograms. Look for high values for these items:
accuracy of the vehicle speed signal by comparing
the vehicle speed signal to the actual vehicle
speed. • Engine speed
If the vehicle speed is greater than the VSL, the • Vehicle speed
Power is limited. If a problem is discovered, refer
High engine speeds and high vehicle speeds can
to Troubleshooting, “Vehicle Speed Circuit - Test”.
cause excessive fuel consumption.
RENR2238-09 91
Troubleshooting Section
Check the air inlet system for restrictions and for g. If the temperature is below 0 °C (32 °F), check
leakage. Check the exhaust system for restrictions for solidified fuel (wax).
and for leakage. Refer to Systems Operation/Testing
and Adjusting, “Air Inlet and Exhaust System”. h. Check for air in the fuel system. Refer to
Testing and Adjusting, “Air in Fuel - Test”.
i01191384 3. Check the Atmospheric Pressure circuit.
Excessive White Smoke a. Connect an Electronic Service Tool.
SMCS Code: 1088-035
b. Check for Diagnostic Codes that are related to
the Atmospheric Pressure circuit.
Probable Causes
c. Monitor the status of the Atmospheric Pressure
The probable root causes are listed in order below: Sensor on the Electronic Service Tool status
screen. Compare the value for the atmospheric
• Normal Operation pressure on the status screen to the actual
atmospheric pressure.
• Fuel Supply
d. If the atmospheric pressure on the status
• Atmospheric Pressure circuit screen is at least 7 kPa (1 psi) greater than
the actual atmospheric pressure, inspect the
• Coolant Temperature circuit crankcase breather for restrictions.
c. Monitor the status of the Coolant Temperature • Malfunctioning transmission neutral switch
Sensor on the Electronic Service Tool
status screen. If an Active Open or Short • Vehicle speed circuit problem
Circuit Diagnostic Code is detected, refer to
Troubleshooting, “Engine Temperature Sensor • Battery power or ground to the ECM
Open or Short Circuit - Test”.
• Adaptive cruise control
5. Check the Electronic Unit Injector.
3. If Cat ET indicates “Brake”, “Clutch” or “Neutral”, c. Inspect both ECM connectors for moisture.
the ECM has detected an open circuit in the switch Refer to Troubleshooting, “Inspecting Electrical
circuit for the service brake, the switch circuit Connectors”.
for the clutch or the transmission neutral switch
circuit. Perform the following tests in order: 5. A problem with the battery power, the ground to
the ECM or the vehicle wiring can cause erratic
a. Ensure that the operator has not actually engine rpm or other more severe problems. If this
depressed the service brake pedal or the clutch is a suspected cause, refer to Troubleshooting,
pedal. Also ensure that the operator has not “Ignition Key Switch Circuit and Battery Supply
actually shifted the transmission to neutral. Circuit Test”.
b. Check the status screen on Cat ET while the 6. Check for proper operation of the adaptive cruise
service brake or the clutch is being used. control.
If the problem is not apparent check the
switches. Check the service brake switch for a. Toggle the cruise control switch to the OFF
the air system. Ensure that the treadle valve position and to the ON position twice within 10
is operating freely. A treadle valve that is not seconds. This will disable the adaptive cruise
operating freely can cause pressure spikes. control.
Check the clutch switch adjustment and the
return spring. b. Attempt to set the cruise control. Operate the
vehicle under the same conditions that caused
c. If the problem is related to the Cruise Control the problem.
or Idle Control refer to Troubleshooting, “Cruise
Control Switch Circuit - Test, Service Brake c. If the problem still exists, then the problem is
Pedal Position (Switch 1) Circuit - Test, and not the adaptive cruise control.
Clutch Pedal Position Switch Circuit - Test”.
d. If the problem is fixed, refer to Eaton for the
d. If the problem is related to the PTO refer to proper troubleshooting procedure.
Troubleshooting, “PTO Switch Circuit - Test”.
i01908313
4. If Cat ET indicates “Bad Vehicle Speed”, the
vehicle speed signal is erratic or intermittent. This
relates to cruise control only.
Intermittent Engine Shutdown
SMCS Code: 1000-035
If Cat ET indicates “Vehicle Speed < Limit”, the
vehicle speed signal was lost at least briefly. This
pertains to cruise control only. Probable Causes
If Cat ET indicates “Vehicle Speed >= Limit”, the The probable root causes are listed in order below:
vehicle speed signal exceeded the programmed
“Idle/PTO Vehicle Speed Limit” or the vehicle • Diagnostic codes
speed limit is erratic or intermittent. This pertains
to idle control and PTO control only. • Battery power or ground to the ECM
Perform the following diagnostic procedure in • Aftermarket engine protection devices
order:
• Fuel supply
a. Inspect the vehicle speed sensor for debris on
the sensor. Inspect the vehicle speed circuit. • Engine speed/timing sensors
b. Check the vehicle speed that is displayed • ECM or personality module
on the status screen on Cat ET while the
vehicle is parked. Adjust the engine rpm up Note: Induce the engine to shut down before
and down. Also check the vehicle speed attempting to troubleshoot the problem.
while the vehicle is being driven in order
to determine that the vehicle speed that is Recommended Actions
indicated by Cat ET does not vary significantly
from the vehicle speed that is indicated by the Perform the following diagnostic procedures in order:
speedometer. If the problem is not apparent,
refer to Troubleshooting, “Vehicle Speed and 1. Check for diagnostic codes.
Speedometer Circuit - Test”.
a. Connect the Caterpillar Electronic Technician
(Cat ET).
94 RENR2238-09
Troubleshooting Section
b. Check for active diagnostic codes on Cat ET. e. Check for fuel supply lines that are restricted.
Note: Certain diagnostic codes will cause the engine f. Check the fuel filters.
to shutdown. Troubleshoot all diagnostic codes
before continuing with this procedure. g. If the temperature is below 0 °C (32 °F), check
for solidified fuel (wax).
2. Check the Battery power or ground to the ECM.
5. Check the Engine Speed/Timing Sensors.
a. Ensure that the following connectors have
been installed correctly: Refer to Troubleshooting, “Engine Speed/Timing
Sensor Circuit - Test”.
• J1/P1 and J2/P2 ECM connectors
6. Check the ECM or the personality module.
• J300/P300 Injector connector
Refer to Troubleshooting, “ECM Memory - Test”.
• J401/P401 Primary engine speed/timing
sensor connector
i01190888
d. Ensure that the fuel system has been primed. a. Connect an Electronic Service Tool.
Refer to Testing and Adjusting, “Fuel System
- Prime”.
RENR2238-09 95
Troubleshooting Section
b. Check for Diagnostic Codes that are capable of a. Connect an Electronic Service Tool.
Derating the engine when “Engine Monitoring”
is programmed to “Derate” or “Shutdown”. b. When the engine is OFF, turn the Ignition Key
Switch to the ON position. Check the boost
• 110-00 High Coolant Temperature Warning pressure on an Electronic Service Tool Status
(61) Screen.
• 110-11 Very High Coolant Temperature (61) When the engine is OFF, the boost pressure
should be 0 kPa (0 psi).
• 111-11 Very Low Coolant Level (62)
c. Monitor the status of the Accelerator Pedal
• 100-11 Very Low Oil Pressure (46) Position Sensor. Operate the engine at high
idle with the vehicle in Neutral.
3. Check the Battery power or ground to the ECM.
If the engine can not reach the programmed
a. Ensure that the following connectors have “Top Engine Limit”, check the Accelerator Pedal
been installed correctly: Position Duty Cycle in order to ensure that the
Accelerator Pedal Position Duty Cycle is within
• ECM connectors (J1/P1 and J2/P2) with calibration (75 to 90 Percent at high idle).
seventy pins
If the accelerator pedal position is unstable,
• Injector connector (J300/P300) check the Accelerator Pedal Position Duty
Cycle. Check the Accelerator Pedal Position
• Crankshaft Position Sensor connector Duty Cycle by slowly operating the accelerator
(J401/P401) pedal in order to verify that the Accelerator
Pedal Position Sensor is within calibration.
• Camshaft Position Sensor connector The Accelerator Pedal Position Sensor is
(J402/P402) within calibration when both of the following
conditions are met:
b. Use an Electronic Service Tool to check for
a 168-02 Intermittent Battery (51) Diagnostic • 10 to 22 percent at low idle
Code. Check the power connections for the
ECM and the ground connections for the ECM. • 75 to 90 percent at high idle
If a problem is suspected, wire a bypass. Refer
to Troubleshooting, “Ignition Key Switch Circuit Also, ensure that the duty cycle changes as the
and Battery Supply Circuit - Test”. pedal position changes.
4. Check for an Electronic System problem. If a problem with the Accelerator Pedal Position
Sensor is suspected, refer to Troubleshooting,
a. Connect an Electronic Service Tool. “Accelerator Pedal (Throttle) Position Sensor
Circuit - Test”.
b. Monitor the Fuel Position, the Rated Fuel Limit
and the FRC Fuel Limit. Note: If the engine exceeds the Top Engine Limit, the
“Top Engine Limit with Droop” is programmed to YES.
While the vehicle is operating under full load,
the parameters should meet the following 6. Monitor the vehicle speed signal. Ensure the
conditions: accuracy of the vehicle speed signal by comparing
the vehicle speed signal to the actual vehicle
• The Fuel Position is equal to the Rated Fuel speed.
Limit.
If the vehicle speed is greater than the “VSL”, the
• The Fuel Position is less than the FRC Fuel Power is limited. If a problem is discovered, refer
Limit. to Troubleshooting, “Vehicle Speed Circuit - Test”.
If the Fuel Position is equal to the Rated Fuel 7. Check the “Power train Data Link”. Ensure that
Limit and the Fuel Position is less than the the SAE J1922 or the SAE J1939 Power train
FRC Fuel Limit, the Electronics are operating Data Link is not limiting the power.
correctly. Go to Step 6.
a. Connect an Electronic Service Tool.
5. If the Fuel Position is not equal to the Rated Fuel
Limit and/or the Fuel Position is not less than b. Monitor the “Power train Data Link” Status
the FRC Fuel Limit, perform the following tests screen while the vehicle is experiencing
in order: problems.
96 RENR2238-09
Troubleshooting Section
a. Monitor the exhaust for smoke while the engine Probable Causes
is being cranked.
The probable root causes are listed in order below:
If no smoke is present, there may be a problem
with the fuel quality or there may be a problem • Customer specified parameters (normal operation)
with the fuel supply.
• Cold mode operation
b. Check the fuel quality. Refer to Testing and
Adjusting, “Fuel Quality - Test”. Also refer to the • PTO on/off switch
Truck Performance and Driveability Diagnostic
Guide, LEBT3477. • Electronic system problem
c. Check the fuel pressure. Refer to Testing and • Fuel supply
Adjusting, “Fuel System Pressure - Test”.
• Leakage in air-to-air aftercooler core
d. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, “Fuel System • Air inlet system or exhaust system
- Prime”.
• Individual malfunctioning cylinder
e. Check for fuel supply lines that are restricted.
• Torque limit switch
f. Check the fuel filters.
Recommended Actions
g. If the temperature is below 0 °C (32 °F), check
for solidified fuel (wax). Perform the following tests in order:
h. Check for air in the fuel system. Refer to 1. Check customer specified parameters.
Testing and Adjusting, “Air in Fuel - Test”.
a. Verify that the complaint is not normal operation
9. Check the Torque Limit Switch. (programmed parameter).
2. Check cold mode operation. When the engine is OFF, the boost pressure
should be 0 kPa (0 psi).
Note: This is normal operation if the problem occurs
only after start-up in cold weather. c. Monitor the status of the accelerator pedal
position sensor. Operate the engine at high idle
a. Connect the electronic service tool. with the vehicle in Neutral.
b. Monitor the electronic service tool in order to If the engine can not reach the programmed
verify that the engine has progressed from cold “Top Engine Limit”, check the duty cycle of the
mode. accelerator pedal position in order to ensure
that the duty cycle is within calibration (75 to 90
An active cold mode is indicated in the upper Percent at high idle).
corner of any status screen.
If the accelerator pedal position is unstable,
3. Check the PTO on/off switch. check the duty cycle of the accelerator
pedal position. Check the duty cycle of the
a. Verify that the PTO on/off switch is in the OFF accelerator pedal position by slowly operating
position. the accelerator pedal in order to verify that
the accelerator pedal position sensor is within
b. Connect the electronic service tool. calibration. The accelerator pedal position
sensor is within calibration when both of the
c. Verify that the status for the “PTO On/Off following conditions are met:
Switch” on the electronic service tool
corresponds to the position of the switch. • 10 to 22 percent at low idle
d. Cycle the PTO on/off switch while you observe • 75 to 90 percent at high idle
the status screen.
Also, ensure that the duty cycle changes as the
4. Check for an electronic system problem. pedal position changes.
a. Connect the electronic service tool. If a problem with the accelerator pedal position
sensor is suspected, refer to Troubleshooting,
b. Monitor the “Fuel Position”, the “Rated Fuel “Accelerator Pedal (Throttle) Position Sensor
Limit” and the “FRC Fuel Limit” on the status Circuit - Test”.
screen.
Note: If the engine exceeds the “Top Engine Limit”,
While the vehicle is operating under full load, the “Top Engine Limit with Droop” is programmed to
the parameters should meet the following YES.
conditions:
6. Monitor the vehicle speed signal. Ensure the
• The “Fuel Position” is equal to the “Rated accuracy of the vehicle speed signal by comparing
Fuel Limit”. the vehicle speed signal to the actual vehicle
speed.
• The “Fuel Position” is less than the “FRC
Fuel Limit”. If the vehicle speed is greater than the “VSL”, the
power is limited. If a problem is discovered, refer
If the “Fuel Position” is equal to the “Rated Fuel to Troubleshooting, “Vehicle Speed Circuit - Test”.
Limit” and the “Fuel Position” is less than the
“FRC Fuel Limit”, the Electronics are operating 7. Check the “Powertrain Data Link”. Ensure that the
correctly. Go to Step 6. SAE J1922 or the SAE J1939 Powertrain Data
Link is not limiting the power.
5. If the “Fuel Position” is not equal to the “Rated
Fuel Limit” and/or the “Fuel Position” is not less a. Connect the electronic service tool.
than the “FRC Fuel Limit”, perform the following
tests in order: b. Monitor the “Powertrain Data Link” status
screen while the vehicle is experiencing
a. Connect the electronic service tool. problems.
b. When the engine is OFF, turn the ignition key If the “Powertrain Data Link” status screen
switch to the ON position. Check the status for indicates that the “Powertrain Data Link ” is
“Boost Pressure” on the electronic service tool. limiting the power or the rpm, verify that this
is not normal operation. If this is not normal
operation, refer to the vehicle OEM for repairs.
98 RENR2238-09
Troubleshooting Section
If no smoke is present, there may be a problem a. Connect the electronic service tool.
with the fuel quality or there may be a problem
with the fuel supply. b. Check the setting for the customer parameter
for the “Torque Limit”.
b. Check the fuel quality. Refer to Testing and
Adjusting, “Fuel Quality - Test”. Also refer to the If the “Torque Limit” is programmed below
Truck Performance and Driveability Diagnostic 3400 N·m (2500 lb ft), check the status screen
Guide, LEBT3477. for the torque limit switch. Ensure that the
status screen indicates that the torque limit
c. Check the fuel pressure. Refer to Testing and switch is OFF. If the status of the torque
Adjusting, “Fuel System Pressure - Test”. limit switch is ON and a “Torque Limit” is
programmed, the system is operating correctly.
d. Ensure that the fuel system has been primed. If the torque limit switch that is connected
Refer to Testing and Adjusting, “Fuel System to this signal input is not switching ON and
- Prime”. switching OFF, refer to Troubleshooting, “PTO
Switch Circuit - Test”.
e. Check for fuel supply lines that are restricted.
i01191691
f. Check the fuel filters.
• “Gear Down Protection Engine RPM Limit” b. Verify that the correct Personality Module has
been installed.
d. Set each parameter to the parameter’s
maximum value one at a time and determine Refer to Troubleshooting, “ECM Memory -
whether the problem is corrected. Test”.
Note: This is normal operation if the problem occurs a. Connect an Electronic Service Tool.
only after start-up in cold weather.
b. Check the setting for the Customer Parameter
a. Connect an Electronic Service Tool. for the “Torque Limit”.
b. Monitor the Electronic Service Tool in order If the “Torque Limit” is programmed below
to verify that the engine has progressed from 3400 N·m (2500 lb ft), check the status screen
Cold Mode. for the Torque Limit Switch. Ensure that the
status screen indicates that the Torque Limit
An Active Cold Mode is indicated in the upper Switch is OFF. If the status of the Torque
corner of any Status Screen. Limit Switch is ON and a “Torque Limit” is
programmed, the system is operating correctly.
3. Check for an individual malfunctioning cylinder. If the switch that is connected to this signal
input is not switching ON and switching OFF,
a. Ensure that the Electronic Unit Injector refer to Troubleshooting, “PTO Switch Circuit
Connector (J300/P300) is fully connected - Test”.
and ensure that the Electronic Unit Injector
Connector (J300/P300) is free of corrosion.
Flash
Code
Code Description of Code 0001-11 Cylinder #1 Injector
High Intake Manifold Air Temperature
current fault (72)
105-00
Warning
64 SMCS Code: 1290-038
Very High Intake Manifold Air
105-11
Temperature Conditions Which Generate This Code:
65 174-00 High Fuel Temperature Warning
The Engine Control Module (ECM) detects one of
54-05 Auxiliary Output #06 current low the following items after attempting to operate the
66
54-06 Auxiliary Output #06 current high injector:
AuxiliaryOutput #07 current low • A low current condition (open circuit) exists in the
55-05
67 wiring for the cylinder injector solenoid.
55-06 Auxiliary Output #07 current high
• A high current condition (short circuit) exists in the
68 191-07 Transmission Not Responding injector solenoid.
71 43-02 Key Switch Fault
System Response:
1-11 Cylinder #1 Injector current fault
72 The ECM will log the diagnostic code and the ECM
2-11 Cylinder #2 Injector current fault
will trigger a snapshot. The check engine lamp will
3-11 Cylinder #3 Injector current fault illuminate while this diagnostic code is active. The
73 automatic “Cylinder Cutout Test” will not work when
4-11 Cylinder #4 Injector current fault
there is an active diagnostic code.
5-11 Cylinder #5 Injector current fault
74 Possible Performance Effect:
6-11 Cylinder #6 Injector current fault
The injector may not operate while the diagnostic
codes are active. The following conditions may exist:
i02127620
Conditions Which Generate This Code: Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
A flash code 55 indicates that the system has not
detected any system faults since the last powerup. Results:
SMCS Code: 1290-038 The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
Conditions Which Generate This Code: illuminate while this diagnostic code is active. The
automatic “Cylinder Cutout Test” will not work when
The Engine Control Module (ECM) detects one of there is an active diagnostic code.
the following items after attempting to operate the
injector: Possible Performance Effect:
• A low current condition (open circuit) exists in the The injector may not operate while the diagnostic
wiring for the cylinder injector solenoid. codes are active. The following conditions may exist:
SMCS Code: 1290-038 The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
Conditions Which Generate This Code: illuminate while this diagnostic code is active. The
automatic “Cylinder Cutout Test” will not work when
The Engine Control Module (ECM) detects one of there is an active diagnostic code.
the following items after attempting to operate the
injector: Possible Performance Effect:
• A low current condition (open circuit) exists in the The injector may not operate while the diagnostic
wiring for the cylinder injector solenoid. codes are active. The following conditions may exist:
A. Check the ECM for indications of an engine Test Step 3. Cylinder Head
overspeed.
A. Determine whether the cylinder head was
B. If there are indications of an engine overspeed, removed.
check the cluster gear for proper alignment.
Also check the cluster gear for damage. Refer B. If the cylinder head was removed, the backlash for
to Testing and Adjusting, “Gear Group (Front) - the camshaft may be out of the specification.
Time”.
C. Check the backlash for the camshaft. Refer to
Expected Result: Testing and Adjusting, “Gear Group (Front) -
Time”.
The cluster gear is properly aligned and there is no
damage to the cluster gear. Expected Result:
• Not OK – The cluster gear is not aligned correctly • OK – Proceed to Test Step 4.
or there is damage to the cluster gear.
• Not OK – The backlash for the camshaft is not
Repair: Align the cluster gear or repair the cluster within specifications.
gear.
Repair: Adjust the backlash for the camshaft.
Run the engine until the engine reaches operating
temperature. Refer to Testing and Adjusting, “Gear Group
(Front) - Time”.
Verify that the repair eliminates the problem.
Run the engine until the engine reaches operating
STOP. temperature.
Test Step 2. Accident Verify that the repair eliminates the problem.
Run the engine until the engine reaches operating The engine speed/timing sensors are properly
temperature. installed. Also, the engine speed/timing sensors are
wired correctly.
RENR2238-09 105
Troubleshooting Section
Results: i02127764
• Not OK – There is a problem with the installation The Engine Control Module (ECM) detects the
or the wiring of the engine speed/timing sensors. following conditions:
Repair: Install the sensors properly or repair the • The “PTO Configuration” is programmed to
wiring. “Remote Throttle”.
Run the engine until the engine reaches operating • The ECM is not receiving a valid signal from the
temperature. PTO throttle.
Verify that the repair eliminates the problem. • The ECM has been powered for at least three
seconds.
STOP.
Note: If the “PTO Configuration” is programmed to
i02127666
“Remote Throttle”, the ECM must receive a proper
signal from the remote throttle at all times. The
0022-13 Engine Speed Signal remote throttle signal must be present even when the
PTO ON/OFF switch is in the OFF position.
Calibration Not Performed (42)
System Response:
SMCS Code: 1912-038
The ECM returns the engine to low idle when the
Conditions Which Generate This Code: problem is detected. “DIAG” will be displayed next
to the status for “Throttle Position” on Caterpillar
The Engine Control Module (ECM) detects the Electronic Technician (ET).
following conditions:
Possible Performance Effect:
• A timing calibration has never been performed on
a new ECM or the timing is off by more than three The engine will remain at low idle while the diagnostic
degrees. code is active.
System Response: Troubleshooting:
This code will not be logged. The check engine lamp Perform the following diagnostic procedure: “Remote
will illuminate while this diagnostic code is active. The PTO Accelerator Position Sensor Circuit - Test”
ECM uses default timing.
Results:
Possible Performance Effect:
• The duty cycle of the signal for the PTO throttle is Possible Performance Effect:
less than 5 percent or more than 95 percent for
more than two seconds. The engine may be limited to low idle.
• The PTO Configuration is programmed to “Remote Note: The 8 volt supply provides power to the
Throttle”. accelerator pedal position sensor.
Perform the following diagnostic procedure: “Remote The Engine Control Module (ECM) detects the
PTO Accelerator Position Sensor Circuit - Test” following conditions:
Results: • The 8 volt supply is less than 7.5 VDC for more
than one second.
• OK – STOP.
• The ECM has been powered for more than three
seconds.
i01942209
high (21) The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
SMCS Code: 5574-038 illuminate while this diagnostic code is active. An
active diagnostic code may not cause any noticeable
Conditions Which Generate This Code: effect on engine response unless the voltage drops
below 6.5 VDC.
The Engine Control Module (ECM) detects the
following conditions: Possible Performance Effect:
• The 8 volt supply is more than 8.5 VDC for more The engine may be limited to low idle.
than one second.
Note: The 8 volt supply provides power to the
• The ECM has been powered for more than three accelerator pedal position sensor.
seconds.
Troubleshooting:
System Response:
Perform the following diagnostic procedure:
The ECM will log the diagnostic code and the ECM “Accelerator Pedal (Throttle) Position Sensor Circuit -
will trigger a snapshot. The check engine lamp will Test”
illuminate while this diagnostic code is active. An
active diagnostic code may not cause any noticeable Results:
effect on engine response unless the voltage is
above 12 or 13 VDC. • OK – STOP.
RENR2238-09 107
Troubleshooting Section
The solenoid that is currently enabled will remain in 0055-05 Auxiliary Output #07
the ON position until neutral is detected. Then manual current low (67)
operation occurs until the system powers down.
Manual operation is defined as both solenoids OFF. SMCS Code: 1901-038
Possible Performance Effect: Conditions Which Generate This Code:
The ECM disables the Eaton Top 2 mode. The Engine Control Module (ECM) detects the
following conditions:
Troubleshooting:
• There is a low current condition (open circuit) in
Perform the following diagnostic procedure: “Eaton the circuit for the shift solenoid.
Top 2 Transmission Circuit - Test”
• The “Transmission Style” is programmed to “Eaton
Results: Top 2”.
i02184006
The solenoid that is currently enabled will remain in
the ON position until neutral is detected. Then manual
0054-06 Auxiliary Output #06 operation occurs until the system powers down.
Manual operation is defined as both solenoids OFF.
current high (66)
Possible Performance Effect:
SMCS Code: 1901-038
The ECM disables the Eaton Top 2 mode.
Conditions Which Generate This Code:
Troubleshooting:
The Engine Control Module (ECM) detects the
following conditions: Perform the following diagnostic procedure: “Eaton
Top 2 Transmission Circuit - Test”
• There is a high current condition (short circuit) in
the circuit for the lockout solenoid for more than Results:
two seconds.
• OK – STOP.
• The “Transmission Style” is programmed to “Eaton
Top 2”.
i02184022
System Response:
0055-06 Auxiliary Output #07
The solenoid that is currently enabled will remain in
the ON position until neutral is detected. Then manual
current high (67)
operation occurs until the system powers down. SMCS Code: 1901-038
Manual operation is defined as both solenoids OFF.
Conditions Which Generate This Code:
Possible Performance Effect:
The Engine Control Module (ECM) detects the
The ECM disables the Eaton Top 2 mode. following conditions:
Troubleshooting: • There is a high current condition (short circuit) in
the circuit for the shift solenoid.
Perform the following diagnostic procedure: “Eaton
Top 2 Transmission Circuit - Test” • The “Transmission Style” is programmed to “Eaton
Top 2”.
Results:
• OK – STOP.
RENR2238-09 109
Troubleshooting Section
The solenoid that is currently enabled will remain in 0071-00 Idle Shutdown
the ON position until neutral is detected. Then manual Override (01)
operation occurs until the system powers down.
Manual operation is defined as both solenoids OFF. SMCS Code: 1901-038
Possible Performance Effect: Conditions Which Generate This Code:
The ECM disables the Eaton Top 2 mode. The Engine Control Module (ECM) detects one of
the following conditions:
Troubleshooting:
• The “Allow Idle Shutdown Override” parameter is
Perform the following diagnostic procedure: “Eaton programmed to “Yes” and the status of the brake
Top 2 Transmission Circuit - Test” switch or the clutch switch changes.
Results: • The “Allow Idle Shutdown Override” parameter
is programmed to “J1587 Outside Temp Based”
• OK – STOP. or “Outside Temperature Based”. The outside
temperature is above the maximum programmed
i01905821
temperature or the outside temperature is below
the minimum programmed temperature.
0064-12 Secondary Engine
The ECM also detects the following conditions:
Speed loss of signal (34)
SMCS Code: 1912-038
• The idle shutdown timer is within the final 90
seconds.
Conditions Which Generate This Code:
• The “Idle Shutdown Time” parameter is
programmed to at least three minutes.
The ECM detects the following conditions:
System Response:
• The signal for the secondary engine speed/timing
sensor is intermittent or lost. The idle shutdown timer stops counting. “OVERRIDE”
will be displayed next to the status for “Idle Shutdown
System Response: Status” on Caterpillar Electronic Technician (ET).
The engine may misfire or the engine may run rough Note: The idle shutdown timer will not begin counting
during starting. The check engine lamp will not be again for shutdown until the vehicle is moved and the
illuminated for this code unless the code has been accelerator pedal is depressed.
active for ten hours.
Customer passwords are required to clear this
Possible Performance Effect: diagnostic code.
There should not be a noticeable change in engine Possible Performance Effect:
response unless the signal for the primary engine
speed/timing sensor is lost. The engine will shut None
down if both the signal for the primary engine
speed/timing sensor and the signal for the secondary Troubleshooting:
engine speed/timing sensor are lost.
Perform the following diagnostic procedure: “Idle
Troubleshooting: Shutdown Timer - Test”
Perform the following diagnostic procedure: “Engine Results:
Speed/Timing Sensor Circuit - Test”
Results:
• OK – STOP.
• OK – STOP.
110 RENR2238-09
Troubleshooting Section
• The “Idle Shutdown Time” parameter is Customer passwords are required to clear this
programmed to at least three minutes. diagnostic code.
• Coolant temperature is greater than 38 °C (100 °F). The engine is shut down.
System Response: Troubleshooting:
The ECM remains powered after the engine Perform the following diagnostic procedure: “PTO
shutdown. “COUNTING” will be displayed next to Shutdown Timer - Test”
the status for “Idle Shutdown Status” on Caterpillar
Electronic Technician (ET). Results:
Customer passwords are required to clear this • OK – STOP.
diagnostic code.
SMCS Code: 1901-038 The ECM will not energize the injector solenoids
while the diagnostic code is active. “Vehicle Speed
Conditions Which Generate This Code: Limit” will be displayed on the status screen.
The Engine Control Module (ECM) detects the Customer passwords are required to clear this code.
following conditions:
Possible Performance Effect:
• The timer for the PTO has expired and the engine
has shut down. Injection is disabled until the vehicle speed falls
below the programmed “Vehicle Overspeed”.
• The PTO on/off switch is in the ON position.
RENR2238-09 111
Troubleshooting Section
Results: Troubleshooting:
0084-01 Vehicle Speed loss of Perform the following diagnostic procedure: “Vehicle
Speed and Speedometer Circuit - Test”
signal (31)
Results:
SMCS Code: 7463-038
• OK – STOP.
Conditions Which Generate This Code:
following conditions:
0084-02 Vehicle Speed signal
• The vehicle speed signal indicates that the vehicle invalid (36)
speed is 0 MPH.
SMCS Code: 7463-038
• Engine speed is greater than the programmed
“VSL Protection” minus 100 RPM for at least 0.06 Conditions Which Generate This Code:
seconds.
The Engine Control Module (ECM) detects the
• Desired engine speed is greater than the following conditions:
programmed “VSL Protection”.
• The vehicle speed signal indicates a constant
• The change in engine speed is less than 133 RPM MPH.
per second for at least 0.06 seconds.
• Engine speed is greater than 950 rpm for at least
• The “VSL Protection” parameter is programmed to 0.06 seconds.
a value that is less than 2120 rpm.
• The “VSL Protection” parameter is programmed to
The following condition must also be met if the a value that is less than 2120 rpm.
“Vehicle Speed Input” is programmed to “J1939-ABS”
or “J1939-Trans”. System Response:
• The message for vehicle speed is not received “DIAG” will be displayed next to the status for “Vehicle
over the J1939 data link for more than 0.5 seconds. Speed” on the Caterpillar Electronic Technician (ET).
The ECM will limit engine rpm to the programmed Engine rpm is limited to the programmed “VSL
“VSL Protection”. If the ECM is providing the Protection” for one hour.
speedometer signal, the speedometer will show 0
rpm. “DIAG” will be displayed next to the status Troubleshooting:
for “Vehicle Speed” on the Caterpillar Electronic
Technician (ET). This code may indicate tampering with the vehicle
speed circuit.
Possible Performance Effect:
Perform the following diagnostic procedure: “Vehicle
The ECM will limit engine rpm to the programmed Speed and Speedometer Circuit - Test”
“VSL Protection”.
112 RENR2238-09
Troubleshooting Section
0084-08 Vehicle Speed signal Note: If the ABS is the source of the vehicle speed,
the ABS must not be active.
out of range (36)
System Response:
SMCS Code: 7463-038
“DIAG” will be displayed next to the status for “Vehicle
Conditions Which Generate This Code: Speed” on the electronic service tool. The check
engine lamp will illuminate.
The Engine Control Module (ECM) detects the
following conditions: Possible Performance Effect:
• The vehicle speed signal indicates that vehicle Engine rpm is limited to the programmed “VSL
speed is greater than 127.5 MPH for more than Protection” for eight seconds.
two seconds.
Troubleshooting:
• The “VSL Protection” parameter is programmed to
a value that is less than 2120 rpm. Perform the following diagnostic procedure: “Vehicle
Speed and Speedometer Circuit - Test”
System Response:
Results:
Vehicle speed is set to 0 km/h (0 mph). If the ECM is
providing the speedometer signal, the speedometer • OK – STOP.
will not display vehicle speed. “DIAG” will be
displayed next to the status for “Vehicle Speed” on
the Caterpillar Electronic Technician (ET). i02127996
Perform the following diagnostic procedure: “Vehicle The Engine Control Module (ECM) detects the
Speed and Speedometer Circuit - Test” following conditions:
Troubleshooting: Results:
Invalid (32) The ECM sets “Throttle Position” to 0%. “DIAG” will
be displayed next to the status for “Throttle Position”
SMCS Code: 1913-038 on the Caterpillar Electronic Technician (ET).
The Engine Control Module (ECM) detects the The engine will remain at low idle while the diagnostic
following conditions: code is active.
Perform the following diagnostic procedure: • The engine oil pressure is below the trip line in
“Accelerator Pedal (Throttle) Position Sensor Circuit - Illustration 30 or Illustration 31 for more than eight
Test” seconds.
114 RENR2238-09
Troubleshooting Section
Troubleshooting:
Expected Result:
Results:
Illustration 30
g00997504 STOP.
C-10 and C -12 low oil pressure
Test Step 2. Verify Proper Sensor
Installation
A. Check the installation of the engine oil pressure
sensor.
Expected Result:
Results:
g00997505
• Not OK – The sensor is not installed properly.
Illustration 31
3406E, C-15, C-16, and C-18 low oil pressure Repair: Install the engine oil pressure sensor
properly. Repair the wiring and/or the connectors
System Response: to the sensor.
The Caterpillar Electronic Technician (Cat ET) will Verify that the repair eliminates the problem.
display “LOW OIL PRESSURE” and “DIAG” next
to the status for “Engine Oil Pressure”. The check STOP.
engine lamp and the warning lamp will illuminate.
Test Step 3. Check for Active Diagnostic
Customer passwords are required to clear this Codes
diagnostic code.
A. Connect Cat ET to the data link connector.
Possible Performance Effect:
None
RENR2238-09 115
Troubleshooting Section
B. Check for active diagnostic codes that are related C. Measure the voltage between terminal A (Engine
to the barometric pressure sensor (atmospheric Pressure Sensor +5V) and terminal B (Engine
pressure) or the boost pressure sensor. Pressure Sensor Common) of each pressure
sensor connector on the engine harness.
Expected Result:
Expected Result:
There are no diagnostic codes that are related to the
barometric pressure sensor (atmospheric pressure) The voltage is 5.0 ± 0.16 VDC.
or the boost pressure sensor.
Results:
Results:
• OK – The voltage is within the range.
• OK – There are no diagnostic codes. Proceed to
Test Step 4. Repair: Reconnect the engine oil pressure sensor
and the boost pressure sensor.
• Not OK – There is a diagnostic code that is related
to the barometric pressure sensor (atmospheric Temporarily connect a new barometric pressure
pressure) and/or the boost pressure sensor. sensor (atmospheric pressure).
Repair: Troubleshoot the diagnostic code before If the new sensor fixes the problem, reconnect the
continuing with this procedure. suspect sensor.
B. Monitor the status for “Boost Pressure” and • Not OK – There is a problem with the 5 volt supply.
“Engine Oil Pressure” on Cat ET.
Repair: Check the J2/P2 ECM connector and the
Expected Result: sensor connectors for corrosion and moisture.
“Boost Pressure” and “Engine Oil Pressure” should Check the 5 volt supply wire. Verify that the wire
be less than 10 kPa (2 psi). is not cut and that the wire is completely inserted
into the connectors for the pressure sensors on
Results: the engine harness.
• OK – The boost pressure and the engine oil Verify that the repair eliminates the problem.
pressure are less than 10 kPa (2 psi). Proceed to
Test Step 6. STOP.
• Not OK - Boost Pressure – The boost pressure is Test Step 6. Install a Pressure Gauge
greater than 10 kPa (2 psi). Proceed to Test Step 8.
A. Remove the engine oil pressure sensor.
• Not OK - Engine Oil Pressure – The engine oil
pressure is greater than 10 kPa (2 psi). Proceed B. Install a 1U-5470 Engine Pressure Group into
to Test Step 9. the oil gallery with a Tee fitting in the port for the
engine oil pressure sensor.
• Not OK - Both – The boost pressure and the
engine oil pressure are greater than 10 kPa (2 psi). C. Connect the engine oil pressure sensor to the
Proceed to Test Step 5. Tee fitting.
Test Step 5. Check the Supply Voltage to D. Turn the key switch to the ON position.
the Pressure Sensors
E. Monitor the status for “Engine Oil Pressure” on
A. Disconnect the barometric pressure sensor Cat ET.
(atmospheric pressure), the boost pressure
sensor, and the engine oil pressure sensor. F. Start the engine and run the engine at low idle.
B. Turn the key switch to the ON position. G. Compare the pressure reading on the gauge to
the pressure reading on Cat ET.
116 RENR2238-09
Troubleshooting Section
H. Monitor the status screen and the gauge while C. Measure the voltage between terminal A (Engine
you increase the engine speed. Pressure Sensor +5V) and terminal B (Engine
Pressure Sensor Common) of the connector for
Expected Result: the boost pressure sensor on the engine harness.
The gauge and the status screen are within 35 kPa Expected Result:
(5.0 psi) of each other.
The voltage is 5.0 ± 0.16 VDC.
Results:
Results:
• OK – The sensor is functioning properly. Proceed
to Test Step 7. • OK – The voltage is within the range.
• Not OK – The sensor is not functioning properly. Repair: Temporarily connect a new boost pressure
sensor.
Repair: Temporarily install a new engine oil
pressure sensor. If the new sensor fixes the problem, reconnect the
suspect sensor.
If the new sensor repairs the problem, reinstall the
suspect sensor. If the problem returns, permanently replace the
sensor.
If the problem returns, replace the sensor.
Verify that the repair eliminates the problem.
Verify that the repair eliminates the problem.
STOP.
STOP.
• Not OK – There is a problem with the 5 volt supply.
Test Step 7. Compare the Readings to the
Oil Pressure Map Repair: Check the sensor connector for corrosion
and moisture.
A. Compare the readings from the pressure gauge
to the oil pressure maps in Illustration 30 or Check the 5 volt supply wire. Verify that the wire
Illustration 31. is not cut and that the wire is completely inserted
into the connector for the boost pressure sensor
Expected Result: on the engine harness.
The engine oil pressure is above the trip points in Verify that the repair eliminates the problem.
Illustration 30 or Illustration 31.
STOP.
Results:
Test Step 9. Check the Supply Voltage to
• OK – The engine oil pressure appears to be OK the Engine Oil Pressure Sensor
at this time. STOP.
A. Disconnect the engine oil pressure sensor.
• Not OK – The engine oil pressure is lower than
the trip line on the oil pressure map. There is a B. Turn the key switch to the ON position.
mechanical problem.
C. Measure the voltage between terminal A (Engine
Repair: Refer to Testing and Adjusting, “Engine Pressure Sensor +5V) and terminal B (Engine
Oil Pressure - Test”. Pressure Sensor Common) of the connector for
the engine oil pressure sensor on the engine
STOP. harness.
Repair: Temporarily connect a new engine oil Note: The engine oil pressure that is displayed on the
pressure sensor. Caterpillar Electronic Technician (ET) is the default
value for engine oil pressure.
If the new sensor fixes the problem, reconnect the
suspect sensor. Possible Performance Effect:
The Engine Control Module (ECM) detects the • The 168-01 Low ECM Battery Power is not active.
following conditions:
• The 232-03 5 Volt Supply voltage high is not active.
• The signal voltage from the engine oil pressure
sensor is greater than 4.95 VDC for more than • The 232-04 5 Volt Supply voltage low is not active.
eight seconds.
• The engine is running or atmospheric pressure is
• The ECM has been powered for at least two greater than 80 kPa (12 psi).
seconds.
Note: Atmospheric pressures below 79 kPa (12 psi)
• The 168-01 Low ECM Battery Power is not active. may cause this code to become active only when the
engine is running. This low atmospheric pressure
• The 232-03 5 Volt Supply voltage high is not active. causes the signal voltage to drop below the trip point
of 0.2 VDC in a good circuit.
• The 232-04 5 Volt Supply voltage low is not active.
Note: Elevations that are higher than 1900 m
• The engine is not running or the engine coolant (6300 ft) will have atmospheric pressures that are
temperature is greater than 38 °C (100 °F). below 79 kPa (12 psi).
The ECM will log the diagnostic code and the ECM The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active illuminate once this diagnostic code has been active
for more than ten hours. The ECM will default to for more than ten hours. The ECM will default to
600 kPa (88 psi) for engine oil pressure. 600 kPa (88 psi) for engine oil pressure.
118 RENR2238-09
Troubleshooting Section
None
Troubleshooting:
Results:
• OK – STOP.
i01907618
The ECM will use the default torque map. The engine
speed is limited to 1350 RPM and the vehicle speed
is limited to 72 km/h (45 mph).
Troubleshooting:
B. Check the wiring of the engine oil pressure sensor. “Boost Pressure” and “Engine Oil Pressure” should
Refer to the Electrical Schematic for the proper be less than 10 kPa (2 psi).
wiring. Ensure that all of the wires and connectors
are properly connected. Results:
• OK – The sensor is properly installed. Proceed • Not OK - Engine Oil Pressure – The engine oil
to Test Step 3. pressure is greater than 10 kPa (2 psi). Proceed
to Test Step 9.
• Not OK – The sensor is not installed properly.
• Not OK - Both – The boost pressure and the
Repair: Install the engine oil pressure sensor engine oil pressure are greater than 10 kPa (2 psi).
properly. Repair the wiring and/or the connectors Proceed to Test Step 5.
to the sensor.
Test Step 5. Check the Supply Voltage to
Verify that the repair eliminates the problem. the Pressure Sensors
STOP. A. Disconnect the barometric pressure sensor
(atmospheric pressure), the boost pressure
Test Step 3. Check for Active Diagnostic sensor, and the engine oil pressure sensor.
Codes
B. Turn the key switch to the ON position.
A. Connect Cat ET to the data link connector.
C. Measure the voltage between terminal A (Engine
B. Check for active diagnostic codes that are related Pressure Sensor +5V) and terminal B (Engine
to the barometric pressure sensor (atmospheric Pressure Sensor Common) of each pressure
pressure) or the boost pressure sensor. sensor connector on the engine harness.
There are no diagnostic codes that are related to the The voltage is 5.0 ± 0.16 VDC.
barometric pressure sensor (atmospheric pressure)
or the boost pressure sensor. Results:
Temporarily connect a new barometric pressure • Not OK – The sensor is not functioning properly.
sensor (atmospheric pressure).
Repair: Temporarily install a new engine oil
If the new sensor fixes the problem, reconnect the pressure sensor.
suspect sensor.
If the new sensor repairs the problem, reinstall the
If the problem returns, permanently replace the suspect sensor.
sensor.
If the problem returns, replace the sensor.
Verify that the repair eliminates the problem.
Verify that the repair eliminates the problem.
STOP.
STOP.
• Not OK – There is a problem with the 5 volt supply.
Test Step 7. Compare the Readings to the
Repair: Check the J2/P2 ECM connector and the Oil Pressure Map
sensor connectors for corrosion and moisture.
A. Compare the readings from the pressure gauge
Check the 5 volt supply wire. Verify that the wire to the oil pressure maps in Illustration 32 or
is not cut and that the wire is completely inserted Illustration 33.
into the connectors for the pressure sensors on
the engine harness. Expected Result:
Verify that the repair eliminates the problem. The engine oil pressure is above the trip points in
Illustration 32 or Illustration 33.
STOP.
Results:
Test Step 6. Install a Pressure Gauge
• OK – The engine oil pressure appears to be OK
A. Remove the engine oil pressure sensor. at this time. STOP.
B. Install a 1U-5470 Engine Pressure Group into • Not OK – The engine oil pressure is lower than
the oil gallery with a Tee fitting in the port for the the trip line on the oil pressure map. There is a
engine oil pressure sensor. mechanical problem.
C. Connect the engine oil pressure sensor to the Repair: Refer to Testing and Adjusting, “Engine
Tee fitting. Oil Pressure - Test”.
E. Monitor the status for “Engine Oil Pressure” on Test Step 8. Check the Supply Voltage to
Cat ET. the Boost Pressure Sensor
F. Start the engine and run the engine at low idle. A. Disconnect the boost pressure sensor.
G. Compare the pressure reading on the gauge to B. Turn the key switch to the ON position.
the pressure reading on Cat ET.
C. Measure the voltage between terminal A (Engine
H. Monitor the status screen and the gauge while Pressure Sensor +5V) and terminal B (Engine
you increase the engine speed. Pressure Sensor Common) of the connector for
the boost pressure sensor on the engine harness.
Expected Result:
Expected Result:
The gauge and the status screen are within 35 kPa
(5.0 psi) of each other. The voltage is 5.0 ± 0.16 VDC.
Results: Results:
• OK – The sensor is functioning properly. Proceed • OK – The voltage is within the range.
to Test Step 7.
RENR2238-09 121
Troubleshooting Section
Repair: Temporarily connect a new boost pressure Repair: Check the sensor connector for corrosion
sensor. and moisture.
If the new sensor fixes the problem, reconnect the Check the 5 volt supply wire. Verify that the wire is
suspect sensor. not cut and that the wire is completely inserted into
the connector for the engine oil pressure sensor
If the problem returns, permanently replace the on the engine harness.
sensor.
Verify that the repair eliminates the problem.
Verify that the repair eliminates the problem.
STOP.
STOP.
i01909510
• Not OK – There is a problem with the 5 volt supply.
Repair: Check the sensor connector for corrosion
0102-00 Excessive Boost
and moisture. Pressure
Check the 5 volt supply wire. Verify that the wire SMCS Code: 1917-038
is not cut and that the wire is completely inserted
into the connector for the boost pressure sensor Conditions Which Generate This Code:
on the engine harness.
The ECM detects the following conditions:
Verify that the repair eliminates the problem.
• The actual boost pressure is higher than the
STOP. desired boost pressure.
If the new sensor fixes the problem, reconnect the 0102-03 Boost Pressure
suspect sensor.
voltage high (25)
If the problem returns, permanently replace the
sensor. SMCS Code: 1917-038
Verify that the repair eliminates the problem. Conditions Which Generate This Code:
• The signal voltage from the boost pressure sensor System Response:
is greater than 4.95 VDC for more than two
seconds. The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
• The ECM has been powered for at least two illuminate while this diagnostic code is active. The
seconds. ECM will default to 100 kPa (14.5 psi) for boost
pressure.
• The engine is not running or the rack position is
less than 50 percent with the engine retarder off. Note: The boost pressure that is displayed on the
Caterpillar Electronic Technician (ET) is the default
System Response: value for boost pressure minus the atmospheric
pressure.
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will Possible Performance Effect:
illuminate while this diagnostic code is active. The
ECM will default to 100 kPa (14.5 psi) for boost The engine will experience low power when this
pressure. diagnostic code is active.
0102-04 Boost Pressure • The intake manifold air temperature is greater than
90 °C (194.0 °F) for more than four seconds.
voltage low (25)
• The engine has been running for at least 30
SMCS Code: 1917-038 seconds.
Conditions Which Generate This Code: • The engine coolant temperature is above 99 °C
(210.0 °F).
The Engine Control Module (ECM) detects the
following conditions: System Response:
• The signal voltage from the boost pressure sensor “DIAG” will be displayed next to the status for “Intake
is less than 0.2 VDC for more than one second. Manifold Air Temperature” on the electronic service
tool. The warning lamp will turn on if the “Engine
• The ECM has been powered for at least two Monitoring Lamps” parameter is programmed to
seconds. “Warning Lamp”. The check engine lamp will turn
on if the “Engine Monitoring Lamps” parameter is
programmed to “Option 1”.
Results: • OK – STOP.
• OK – There are no restrictions in the air flow. i02128473
Verify that the repair eliminates the problem. • The signal voltage from the intake manifold air
temperature sensor is less than 0.2 VDC for more
STOP. than eight seconds.
• Engine coolant temperature is above −10 °C Perform the following diagnostic procedure: “Engine
(15.0 °F). Temperature Sensor Open or Short Circuit - Test”
• The signal voltage from the atmospheric pressure Customer passwords are required to clear this
sensor is less than 0.2 VDC for more than 30 diagnostic code.
seconds.
Possible Performance Effect:
• The ECM has been powered for at least two
seconds. None
Temperature Warning (61) • The ECM has been powered for at least two
seconds.
SMCS Code: 1906-038
• The engine has been running for more than seven
Conditions Which Generate This Code: minutes.
• The engine coolant temperature is greater than The ECM will log the diagnostic code and the ECM
103 °C (217 °F) for the C-10 or C-12. will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
• The engine coolant temperature is greater than for more than ten hours. The ECM will default to
108 °C (226 °F) for the 3406E, C-15, C-16 and 90 °C (194 °F) for engine coolant temperature. The
C-18. ECM will activate the cooling fan after this code has
been active for more than eight seconds.
• The engine has been running at least 30 seconds.
Possible Performance Effect:
System Response:
None
“DIAG” will be displayed next to the status for “Engine
Coolant Temperature” on the Caterpillar Electronic Troubleshooting:
Technician (Cat ET). The check engine lamp and the
warning lamp will illuminate. Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test”
Note: If a high coolant temperature lamp is installed,
the high coolant temperature lamp will turn on instead Results:
of the warning lamp.
• OK – STOP.
126 RENR2238-09
Troubleshooting Section
Conditions Which Generate This Code: If a high coolant temperature lamp is installed, the
high coolant temperature lamp will turn on instead
The Engine Control Module (ECM) detects the of the warning lamp.
following conditions:
Customer passwords are required to clear this
• The signal voltage from the engine coolant diagnostic code.
temperature sensor is less than 0.2 VDC for more
than eight seconds. Possible Performance Effect:
• The ECM has been powered for at least two The engine will be derated to the default torque map
seconds. and vehicle speed will be limited to 72 km/h (45 mph).
i01907623
0111-01 Low Coolant Level
0110-11 Very High Coolant Warning (62)
Temperature (61)
SMCS Code: 5574-038-CLT
SMCS Code: 1906-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
The ECM detects the following conditions: following conditions:
• The engine coolant temperature is greater than • The coolant level is low for more than ten seconds.
106 °C (223 °F) for the C-10 or C-12.
• The “Coolant Level Sensor” parameter is
• The engine coolant temperature is greater than programmed to “4-pin” or “2-wire Float Sensor”.
111 °C (232 °F) for the 3406E, C-15, C-16 and
C-18. • The engine has been running for at least 30
seconds.
• The engine has been running for at least 30
seconds.
RENR2238-09 127
Troubleshooting Section
Note: If a lamp for low coolant level is installed, the Recheck the engine coolant level. If the coolant
lamp for low coolant level will turn on instead of the level is low, add more engine coolant.
warning lamp.
STOP.
Factory passwords are required to clear this
diagnostic code. • Not OK – The engine is leaking engine coolant or
there is coolant in the engine oil.
Possible Performance Effect:
Repair: Repair the leaks.
None
Verify that the repair eliminates the problem.
Troubleshooting:
STOP.
Test Step 1. Check the Coolant Level
i02184401
A. Check the engine coolant level. Refer to the
Operation and Maintenance Manual for more
information.
0111-02 Coolant Level signal
invalid (12)
Expected Result:
SMCS Code: 5574-038-CLT
The engine coolant level is normal.
Conditions Which Generate This Code:
Results:
The Engine Control Module (ECM) detects the
• OK – The engine coolant level is normal. following conditions:
Repair: Ensure that the coolant level sensor is • The coolant level sensor is sending an invalid
properly installed. signal for more than ten seconds.
Proceed to Test Step 2. The ECM will default to OK for engine coolant
level. “DIAG” will be displayed next to the status for
Test Step 2. Check for Leaks in the “Engine Coolant Level” on the Caterpillar Electronic
Cooling System Technician (ET).
There are no leaks. There is no coolant in the engine Perform the following diagnostic procedure: “Coolant
oil. Level Sensor Circuit - Test”
Results: Results:
SMCS Code: 5574-038-CLT The ECM will default to “OK” for coolant level.
“DIAG” will be displayed next to the status for
Conditions Which Generate This Code: “Engine Coolant Level” on the Caterpillar Electronic
Technician (ET).
The Engine Control Module (ECM) detects the
following conditions: Possible Performance Effect:
SMCS Code: 5574-038-CLT The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp
Conditions Which Generate This Code: will illuminate while this diagnostic code is active.
The ECM will display “Low” next to the status for
The Engine Control Module (ECM) detects the “Engine Coolant Level” on the Caterpillar Electronic
following conditions: Technician (ET).
• The signal voltage from the coolant level sensor is Note: If a lamp for low coolant level is installed, the
less than 0.5 VDC for more than ten seconds. lamp for low coolant level will illuminate instead of the
warning lamp.
• The “Coolant Level Sensor” parameter is
programmed to “2-wire float sensor”. Factory passwords are required to clear this
diagnostic code.
RENR2238-09 129
Troubleshooting Section
Possible Performance Effect: Recheck the engine coolant level. If the coolant
level is low, add more engine coolant.
The engine power is derated by 35 percent at a rate
of 1 percent per second. The vehicle speed is limited STOP.
to a maximum of 72 km/h (45 mph).
• Not OK – The engine is leaking engine coolant or
Note: If “Engine Monitoring” is programmed to there is coolant in the engine oil.
Shutdown, the engine will be shutdown once this
diagnostic code has been active for 30 seconds. Repair: Repair the leaks.
• OK – The engine coolant level is normal. The Engine Control Module (ECM) detects the
following conditions:
Repair: Ensure that the coolant level sensor is
properly installed. • The ECM detects a low current condition (open
circuit) for one second while the ECM is attempting
STOP. to energize the solenoid for cylinders 3 and 4.
• Not OK – The engine coolant level is low. • The engine retarder switch is in the low or high
position.
Repair: Add coolant to the engine. Refer to the
Operation and Maintenance Manual for more System Response:
information.
The ECM will log the diagnostic code and the ECM
Proceed to Test Step 2. will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active.
Test Step 2. Check for Leaks in the
Cooling System Possible Performance Effect:
A. Check for leaking engine coolant. The engine retarder may not activate.
Results: • OK – STOP.
• OK – The engine is not losing any engine coolant.
Repair: Ensure that the engine coolant level is
normal.
• The ECM detects a high current condition (short Perform the following diagnostic procedure: “Retarder
circuit) for one second while the ECM is attempting (Compression Brake) Solenoid Circuit - Test”
to energize the solenoid for cylinders 3 and 4.
Results:
• The engine retarder switch is in the low or high
position. • OK – STOP.
The ECM will log the diagnostic code and the ECM 0122-06 Med/High Retarder
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. current high (14)
Possible Performance Effect: SMCS Code: 1129-038
The engine retarder may not activate. Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the The engine retarder may not activate.
following conditions:
Troubleshooting:
• The ECM detects a low current condition (open
circuit) for one second while the ECM is attempting Perform the following diagnostic procedure: “Retarder
to energize the solenoids for cylinders 1, 2, 5, and (Compression Brake) Solenoid Circuit - Test”
6.
Results:
• The engine retarder switch is in the medium or
high position. • OK – STOP.
RENR2238-09 131
Troubleshooting Section
SMCS Code: 1401-038 • The battery voltage drops below 6 VDC for at least
0.50 seconds.
Conditions Which Generate This Code:
• Three voltage readings in the past seven seconds
The Engine Control Module (ECM) detects the were below 6 VDC.
following conditions:
System Response:
• The battery voltage to the ECM is less than 9.0
VDC for 12 volt systems or 18.0 VDC for 24 volt The ECM may stop injecting fuel. This may be
systems. dependent on the length of time of the occurrence
of the fault.
• The engine is running.
The check engine lamp and the warning lamp may
System Response: come on as if the ignition key switch was just turned
on and the engine started.
The ECM will use a default torque map. The check
engine lamp will illuminate. Possible Performance Effect:
Possible Performance Effect: The engine may experience changes in the engine
rpm, and intermittent engine shutdowns or complete
The engine will be derated. engine shutdowns while the conditions that cause
this diagnostic code are present.
Troubleshooting:
Troubleshooting:
This diagnostic code could indicate a faulty charging
system or poor battery connections. Perform the following diagnostic procedure: “Ignition
Key Switch Circuit and Battery Supply Circuit - Test”
Perform the following diagnostic procedure: “Ignition
Key Switch Circuit and Battery Supply Circuit - Test” Results:
Results: • OK – STOP.
• OK – STOP. i02184426
i02129377
0171-03 Ambient Air
Temperature voltage high
0168-02 ECM Battery Power
Intermittent (51) SMCS Code: 1928-038
Conditions Which Generate This Code: The Engine Control Module (ECM) detects the
following conditions:
This condition indicates that the battery circuit to the
Engine Control Module (ECM) has a battery condition • The signal voltage from the ambient air temperature
that is intermittent while the engine is running. If sensor is greater than 4.92 VDC for more than
battery voltage disappears without returning, the eight seconds.
ECM will not log this diagnostic code and the engine
will shut down. • The signal voltage from the ambient air temperature
sensor is greater than 4.95 VDC for more than
The ECM detects the following conditions: eight seconds. Only engines with software after
DEC 03
• The ignition key switch is in the ON position.
• The “Allow Idle Shutdown Override” parameter is
• The engine is running. programmed to “Outside Temperature Based” or
“J1587 Outside Temperature Based”.
• The engine is not cranking.
132 RENR2238-09
Troubleshooting Section
Perform the following diagnostic procedure: “Engine Conditions Which Generate This Code:
Temperature Sensor Open or Short Circuit - Test”
The Engine Control Module (ECM) detects the
Results: following conditions:
• The “Allow Idle Shutdown Override” parameter is Perform the following diagnostic procedure: “ATA
programmed to “Outside Temperature Based” or (SAE J1587 / J1708) Data Link Circuit - Test”
“J1587 Outside Temperature Based”.
Results:
• The ECM has been powered for at least two
seconds. • OK – STOP.
System Response:
i02184446
Customer passwords are required to clear this Conditions Which Generate This Code:
diagnostic code.
The Engine Control Module (ECM) detects the
Possible Performance Effect: following conditions:
No troubleshooting is required. • The ECM has been powered for at least two
seconds.
Results:
System Response:
• OK – STOP.
The ECM will default to the lower of engine coolant
temperature or 50 °C (122 °F) for fuel temperature.
i01956975
Conditions Which Generate This Code: Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test”
The Engine Control Module (ECM) detects the
following conditions: Results:
The ECM will default to the lower of engine coolant The engine speed exceeded 2600 rpm for more than
temperature or 50 °C (122 °F) for fuel temperature. one second.
Fuel injection will be disabled until engine speed 0191-07 Transmission Not
drops below the “Top Engine Limit”. Responding (68)
Troubleshooting: SMCS Code: 3174-038
The operator may be operating the engine incorrectly. Conditions Which Generate This Code:
Talk to the Operator The ECM detects the following conditions:
Determine the events that caused the overspeed of • Three attempts to complete an Eaton Top 2 shift
the engine. were unsuccessful.
Results: • The “Transmission Style” is programmed to “Eaton
Top 2”.
• OK – STOP.
System Response:
i01905839
The solenoid that is currently enabled will remain in
0190-12 Primary Engine Speed the ON position until neutral is detected. Then Manual
operation occurs until the system powers down.
loss of signal (34) Manual operation is defined as both solenoids OFF.
SMCS Code: 1912-038 Possible Performance Effect:
Conditions Which Generate This Code: The ECM disables the Eaton Top 2 mode.
The ECM detects the following conditions: Troubleshooting:
• The signal from the primary engine speed/timing Perform the following diagnostic procedure: “Eaton
sensor is intermittent or lost. Top 2 Transmission Circuit - Test”
System Response: Results:
The ECM will use the secondary engine speed/timing
sensor to determine engine speed. The check engine
• OK – STOP.
lamp will not be illuminated for this code unless the
code has been active for 10 hours. i02129525
This diagnostic code indicates that the theft deterrent • The parameter “Powertrain Data Link” must be
feature has been enabled. There is no electronic programmed to J1939.
system fault.
The ECM also detects one of the following conditions:
No Troubleshooting is required.
• The ECM is unsuccessful in receiving a specific
Results: message from a device.
• OK – STOP. or
with Engine Cranking (00) • The device is broadcasting a code that is not
supported.
SMCS Code: 1901-038
System Response:
Conditions Which Generate This Code:
J1939 communications to the engine and from the
The Engine Control Module (ECM) detects the engine are terminated for the specific message while
following conditions: this code is active. The functionality of some features
may be affected while this code is active. Traction
• The engine is cranking. control or transmission controls may be disabled.
“Diag” or “J1939 No Support” will be displayed next
• The theft deterrent is active. to the status on the Caterpillar Electronic Technician
(ET).
System Response:
Possible Performance Effect:
The diagnostic code is active only. The diagnostic
code will be active when the theft deterrent is Features that utilize the J1939 data link may not work
enabled and the engine is cranking for more than five properly or the features may be disabled.
seconds.
Perform the following diagnostic procedure:
Possible Performance Effect: “Powertrain Data Link Circuit - Test”
The engine will not start until the correct password Results:
is entered.
• OK – STOP.
Troubleshooting:
The engine will experience low power when this 0246-11 Brake Pedal Switch #1
diagnostic code is active. Fault
Troubleshooting: SMCS Code: 1435-038-BRK
Perform the following diagnostic procedure: “5 Volt Conditions Which Generate This Code:
Engine Pressure Sensor Supply Circuit - Test”
The Engine Control Module (ECM) detects the
Results: following conditions:
The engine will disengage or the engine will not Perform the following diagnostic procedure:
allow setting of the cruise control, the PTO, or the “Powertrain Data Link Circuit - Test”
idle speed.
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Service
Brake Pedal Position (Switch 2) Circuit - Test”
i02336574
0249-11 J1922 Data Link Fault Conditions Which Generate This Code:
Note: If the vehicle is not using the J1922 data link for The flash file in the ECM is from the wrong engine
the vehicle’s power train control, program the “Power family.
Train Data Link” (customer parameter) to “None”.
After the “Power Train Data Link” is programmed Perform the following diagnostic procedure: “ECM
correctly, repair the following active diagnostic code: Memory - Test”
• OK – STOP.
RENR2238-09 139
Troubleshooting Section
i02117488 i01225847
Conditions Which Generate This Code: Conditions Which Generate This Code:
This condition indicates a customer specified This condition indicates that the “Transmission Style”
parameter or a system configuration parameter that parameter is programmed to the Eaton Top 2 and any
requires programming has not been programmed. one of the following parameters are not programmed:
Once this parameter has been programmed, the
code may still be active. This can happen if there is • “Top Gear Ratio”
yet another parameter that requires programming.
• “Top Gear Minus One Ratio”
System Response:
• “Top Gear Minus Two Ratio”
The code is active only and the code is not Logged. If
the personality module code of the new personality System Response:
module does not match the code of the old personality
module, the engine is limited to low idle. If the “Rating Engine Response The engine will not operate above
Number” has not been programmed, the ECM limits low idle.
the engine to 119 kW (160 hp). When a new ECM is
initially powered up, the following parameters must Troubleshooting:
be programmed to avoid this diagnostic code:
Program the “Transmission Style” parameter that is
• “FLS” (Full Load Setting) Eaton Top 2 to the correct setting. If an Eaton Top
2 Transmission is not used, program the correct
• “FTS” (Full Torque Setting) “Transmission Style” parameter to the correct setting.
Troubleshooting:
Results:
• OK – STOP.
140 RENR2238-09
Troubleshooting Section
Diagnostic Functional
Tests
i01907586
g00692909
Illustration 34
Sensor locations for C-10 and C-12 engines
g00662230
Illustration 35
Sensor locations for 3406E engines
142 RENR2238-09
Troubleshooting Section
g00693763
Illustration 36
Sensor locations for C-15, C-16 and C-18 engines
g00662235
Illustration 37
Schematic
RENR2238-09 143
Troubleshooting Section
g00662237
Illustration 38
P2 ECM connector
Expected Result:
Results:
Illustration 39
g00810608 • OK – The 5 volt diagnostic codes are not active.
Sensor connector
Repair: Reconnect the P2 ECM connector.
Test Step 1. Disconnect the ECM
Connector and Check for Active Proceed to Test Step 2.
Diagnostic Codes
• Not OK – The 5 volt diagnostic codes are still
A. Turn the key switch to the OFF position. active.
B. Connect the Caterpillar Electronic Technician (Cat Repair: Connect a test ECM.
ET) to the data link connector.
144 RENR2238-09
Troubleshooting Section
If the test ECM fixes the problem, reconnect the Expected Result:
suspect ECM.
The voltage should be less than 7.0 VDC.
If the problem returns, permanently install the new
ECM. Results:
Verify that the repair eliminates the problem. • OK – The voltage is within the range.
STOP. Repair: Temporarily connect a new sensor.
Test Step 2. Disconnect the Sensors If the problem is resolved with the new sensor,
reconnect the suspect sensor.
A. Turn the key switch to the ON position.
If the problem returns, replace the suspect sensor.
B. Monitor the active diagnostic code screen on Cat
ET. Verify that the repair eliminates the problem.
The 5 volt diagnostic code is still active when all of Test Step 4. Determine the Condition that
the pressure sensors are disconnected. is Present
Results: A. Turn the key switch to the ON position.
• OK – The 5 volt diagnostic code is still active. B. Access the active diagnostic code screen on Cat
ET.
Repair: Leave all of the pressure sensors
disconnected. Expected Result:
B. Measure the voltage between terminal C (Signal) B. Measure the voltage between terminal A
and terminal B (Pressure Sensor Common) of the (Pressure Sensor +5V) and chassis ground for
connector for the suspect sensor on the engine each pressure sensor.
harness.
RENR2238-09 145
Troubleshooting Section
Repair the 5 volt supply wire or replace the 5 volt The resistance should be greater than 20,000 Ohms,
supply wire. or “OL” is displayed on the multimeter.
B. Measure the voltage between terminal A (Pressure Repair the 5 volt supply wire or replace the 5 volt
Sensor +5V) and terminal B (Pressure Sensor supply wire.
Common) on all of the pressure sensors.
Verify that the repair eliminates the problem.
C. While the voltage is monitored, perform a 45 N
(10 lb) pull test on the common wires for the 5 volt STOP.
supply.
• Not OK – There is a short between the 5 volt
• P2:3 (Pressure Sensor Common) supply and the pressure sensor common.
• P2:42 (Pressure Sensor Common (Actuator)) Repair: Locate the short between the 5 volt supply
and the pressure sensor common.
Expected Result:
Repair the faulty wiring or replace the faulty wiring.
The voltage should be 5.0 ± 0.16 VDC.
Verify that the repair eliminates the problem.
Results:
STOP.
• OK – The voltage is within the range.
i02173336
Repair: If the problem is intermittent, refer to
Troubleshooting, “Electrical Connectors - Inspect”. Accelerator Pedal (Throttle)
STOP. Position Sensor Circuit - Test
• Not OK – The voltage is not within the range. SMCS Code: 1913-038
Repair: Inspect the common wire for an open System Operation Description:
circuit.
Use this procedure to troubleshoot any suspect
Repair the common wire or replace the common problems with the accelerator pedal position sensor.
wire.
This procedure covers the following diagnostic codes:
Verify that the repair eliminates the problem.
• 41-03 8 Volt Supply voltage high
STOP.
• 41-04 8 Volt Supply voltage low
146 RENR2238-09
Troubleshooting Section
• “Remote Switches”
• “Remote Throttle”
Note: In the cab switches configuration, the cab
accelerator pedal can be used in order to control
the engine rpm for the PTO operation. The cab
accelerator pedal can also be ignored in the “Cab
Switches” PTO configuration. Programming of
customer parameters is required in order to ignore
the cab accelerator pedal in the “Cab switches”
configuration.
g00642016
Illustration 40
Schematic
Expected Result:
Results:
STOP.
Illustration 41
g01101367 Test Step 2. Monitor the Duty Cycle
P1 ECM connector
A. Turn the key switch to the ON position.
(4) Accelerator pedal position +8 VDC supply
(5) Common for the accelerator pedal position sensor
(66) Accelerator pedal position sensor
B. Access the following display screen in order:
The duty cycle is 10 percent to 22 percent when the • OK – The harness and connectors appear to be
accelerator pedal is released. The duty cycle is 75 OK. Proceed to Test Step 4.
percent to 90 percent when the accelerator pedal is
depressed. • Not OK – There is a problem with the connectors
and/or wiring.
Results:
Repair: Perform the following repair:
• OK – The duty cycle is within the specified range.
Repair the connectors or wiring and/or replace
Repair: If the problem is intermittent, refer to the connectors or wiring. Ensure that all of the
Troubleshooting, “Electrical Connectors - Inspect”. seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the engine is not in PTO mode. PTO
mode may cause the accelerator pedal position Verify that the repair eliminates the problem.
sensor to be ignored.
STOP.
Verify that all required parameters are
programmed. Certain unprogrammed parameters Test Step 4. Check for Active Diagnostic
may cause the engine to be limited to low idle. Codes
Refer to Troubleshooting, “System Configuration
Parameters”. A. Turn the key switch to the ON position.
• Not OK – The duty cycle is not within the range. Note: When the ECM automatically calibrates new
Proceed to Test Step 3. duty cycle values for the low idle throttle position and
the high idle throttle position the ECM assumes 22
Test Step 3. Inspect Electrical Connectors percent duty cycle at low idle and 75 percent duty
and Wiring cycle at high idle. As a result, you may notice that
the throttle position status reaches 100 percent well
A. Thoroughly inspect the J1/P1 ECM connector, the before the accelerator pedal is fully depressed. This
firewall bulkhead connector and the accelerator is normal. After some cycling of the accelerator pedal
pedal position sensor connector. Refer to to the high idle position, the ECM will adjust the
Troubleshooting, “Electrical Connectors - Inspect” calibration automatically. The ECM will adjust the
for details. calibration automatically provided that the high idle
stop position is within the 75 to 90 percent duty cycle
B. Perform a 45 N (10 lb) pull test on each of the range, and the low idle is in the 10 to 22 percent
wires in the ECM connector that are associated duty cycle range. During normal operation, you may
with the accelerator pedal position sensor: also notice that more movement of the accelerator
pedal is required for the throttle position status to
• P1-4 increase above 3 percent. You may also observe that
the status reaches the 100 percent value prior to the
• P1-5 limit of the high idle position. This is done in order
to ensure that the throttle reaches these two critical
• P1-66 points for engine operation.
C. Check the ECM connector (Allen head screw) for Expected Result:
the proper torque of 6.0 N·m (55 lb in).
Result 1 91-08 or 91-13 is Active.
D. Check the harness and wiring for abrasion and
pinch points from the accelerator pedal position Result 2 41-03 is Active.
sensor to the ECM.
Result 3 41-04 is Active.
Expected Result:
Results:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring • Result 1 – Proceed to Test Step 5.
are free of corrosion, of abrasion or of pinch points.
• Result 2 – Proceed to Test Step 10.
RENR2238-09 149
Troubleshooting Section
• Result 3 – Proceed to Test Step 12. E. Turn the key switch to the ON position.
Test Step 5. Check the Supply Voltage F. While the duty cycle is being monitored on the
at the Sensor for the Accelerator Pedal multimeter, depress the accelerator pedal and
Position Sensor release the accelerator pedal.
The measured voltage is between 7.5 VDC and 8.5 Repair: Insert the signal wire into terminal C of the
VDC for the pedal mounted throttle position sensor P403 connector.
that is used in the cab.
Proceed to Test Step 7.
Results:
• Not OK – Leave the PWM probe connected to the
• OK – The measured voltage is between 7.5 breakout T. Insert the wire (terminal C) into the
VDC and 8.5 VDC for the pedal mounted throttle vehicle harness connector. The accelerator pedal
position sensor that is used in the cab. Proceed position sensor or the accelerator pedal assembly
to Test Step 6. is faulty. Proceed to Test Step 8.
• Not OK – The sensor is not receiving the correct Test Step 7. Check the Duty Cycle of the
voltage. Accelerator Pedal Position Sensor at the
ECM
Repair: Inspect the electrical connectors and
wiring. Note: Performing certain steps within this procedure
requires the use of a multimeter that is capable of
Repair the faulty wiring. measuring a PWM duty cycle.
Verify that the repair eliminates the problem. A. Turn the key switch to the OFF position.
B. Remove the signal wire for the accelerator pedal D. Reconnect the P1 ECM connector to the ECM.
position sensor (terminal “C”) from P403. This is
the harness side of the accelerator pedal position E. Turn the key switch to the ON position.
sensor connector.
F. While the duty cycle output of the accelerator
C. Install a breakout T with three terminals between pedal position sensor is being monitored on the
the J403 and the P403 Accelerator pedal position multimeter, depress the accelerator pedal and
sensor connector. release the accelerator pedal.
D. Connect the multimeter probes to terminal “C” G. Turn the key switch to the OFF position.
(Accelerator Pedal Position) and terminal “B”
(Accelerator/Switch Sensor Common) of the H. Reinsert the signal wire into P1-66 of the P1 ECM
breakout T. connector.
150 RENR2238-09
Troubleshooting Section
Expected Result:
Results:
STOP.
g00706977
Illustration 42
Accelerator pedal assembly
B. Remove the signal wire for the accelerator pedal D. Turn the key switch to the ON position.
position sensor from P1-66.
E. Check for active diagnostic codes on Cat ET.
C. Remove terminal “C” (Accelerator Pedal Position)
from the accelerator pedal position sensor Expected Result:
connector.
The 41-03 changes to 41-04 when the jumper wire
D. Route new wiring from the ECM to the accelerator is installed.
pedal position sensor.
Results:
E. Turn the key switch to the ON position.
• OK – There is a problem with the accelerator
F. Check the duty cycle of the accelerator pedal pedal position sensor.
position sensor on Cat ET while the accelerator
pedal assembly is being moved over the full range. Repair: Remove the breakout T. Temporarily
connect a new sensor. If the new sensor eliminates
Expected Result: the problem, reconnect the suspect sensor. If the
problem returns, permanently replace the sensor.
The duty cycle is between 10 percent and 22 percent
when the accelerator pedal is fully released. The duty Verify that the repair eliminates the problem.
cycle is between 75 percent and 90 percent when the
accelerator pedal is fully depressed. STOP.
Results: • Not OK – The ECM did not see the short at the
sensor. Proceed to Test Step 11.
• OK – The duty cycle is between 10 percent and
22 percent when the accelerator pedal is fully Test Step 11. Short the +8 Volt Supply at
released. The duty cycle is between 75 percent the ECM
and 90 percent when the accelerator pedal is fully
depressed. A. Turn the key switch to the OFF position.
STOP. Results:
Test Step 10. Short the +8 Volt Supply at • OK – There is a problem with the wiring between
the Sensor the ECM and the accelerator pedal position sensor.
A. Turn the key switch to the OFF position. Repair: Remove the breakout T.
B. Connect a breakout T between the J403 and Inspect the wiring between the ECM and the
the P403 Accelerator Pedal Position Sensor sensor.
connectors.
Repair the faulty wiring.
C. Insert a jumper wire between terminal A and
terminal B of the breakout T.
RENR2238-09 153
Troubleshooting Section
Verify that the repair eliminates the problem. C. Turn the key switch to the ON position.
Repair: Remove the breakout T. The 41-04 changes to 41-03 when the wires are
removed.
Temporarily connect a test ECM.
Results:
If the test ECM fixes the problem, reconnect the
suspect ECM. • OK – There is a problem with the wiring between
the ECM and the accelerator pedal position sensor.
If the problem returns, permanently replace the
ECM. Repair: Inspect the wiring between the ECM and
the sensor.
Verify that the repair eliminates the problem.
Repair the faulty wiring.
STOP.
Verify that the repair eliminates the problem.
Test Step 12. Disconnect the Sensor
STOP.
A. Turn the key switch to the OFF position.
• Not OK – There may be a problem with the ECM.
B. Disconnect the J403/P403 Accelerator Pedal
Position Sensor connector. Repair: Temporarily connect a test ECM.
C. Turn the key switch to the ON position. If the test ECM fixes the problem, reconnect the
suspect ECM.
D. Check for active diagnostic codes on Cat ET.
If the problem returns, permanently replace the
Expected Result: ECM.
The 41-04 changes to 41-03 when the sensor is Verify that the repair eliminates the problem.
disconnected from the harness.
STOP.
Results:
i01620144
• OK – There is a problem with the accelerator
pedal position sensor. Air Inlet Shutoff Circuit - Test
Repair: Temporarily connect a new sensor. SMCS Code: 1078-038
If the new sensor eliminates the problem, System Operation Description:
reconnect the suspect sensor.
The Air Inlet Shutoff is available for certain engine
If the problem returns, permanently replace the ratings that operate in areas with large amounts of
sensor. combustible gases. The air inlet shutoff will protect
the engine from an overspeed when these gases
Verify that the repair eliminates the problem. are present. When an overspeed is detected, a
relay activates the air inlet shutoff and injection is
STOP. disabled until the engine speed reaches 0 rpm. This
is accomplished by closing a flap in order to cut off
• Not OK – The ECM did not see the open. Proceed the air supply to the engine. Once the Air Inlet Shutoff
to Test Step 13. is activated the flap must be manually reset before
the engine can be restarted.
Test Step 13. Remove the +8 Volt Supply
Wires from the ECM
A. Turn the key switch to the OFF position.
g00838497
Illustration 43
Schematic
Expected Result:
Results:
Test Step 2. Check the Interlock for the Verify that the repair eliminates the problem.
Air Inlet Shutoff
STOP.
A. Verify that J1/P1:62 (Output 12) is connected to
the +Battery. Test Step 4. Perform the “Air Inlet Shutoff
Relay Output” Test
Expected Result:
A. Turn the keyswitch to the OFF position.
J1/P1:62 is connected to the +Battery.
B. Connect ET to the cab data link connector.
Results:
C. Turn the keyswitch to the ON position. Do not start
• OK – J1/P1:62 (Output 12) is connected to the the engine.
+Battery. Proceed to Test Step 3.
D. Go to the “Air Inlet Shutoff Relay Output” test on
• Not OK – J1/P1:62 (Output 12) is not connected ET.
to the +Battery.
E. Start the test and listen for a click from the relay
Repair: Connect J1/P1:62 to the +Battery. for the air inlet shutoff.
C. Perform a 45 N (10 lb) pull test on the wires that Test Step 5. Check the Supply Voltage to
are associated with the air inlet shutoff system. the Air Inlet Shutoff Solenoid
D. Check the ECM connector (allen head screw) for
the proper torque of 6.0 N·m (55 lb in).
Expected Result:
Results:
g00850138
• OK – All the wires and connections are OK. Illustration 45
Proceed to Test Step 4. Air Inlet Shutoff Solenoid
Repair: Perform the following repair: B. Turn the keyswitch to the ON position.
Repair the connectors or wiring and/or replace C. Proceed to the “Air Inlet Shutoff Relay Output”
the connectors or wiring. Ensure that all of the test on ET.
seals are properly in place and ensure that the
connectors are completely coupled. D. Activate the relay for the air inlet shutoff solenoid.
156 RENR2238-09
Troubleshooting Section
E. Use signal reading probes to measure the voltage Test Step 7. Check the Resistance of the
across the two terminals of the air inlet shutoff Relay
solenoid.
Expected Result:
Results:
g00850059
• OK – The ECM is properly controlling the relay for Illustration 46
the air inlet shutoff solenoid, but the air inlet shutoff Relay Terminals
solenoid is not working. Proceed to Test Step 6.
A. Turn the keyswitch to the OFF/RESET position.
• Not OK – The air inlet shutoff solenoid is not
receiving the correct signal. Proceed to Test Step B. Unplug the relay for the air inlet shutoff solenoid.
10.
C. Measure the resistance between J520:1 (Solenoid
Test Step 6. Check the Resistance of the Common) and J520:2 (Air Inlet Shutoff Output).
Solenoid
Expected Result:
A. Disconnect the wires for the air inlet shutoff
solenoid. The resistance should be between 5 Ohms and 10
Ohms.
B. Measure the resistance of the air inlet shutoff
solenoid. Results:
C. Reconnect the wires for the air inlet shutoff • OK – The resistance of the relay is OK. Proceed
solenoid. to Test Step 8.
STOP.
STOP.
RENR2238-09 157
Troubleshooting Section
Test Step 8. Check the Signal Voltage to Test Step 9. Check the Power Supply to
the Relay the Relay
g00850154 g00850141
Illustration 47 Illustration 48
Schematic for the Relay Signal Air Inlet Shutoff Relay
A. Unplug the relay for the air inlet shutoff solenoid. A. Measure the voltage between the +Battery
terminal of the relay and the engine ground.
B. Turn the keyswitch to the ON position.
Expected Result:
C. Proceed to the “Air Inlet Shutoff Relay Output”
test on ET. The voltage should be 12.0 ± 4.0 VDC.
The voltage should be 12.0 ± 4.0 VDC. Repair: Repair the circuit.
g00850141
Illustration 49
Air Inlet Shutoff Relay
B. Turn the keyswitch to the ON position. D. Measure the resistance between P2:13 (Air Inlet
Shutoff Output) and P2:9 (Solenoid Common).
C. Go to the “Air Inlet Shutoff Relay Output” test on
ET. Expected Result:
D. Activate the system for the air inlet shutoff The resistance should be greater than 20,000 Ohms.
solenoid.
Results:
E. Measure the voltage from the output terminal on
the relay to the engine ground. • OK – There are no shorts in the wiring harness.
Proceed to Test Step 12.
Expected Result:
• Not OK – There is a short in the wiring harness
The voltage should be 12.0 ± 4.0 VDC. between the ECM and the relay.
• OK – There is a problem in the wiring between the Verify that the repair eliminates the problem.
relay and the air inlet shutoff solenoid.
STOP.
Repair: Repair the circuit.
Test Step 12. Check the Relay Signal at
Verify that the repair eliminates the problem. the ECM
STOP.
STOP.
g00848592
Illustration 50
ECM connector P1 (Harness Side)
g00848592
A. Ensure that the keyswitch is in the OFF/RESET Illustration 52
position. ECM connector P1 (Harness side)
B. Disconnect the J2/P2 ECM connector. A. Turn the keyswitch to the OFF/RESET position.
B. Remove the wire from P2:13 (Air Inlet Shutoff The ATA data link (American Trucking Association)
Output) in the P2 ECM connector. is the standard data link that is used by the ECM
to communicate with electronic service tools. The
C. Turn the keyswitch to the ON position. SAE specification J1587 defines the format of the
messages and data that is communicated. The
D. Activate the “Air Inlet Shutoff Relay Output” test SAE specification J1708 defines the hardware
on ET. requirements and the protocol of the serial
communications. The Cat ET is an example of one
E. Measure the voltage between the open terminal of the electronic service tools. Some electronic
at P2:13 (Air Inlet Shutoff Output) and P2:9 dashboards use this data link to receive information.
(Solenoid Common). Some automatic transmissions also receive
information from this data link.
F. Turn the keyswitch to the OFF/RESET position.
The ECM provides the following two ATA data link
G. Reinstall the wire to P2:13 (Air Inlet Shutoff connection terminals from the ECM vehicle harness
Output). connector J1:
STOP.
i02309648
g00650338
Illustration 53
Schematic for ATA data link with 6-pin connector
g01156829
Illustration 54
Schematic for ATA data link with 9-pin connector
g01157130
Illustration 55
Terminal locations for ECM
• ATA data link (terminal 8 and terminal 9) in the • Not OK – There is a problem with the wiring and/or
connectors the connectors.
C. Check the allen head screws on the ECM Verify that the repair eliminates the problem.
connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect” STOP.
for details.
Test Step 2. Determine the Type of
D. Check the harness and wiring for abrasion and for Problem with the Data Link
pinch points from the connector to the ECM.
A. Connect Cat ET to the cab data link connector.
Refer to Illustration 55.
162 RENR2238-09
Troubleshooting Section
Result 1 The engine starts. The electronic service • Result 5 – Cat ET does not power up or the
tool powers up and Cat ET communicates without communications adapter does not power up.
error. Ensure that the ECM is receiving the correct
battery power. Proceed to Test Step 3.
Result 2 The engine starts. Cat ET powers up but
an error is displayed.
Results:
STOP.
STOP.
g00650354
Illustration 56
ATA Data Link connector
A. Turn the ignition key switch to the ON position. Test Step 4. Change Electronic Service
Tool Components
B. Use a multimeter in order to measure the voltage
from the +Battery terminal of the cab data link A. If another vehicle or another ECM is available,
connector to the −Battery terminal of the cab data connect Cat ET to the other vehicle by using the
link connector. same cables.
Refer to Illustration 56. B. Turn the ignition key switch to the ON position.
Determine if Cat ET operates correctly on the
Expected Result: other ECM.
The voltage is between 11.0 and 13.5 VDC for a 12 Expected Result:
Volt system or between 22.0 and 27.0 VDC for a 24
Volt system. Result 1 The original Cat ET works on another ECM.
STOP.
164 RENR2238-09
Troubleshooting Section
g00650356
Illustration 57
ECM Breakout T-connector and terminal locations for ECM P1
A. Ensure that Cat ET is connected to the cab data • Not OK – The ECM is not receiving the correct
link connector. voltage. Ensure that there is not an aftermarket
engine protection switch that is overriding battery
B. Disconnect vehicle harness connector P1 from power to the ECM.
ECM connector J1 and insert a 70-Terminal
breakout T. Repair: Perform the following diagnostic
procedure:
C. Turn the ignition key switch to the ON position.
Troubleshooting, “Ignition Key Switch Circuit and
D. Measure the voltage between P1:52 (Unswitched Battery Supply Circuit - Test”
+Battery) and P1:65 (−Battery).
STOP.
E. Measure the voltage between P1:70 (Ignition Key
Switch) and P1:65 (−Battery). Test Step 6. Connect Cat ET Directly to
the ECM
Refer to Illustration 57.
Expected Result:
Batteries give off flammable fumes which can ex-
The voltage is between 11.0 and 13.5 VDC for a 12 plode.
Volt system or between 22.0 and 27.0 VDC for a 24
Volt system. To avoid injury or death, do not strike a match,
cause a spark, or smoke in the vicinity of a battery.
Results:
• OK – The ECM is currently receiving the correct A. Turn the ignition key switch to the ON position.
voltage. Proceed to Test Step 6.
RENR2238-09 165
Troubleshooting Section
B. Disconnect vehicle harness connector J1/P1 from Troubleshooting, “Ignition Key Switch Circuit and
the ECM. Battery Supply Circuit - Test”
There is a problem in the vehicle wiring, or another 6. If the problem returns with the suspect ECM,
device in the vehicle is causing problems on the replace the ECM.
data link. Determine the device that is causing the
problem or send the vehicle to the OEM dealer for 7. Verify that the repair eliminates the problem.
repair.
STOP.
Verify that the repair eliminates the problem.
i02375119
STOP.
Auxiliary Brake Circuit - Test
• Not OK – Cat ET is not operating correctly. Verify
that the 20 Amp fuse in the bypass harness is not SMCS Code: 1129-038-AX
open. A fuse that is open is a blown fuse. Proceed
to Test Step 7. System Operation Description:
Test Step 7. Connect Cat ET and the ECM Use this procedure to determine if the auxiliary brake
to Another Battery circuit is operating properly. No diagnostic codes are
provided for the auxiliary brake output. There may be
a problem with the circuit if the operator notes that
the vehicle’s braking is poor.
Batteries give off flammable fumes which can ex-
plode. Background Information
To avoid injury or death, do not strike a match, The Engine Control Module (ECM) has an output
cause a spark, or smoke in the vicinity of a battery. that can be configured to activate an auxiliary brake.
The “Auxiliary Brake Output” must be programmed
to “J1/P1:12” in order to enable the auxiliary brake
A. Connect the battery wires from the bypass output. The OEM provides the wiring from terminal
harness to a different battery that is not on the P1-12 to the system’s components.
vehicle.
Typically, the ECM output energizes a relay. The
Expected Result: relay’s contacts apply battery power to the other
components in the system. A switch on the dashboard
Cat ET is operating correctly. interrupts the signal from the relay. This allows the
operator to deactivate the system, if necessary.
Results:
The ECM constantly monitors the vehicle’s operating
• OK – Cat ET is operating correctly. The vehicle conditions. The ECM provides battery voltage to
battery is causing the problem. terminal P1-12 when all of the following conditions
are met:
Repair: Perform the following diagnostic
procedure: • Engine speed is above 800 rpm.
166 RENR2238-09
Troubleshooting Section
• The percent of accelerator pedal position is less The following components can cause problems with
than eight percent. the auxiliary brake:
g01185722
Illustration 58
Typical circuit for the auxiliary brake output
Expected Result:
Results:
A. Establish communication between Cat ET and the • OK – The status parameters are correct. Proceed
service tool connector. to Test Step 4.
B. Turn the ignition key switch to the ON position. • Not OK – There is a problem with the accelerator
pedal position.
C. Verify that the following parameters are
programmed correctly: Repair: Refer to Troubleshooting, “Pulse Width
Modulated Sensor”.
• “Auxiliary Brake”
STOP.
• “Engine Retarder Minimum Vehicle Speed”
• Not OK – There is a problem with the clutch pedal
Expected Result: position.
The parameters are programmed correctly. Repair: Refer to Troubleshooting, “Clutch Pedal
Position Switch Circuit - Test”.
Results:
STOP.
• Yes – The parameters are programmed correctly.
Proceed to Test Step 3. Test Step 4. Use Cat ET to Check the
Relay and Solenoids
• No – At least one parameter is programmed
incorrectly. A. Turn the ignition key switch to the ON position.
Repair: Program the parameter to the correct B. Click on the following menus in order to access
value. the “Auxiliary Brake Special Test” on Cat ET:
The status parameters are correct. • OK – There is an audible click from the relay and
the solenoids. The ECM is operating correctly. The
Note: The clutch pedal position switch is ON when circuit is operating correctly.
the clutch pedal is depressed. The clutch pedal
position switch is OFF when the clutch pedal is
released.
RENR2238-09 169
Troubleshooting Section
Repair: If the auxiliary brake is not operating 1. Temporarily connect a test ECM.
correctly, there is a problem with a component in
the circuit. Send the vehicle to the OEM dealer for 2. Use the “Auxiliary Brake Output Special Test”
repair. on Cat ET in order to test the ECM.
Test Step 5. Use Cat ET to Check the ECM If the problem is not resolved with the test ECM,
install the original ECM. There is a problem
Note: A multimeter cannot be used in place of the in the wiring between the ECM and the relay.
voltage test lamp when the ECM outputs are being Check the following components:
tested.
• Wiring
A. Turn the ignition key switch to the OFF position.
• Connectors
B. Connect a 70-Terminal breakout T between ECM
connectors J1 and P1. • Relay
C. Connect a voltage test lamp to terminals 65 Send the vehicle to the OEM dealer for repair,
(−Battery) and 12 (Output 3) of the breakout T. if necessary.
Repair: Inspect the vehicle wiring and then repair The check engine lamp is used to provide the
the vehicle wiring. Send the vehicle to the OEM following functions:
dealer for repair, if necessary.
• Indicate the existence of an active diagnostic code.
STOP.
• Indicate driver alert status of the idle shutdown
• Not OK – The voltage test lamp remained off while timer.
the test was active.
• Read diagnostic flash codes.
Repair: There is probably a short circuit in the
wiring between the ECM and the relay. However, it Power Up Lamp Check
is easier to test the ECM first. Perform the following
procedure:
170 RENR2238-09
Troubleshooting Section
At powerup, the lamp will turn on for five seconds. Some vehicles are equipped with a diagnostic enable
The lamp will continue to flash if there is an active switch. The diagnostic enable switch is used to flash
diagnostic code. the diagnostic codes by grounding the input of the
diagnostic enable switch from P1-46 (Input 7) to P1-5
Operation with an Active Diagnostic Code (Sensor Common).
While the engine is operating, the lamp will turn on Note: The check engine lamp should not continuously
for a minimum of five seconds when certain fault flash the diagnostic flash codes. If the set switch, the
conditions exist. If certain fault conditions exist, the resume switch, or the diagnostic enable switch has
lamp will operate in the following manner: not been used, then the circuit is probably shorted to
ground.
• The check engine lamp will turn on for five seconds.
Electrical Connection of the Check Engine Lamp
• The check engine lamp will turn off for a short time.
One terminal of the check engine lamp must be
• The check engine lamp will turn on for another connected to battery voltage through the vehicle
five seconds. wiring. The other terminal is connected to the
Engine Control Module (ECM) at the vehicle harness
The check engine lamp will continue to operate in connector P1-28 (Check Engine Lamp).
this manner while the fault condition exists.
The ECM provides a path to ground in order for the
Indication of the Driver Alert Status of the Idle lamp to turn on.
Shutdown Timer
g00676880
Illustration 60
Schematic for lamp
Expected Result:
Results:
The check engine lamp turns on and the check • Result 2 – The lamp did not turn on. The vehicle’s
engine lamp turns off per the above description. lamp circuit is not functioning properly.
• Not OK – The check engine lamp does not turn on Repair: Perform the following diagnostic
or the check engine lamp does not turn off per the procedure:
above description. Proceed to Test Step 3.
The circuit between the ECM and the lamp is
Test Step 3. Test the Lamp Circuit shorted to chassis ground. Repair the circuit or
send the vehicle to the OEM dealer for repairs.
A. Disconnect ECM vehicle harness connector
J1/P1. STOP.
STOP.
D. The test lamp should turn on. If the test lamp does Use this procedure under the following situation:
not turn on, either the test lamp is faulty or the
wiring to the ECM is faulty. Continue with this step The clutch pedal position switch is suspected of
if the lamp turns on. preventing normal operation of cruise control, idle set
speed, or PTO operation.
E. Leave the voltage test lamp probe connected to
terminal 52 (Unswitched +Battery). The following switch circuits can also prevent the
correct operation of the cruise control, idle set speed
F. Connect the other probe of the test lamp to or PTO operation:
Terminal 28 (Check Engine Lamp) of the breakout
T. • Service brake pedal position (Switch 1)
Refer to Illustration 62. • Service brake pedal position (Switch 2)
G. Watch the voltage test lamp. Turn the ignition key • Neutral switch
switch to the ON position.
• Cruise control set/resume switch
H. The lamp should turn on for five seconds. Then,
the lamp should turn off. The lamp will continue • Cruise control On/Off switch
flashing if there is an active diagnostic code. If
there is an active diagnostic code, connect Cat • PTO On/Off switch
ET in order to read the active diagnostic code.
Troubleshoot the problem. The switches are described in the respective circuit
tests in Troubleshooting.
Expected Result:
All of the following customer programmable
The check engine lamp turns on and the check parameters can affect cruise control, idle set speed,
engine lamp turns off per the above description. and PTO operation:
174 RENR2238-09
Troubleshooting Section
• “Low Cruise Control Speed Set Limit” • Service brake pedal position (Switch 1)
• “High Cruise Control Speed Set Limit” • Service brake pedal position (Switch 2)
• “Idle Vehicle Speed Limit” Refer to Table 142 for additional information.
Switch Usage.
• “Idle/PTO Bump rpm” Setting For
Transmission Service Service
Style Brake Brake
• “Idle/PTO rpm Ramp Rate” Switch Switch
Clutch Neutral
Parameter
1 2
• “PTO Vehicle Speed Limit”
Manual Option
X X
The vehicle speed calibration can also affect the 1
cruise control, the idle set speed, and the PTO if the Automatic
vehicle speed calibration is incorrectly programmed. X
Option 1
Refer to Troubleshooting, “Customer Specified
Parameters”. Automatic
X X
Option 2
Clutch Switch Automatic
X X X
Option 3
The clutch pedal position switch is normally closed
when the pedal is released. Depressing the clutch Automatic
X X
Option 4
pedal should open the circuit. This switch is OEM
supplied. The clutch pedal position switch is typically Eaton Top 2 X X
a limit switch that is mounted near the pedal. The
clutch pedal position switch is usually adjustable.
If the “Transmission Style” parameter is programmed
to one of the following options, the input for the clutch
The following background information is related
pedal position switch is not used:
to this procedure:
The kickout switch refers to the switch that is used to • Automatic Option 1
exit the cruise control, the PTO, or the idle set speed.
• Automatic Option 2
The operation of the Caterpillar electronic engine
cruise control is similar to the operation of the • Automatic Option 3
cruise controls that are installed in automobiles. The
operation of idle and PTO are similar to the operation • Automatic Option 4
of cruise except that the Idle and the PTO govern
A service brake pedal position (Switch 1) is required
engine rpm instead of vehicle speed.
for all configurations. The service brake pedal
position (Switch 1) connects to the Engine Control
Note: Idle in this procedure is an engine idle rpm
Module (ECM) through connector P1-45. The service
above the programmed low idle rpm. Idle is set
brake pedal position (Switch 2) connects to the ECM
by using the cruise control On/Off switch and the
through connector P1-64. The clutch pedal position
set/resume switch. Refer to Troubleshooting, “PTO
switch connects to the ECM through connector
Switch Circuit - Test” for additional information
P1-22. The neutral switch connects to the ECM
regarding the programmable options for the
through connector P1-62.
dedicated PTO.
g00643881
Illustration 63
Schematic for cruise control switch, service brake pedal position switch 1 and clutch pedal position switch
176 RENR2238-09
Troubleshooting Section
Expected Result:
Results:
Expected Result:
A. Connect Caterpillar Electronic Technician (ET) to • Not OK – The clutch pedal position switch uses
the data link connector. the J1939 data link.
B. Turn the key switch to the ON position. Repair: Verify that the parameter for the clutch
pedal position switch is programmed “J1939 - Body
C. Check the status of the clutch pedal position Controller”, “J1939 - Cab Controller”, or “J1939 -
switch. Instrument Cluster”.
Test Step 3. Inspect Electrical Connectors E. Install the jumper into terminal 22 (Clutch Pedal
and Wiring Position Switch) of the breakout T. Connect
the other end of the jumper to terminal 5 (AP
A. Thoroughly inspect the J1/P1 ECM connector, the Sensor/Switch Sensor Common) of the breakout
firewall bulkhead connector and the terminals for T.
the following switches in the connectors:
F. Turn the key switch to the ON position.
• P1-22 (Clutch Pedal Position Switch)
G. Connect Cat ET to the data link connector.
• P1-5 (AP Sensor/Switch Sensor Common)
H. Access the status for the clutch pedal position
Refer to Troubleshooting, “Electrical Connectors - switch on Cat ET.
Inspect” for details.
I. While the status for the clutch pedal position
B. Perform a 45 N (10 lb) pull test on each of the switch is being monitored on Cat ET, remove the
wires in the ECM connector that are associated jumper from terminal 5 (AP Sensor/Switch Sensor
with the switches. Common). Insert the jumper into terminal 5 (AP
Sensor/Switch Sensor Common).
Refer to Illustration 64.
Expected Result:
C. Check the ECM connector (Allen Head Screw) for
the proper torque of 6.0 N·m (55 lb in). When the jumper wire is installed, the status for
the clutch pedal position switch is “Off”. When the
D. Check the harness and wiring for abrasion and for jumper wire is removed, the status for the clutch
pinch points from the sensor to the ECM. pedal position switch is “On”.
All connectors, pins and sockets are completely • OK – The ECM is functioning properly.
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion or of pinch points. Repair: Remove the breakout T and reconnect the
P1 ECM connector to the ECM.
Results:
Proceed to Test Step 5.
• OK – The harness and connectors appear to be
OK. Proceed to Test Step 4. • Not OK – The ECM is not functioning properly.
• Not OK – There is a problem with the connectors Repair: Perform the following repair:
and/or wiring.
1. Temporarily connect a test ECM.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of 2. Remove the breakout T and reconnect the P1
the seals are properly in place and ensure that the ECM connector to the ECM.
connectors are completely coupled.
3. If the problem is resolved with the test ECM,
Verify that the repair eliminates the problem. reconnect the suspect ECM.
E. Connect Cat ET to the data link connector. When the jumper wire is installed, the status for
the clutch pedal position switch is “Off”. When the
F. Access the status screen on Cat ET. jumper wire is removed, the status for the clutch
pedal position switch is “On”.
G. While the status for the clutch pedal position
switch is being monitored on Cat ET, connect the Results:
switch wires and disconnect the switch wires.
• OK – The problem is in the vehicle wiring between
Expected Result: the bulkhead connector and the switch.
When the switch wires are connected the status Repair: Perform the following repair:
for the clutch pedal position switch is “Off”. When
the switch wires are disconnected the status for the Inspect the vehicle wiring and repair the vehicle
clutch pedal position switch is “On”. wiring, as required. If the problem still exists with
the wiring, send the vehicle to the OEM dealer.
Results:
STOP.
• OK – The wiring between the clutch pedal position
switch and the ECM is OK. • Not OK – The problem is in the vehicle wiring
between the bulkhead connector and the ECM.
Repair: Replace the faulty switch.
Repair: Perform the following repair:
Verify that the repair eliminates the problem.
Inspect the vehicle wiring and repair the vehicle
STOP. wiring, as required. If the problem still exists with
the wiring, send the vehicle to the OEM dealer.
• Not OK – There is a problem in the harness
between the switch and the ECM. Proceed to Test STOP.
Step 6.
The coolant level sensor is an OEM installed • 111-02 Coolant Level signal invalid
component for the vehicle. This sensor is the only
optional sensor for “Engine Monitoring”. “Engine The “Engine Monitoring Lamps” parameter is used in
Monitoring” is a programmable feature of the engine’s order to determine if a single warning lamp is used
Electronic Control Module (ECM). The sensor for the engine monitoring system or if discrete lamps
is selectable through a customer programmable are used for each monitored condition. If the “Engine
parameter and the customer programmable Monitoring Lamps” parameter is programmed to
parameter may be protected by customer passwords. “Warning Lamp”, a single lamp is connected to
Some OEM installed coolant level sensors are not P1-29. If the “Engine Monitoring Lamps” parameter is
connected to the ECM. Do not confuse an OEM programmed to “Option 1” and a coolant level sensor
installed “Coolant Level Sensor” that is independent is installed, then a discrete lamp for low coolant level
of “Engine Monitoring” with the “Coolant Level is connected to P1-30. The “Coolant Level Sensor”
Sensor” that is used for “Engine Monitoring”. parameter must be programmed for the lamp to
operate correctly.
The sensor operates as a coolant level sensor. The
sensor indicates the presence or the absence of Test Step 1. Check for an Active Coolant
coolant at the sensor probe. There are two options if Level Sensor Fault
a coolant level sensor is installed.
A. Connect the Caterpillar Electronic Technician (ET)
• “4-pin” to the data link connector.
If a coolant level sensor is not installed or the coolant C. Check for active diagnostic codes on Cat ET.
level sensor is independent from the ECM, the
parameter should be programmed to “None”. Expected Result:
The sensor is powered from the ECM through the • 111-02 Coolant Level signal invalid
ECM connector P1-2 (+5 VDC). The signal wires
for the coolant level sensor are connected to pins • 111-03 Coolant Level voltage high
P1-54 (Coolant Level Low) and to P1-49 (Coolant
Level Normal) on the ECM. The sensor common • 111-04 Coolant Level voltage low
is connected to the ECM connector P1-5 (AP
Sensor/Switch Sensor Common). Results:
If coolant is present at the sensor probe, “Coolant • OK – 111-02, 111-03, or 111-04 is active. Proceed
Level Low” has an output of near 0 VDC. If coolant is to Test Step 2.
present at the sensor probe, “Coolant Level Normal”
has an output near +5 VDC. If coolant is not present • Not OK – 111-01, 111-11, or 111-14 is active.
at the sensor probe, the “Coolant Level Low” output
would be near +5 VDC. If coolant is not present at Repair: Refer to Troubleshooting, “Troubleshooting
the sensor probe, the “Coolant Level Normal” output with a Diagnostic Code” for the proper
would be near 0 VDC. troubleshooting procedure.
The sensor is powered with +5 VDC from the • No Codes – If none of the specified diagnostic
ECM through ECM connector P1-26. The sensor is codes are present, clear all diagnostic codes. If
also connected to P1-5 (AP Sensor/Switch Sensor a problem is still suspected with the coolant level
Common). sensor, proceed to Test Step 2.
Resistance through the sensor is varied by the Test Step 2. Determine the type of
coolant level. The voltage at the normal operating Coolant Level Sensor
range is between 0.75 VDC and 1.75 VDC.
A. Check the coolant level sensor in order to
Note: The “Coolant Level Sensor” is set when the determine the type of sensor that is installed on
coolant level sensor is programmed to “4-Pin” or the vehicle.
“2-wire Float Sensor”. If this parameter is set and a
sensor is not installed, the following diagnostic code Expected Result:
will be logged:
A “4-pin” or “2-wire Float Sensor” is installed.
180 RENR2238-09
Troubleshooting Section
Results:
• None
Repair: If a coolant level sensor is not installed,
change the “Coolant Level Sensor” parameter to
“None”.
STOP.
g00650999
Illustration 65
Schematic for “4-pin” coolant level sensor
RENR2238-09 181
Troubleshooting Section
• P1-2
• P1-5
• P1-49
• P1-54
Refer to Illustration 66.
Expected Result:
Results:
Illustration 66
g01104384 Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
Terminal locations for ECM for “4-pin” coolant level sensor
the seals are properly in place and ensure that the
(2) +5 VDC connectors are completely coupled.
(5) AP sensor/switch sensor common
(49) Normal coolant level
(54) Low coolant level Verify that the repair eliminates the problem. Clear
all diagnostic codes.
STOP.
G. Measure the voltage between the wire jumper in If the problem returns with the suspect ECM,
P1-2 and the wire jumper in P1-5. permanently replace the ECM.
H. Turn the key switch to the OFF position. Verify that the repair eliminates the problem.
Repair: Perform the following steps: C. Turn the key switch to the ON position.
1. Disconnect the J1/P1 ECM connector. D. While the jumper wire is in place, access the
status for “Coolant Level” on Cat ET.
2. Check continuity of the wire for the 5 VDC
between the ECM and the sensor connector. E. Check for active diagnostic codes.
a. If the wire does not have continuity between F. Turn the key switch to the OFF position.
the ECM and the sensor connector, replace
the wire. Expected Result:
3. Check continuity of the wire for the sensor The status for “Coolant Level” indicates “LOW” while
common between the ECM and the sensor the jumper wire is in place. A 111-01 Low Coolant
connector. Level Warning is active while the jumper wire is in
place.
RENR2238-09 183
Troubleshooting Section
• Not OK – The status for “Coolant Level” does not F. Monitor the status for “Coolant Level” while the
indicate “LOW” while the jumper wire is in place. jumper is being inserted and removed. Wait for 30
Proceed to Test Step 8. seconds between the insertion of the jumper and
the removal of the jumper. The status for “Coolant
Test Step 7. Simulate a “NORMAL” Level” will display “Low” while the jumper wire is in
Coolant Level place. Also, the following diagnostic code should
be active:
A. Turn the key switch to the OFF position.
• 111-01 Low Coolant Level Warning
B. Insert a jumper wire between Terminal A (Coolant
Level Low) and Terminal B (AP Sensor/Switch Note: 111-14 Low Coolant Level Warning will be
Sensor Common) at the harness connector. active during the first six hours of engine operation.
D. Check for active diagnostic codes on Cat ET. H. Monitor the status for “Coolant Level” on Cat ET.
Insert a jumper wire between P1-54 (Coolant
E. Check the status for “Coolant Level” on Cat ET. Level Low) and P1-5 (AP Sensor/Switch Sensor
Common) of the breakout T.
Expected Result:
I. Monitor the status for “Coolant Level” while the
There are no active diagnostic codes while the jumper is being inserted and removed. Wait for 30
jumper wire is in place. The status for “Coolant Level” seconds between the insertion of the jumper and
displays “OK”. the removal of the jumper. The status for “Coolant
Level” will display “OK” while the jumper wire is in
Results: place. Also, there should be no active diagnostic
codes.
• OK – The harness and the ECM are working
correctly. Expected Result:
Repair: Remove the jumper wire. The “Coolant Level” status behaves in the following
manner:
Replace the sensor and reconnect the harness to
the sensor. • The status for “Coolant Level” indicates “Low”
when the jumper wire is installed between P1-49
Verify that the repair eliminates the problem. and P1-5. Also, 111-01 Low Coolant Level Warning
is active.
STOP.
Note: 111-14 Low Coolant Level Warning will be
• Not OK – The ECM did not see the short circuit. active during the first six hours of engine operation.
Proceed to Test Step 8.
• The status for “Coolant Level” indicates “OK” when
Test Step 8. Check the ECM for Proper the jumper wire is installed between P1-54 and
Operation P1-5. Also, there are no active diagnostic codes.
B. Install a breakout T between the J1 and P1 ECM • OK – The ECM is functioning properly.
connectors.
Repair: Repair the harness or replace the harness,
C. Fabricate two jumper wires 100 mm (4 inch) long. as required.
Crimp a Deutsch pin to both ends of each wire.
Verify that the repair eliminates the problem. Clear
D. Turn the key switch to the ON position. all diagnostic codes.
STOP.
• Not OK
184 RENR2238-09
Troubleshooting Section
STOP.
g00907746
Illustration 68
Schematic for “2-wire Float Sensor”
RENR2238-09 185
Troubleshooting Section
Expected Result:
Results:
STOP.
Expected Result:
g01104386
Illustration 69
One of the following diagnostic codes is active.
Terminal locations for ECMfor “2-wire Float Sensor”
(5) AP sensor/switch sensor common
(26) Coolant level input
• 111-02 Coolant Level signal invalid
A. Thoroughly inspect the J1/P1 ECM connector, • 111-03 Coolant Level voltage high
the connector for the coolant level sensor and
the terminals for the coolant level sensor in the • 111-04 Coolant Level voltage low
connectors. Refer to Troubleshooting, “Electrical Results:
Connectors - Inspect” for details.
B. Perform a 45 N (10 lb) pull test on each of the • 111-02 – A fault for the coolant level sensor is
active. Proceed to Test Step 11.
wires in the ECM connector that are associated
with the following connections:
• 111-03 – A “voltage high” diagnostic code (open
circuit) is active at this time. Proceed to Test Step
• P1-26 (Coolant level input) 15.
• P1-5 (AP sensor/switch sensor common) • 111-04 – A “voltage low” diagnostic code (short
circuit) is active at this time. Proceed to Test Step
Refer to Illustration 69. 13.
C. Check the ECM connector (allen head screw) for
Test Step 11. Disconnect the Coolant
the proper torque of 6.0 N·m (55 lb in).
Level Sensor and Check the Supply
D. Check the harness and wiring for abrasion and for
Voltage (+5 VDC)
pinch points from the sensor to the ECM.
A. Turn the key switch to the OFF position.
186 RENR2238-09
Troubleshooting Section
B. Disconnect the coolant level sensor from the Refer to Illustration 70.
harness.
Expected Result:
C. Use a multimeter to measure the voltage at the
harness connector. The measured voltage is between 4.5 VDC and 5.5
VDC.
D. Turn the key switch to the ON position.
Results:
Expected Result:
• OK – The problem is located in the harness wiring.
The measured voltage is between 4.5 VDC and 5.5
VDC. Repair: Repair the wiring or replace the wiring,
as required.
Results:
Verify that the repair eliminates the problem.
• OK – The correct voltage is reaching the sensor.
STOP.
Repair: Replace the sensor.
• Not OK – The problem is on the ECM side.
STOP.
Repair: Temporarily connect a test ECM. Ensure
• Not OK – The correct voltage is not reaching the that the “Engine Monitoring” and the “Coolant Level
sensor. Proceed to Test Step 12. Sensor” are programmed to match the old ECM.
Check the test ECM by measuring the voltage
Test Step 12. Disconnect the Terminal at the breakout T from terminal 26 to terminal 5
for the Sensor Supply (+5 VDC) from the again. If the problem is resolved with the test ECM,
ECM Connector reconnect the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM.
STOP.
A. Turn the key switch to the OFF position. 111-03 Coolant Level voltage high is now active.
C. Remove the wires from P1-26 and P1-5 at the • OK – There is a “voltage high” diagnostic code
ECM. (open circuit) when the connector is disconnected.
D. Install a breakout T between ECM connector J1 Repair: There is a short in the coolant level
and ECM connector P1. sensor. Replace the sensor. Verify that the repair
eliminates the problem.
E. Turn the key switch to the ON position.
STOP.
F. Measure the voltage at the breakout T between
terminal 26 and terminal 5.
RENR2238-09 187
Troubleshooting Section
• OK – There is a short circuit in the harness D. Turn the key switch to the ON position. Wait at
between the ECM and the coolant level sensor. least 15 seconds for activation of the diagnostic
Proceed to Test Step 17. codes.
• Not OK – The “voltage low” diagnostic code (short E. Check for active diagnostic codes on Cat ET.
circuit) is still present.
Expected Result:
Repair: Perform the following procedure:
111-04 Coolant Level voltage low is now active.
1. Temporarily connect a test ECM. Refer to
Troubleshooting, “Programming Parameters” Results:
before replacing the ECM.
• OK – There is a problem in the harness between
2. If the test ECM fixes the problem, reconnect the ECM and the sensor. Proceed to Test Step 17.
the suspect ECM. If the problem returns,
permanently install the new ECM. • Not OK – There is still a “voltage high” diagnostic
code (open circuit).
STOP.
Repair: Perform the following procedure:
Test Step 15. Create a Short Circuit at the
Sensor 1. Temporarily connect a test ECM. Refer to
Troubleshooting, “Programming Parameters”
A. Turn the key switch to the OFF position. before replacing the ECM.
B. Disconnect the coolant level sensor at the sensor. 2. If the test ECM fixes the problem, reconnect
the suspect ECM. If the problem returns,
C. Fabricate a jumper wire between terminal 1 and permanently install the new ECM.
terminal 2 of the connector for the coolant level
sensor in order to create a short circuit. STOP.
D. Turn the key switch to the ON position. Wait at Test Step 17. Bypass the Harness Wiring
least 15 seconds for activation of the diagnostic between the ECM and the Solenoid
codes.
A. Turn the key switch to the OFF position.
E. Check for active diagnostic codes on Cat ET.
B. Remove the wires from P1-26 and P1-5. Also
Expected Result: remove the wires from the connector for the
coolant level sensor.
111-04 Coolant Level voltage low is now active.
188 RENR2238-09
Troubleshooting Section
C. Fabricate two jumper wires to reach from the Check the following items in order to determine if a
ECM to the connector for the coolant level sensor. vehicle is using the ECM cooling fan circuit:
Crimp Deutsch sockets to both ends of each wire.
• The “Fan Control Type” parameter must be
D. Connect one wire between P1-26 and terminal programmed to “On/Off”, “Three-Speed Fan”, or
1 of the coolant level sensor. Connect the other “Variable Speed Fan Option S”. The Caterpillar
wire between P1-5 and terminal 2 of the coolant factory default is None.
level sensor.
• A wire is present in the ECM vehicle harness
E. Turn the key switch to the ON position. Wait at connector J1/P1:11 which is Output 5 (Cooling Fan
least 15 seconds for activation of the diagnostic Solenoid). This occurs if an “On/Off” type of fan
codes. is used.
• OK – There was a problem in the harness. • Perform the Special Test for the “On/Off Cooling
Fan” or the special tests for the “Three-Speed
Repair: Permanently replace the faulty wiring. Fan”. Access each menu in the order that follows:
Clear all diagnostic codes. Verify that the repair “Diagnostics”, “Diagnostic Tests”, and “Special
eliminates the problem. Test”. Activating and then deactivating the circuit
should cause the air solenoid to click if the circuit
STOP. is working properly.
• Not OK – Bypassing the harness did not fix the The following background information is related
problem. to this procedure:
i01907624
• Intake Manifold Air Temperature Sensor
The output for the cooling fan is intended to connect The last four items in the list are programmed by
directly to the circuit for the cooling fan solenoid. the customer in the “Configuration” screen on the
The solenoid and clutch configuration must be Caterpillar Electronic Technician (Cat ET).
selected in order for the ECM output to turn the fan
“Off”. The fan will remain on for a minimum of 30 Note: With OCT99 and newer software, the ECM
seconds. The fan will not remain on for 30 seconds will turn the cooling fan “Off” for 10 seconds during
during engine start-up. The fan will not remain on an engine shutdown.
for 30 seconds if the “A/C Pressure Switch Fan
On Time” is programmed to less than 30 seconds. Cooling Fan OFF Conditions
During engine start-up, the ECM will keep the fan
on for two seconds after the engine has reached The cooling fan will be turned off by the ECM if engine
the programmed low idle (600 to 750 rpm). The fan rpm exceeds 2300 rpm or when all the following
will be on continuously if the electrical circuit to the circumstances are met:
cooling fan air solenoid valve has an open circuit or if
the ECM fan relay circuit is opened. • The engine coolant temperature for the C-10 or the
C-12 engines is less than 92 °C (198 °F).
Cooling Fan On Conditions (On/Off Fan)
• The engine coolant temperature for the 3406E,
The ECM will turn on the cooling fan, if any of the C-15, C-16 and C-18 engines is less than 98 °C
following conditions are met: (208 °F).
• Engine speed is less than 2250 rpm. • The fan has been on for at least 30 seconds.
• The engine is not running. • The intake manifold air temperature is less than
53 °C (127 °F).
• The engine is cranking.
• The “Fan with Engine Retarder in High Mode”
• The temperature of the coolant temperature sensor strategy is not active.
for the C-10 and the C-12 engines is greater than
96 °C (205 °F). • The “A/C High Pressure Switch Strategy” is not
active.
• The temperature of the coolant temperature sensor
for the 3406E, C-15, C-16 and C-18 engines is • The “PTO Activates Cooling Fan” strategy is not
greater than 102 °C (216 °F). active.
• Active diagnostic code for the coolant temperature • The manual fan override switch is off.
sensor
Three-Speed Fan
• The intake manifold air temperature is greater than
87 °C (189 °F). The Three-Speed Fan operates in three modes:
• Coolant temperature
• Intake manifold air temperature g00783987
Illustration 71
• Engine operating conditions Trip Points for a Three-Speed Fan (C-10 and C-12)
Table 143
Trip Points for a Three-Speed Fan (C-10 and C-12)
Intake Manifold Air Intake Manifold Air
Intake Manifold Air Temperature with Temperature with
Mode Coolant Temperature
Temperature Boost that is Less Boost that is Greater
Than 70 kPa (10 psi) Than 70 kPa (10 psi)
Brake Mode to Slip
90 °C (194 °F) 53 °C (127 °F)
Mode
Slip Mode to Direct
95 °C (203 °F) 81 °C (178 °F) 65 °C (149 °F)
Mode
Direct Mode to Slip
92 °C (198 °F) 53 °C (127 °F)
Mode
Slip Mode to Brake
80 °C (176 °F) 0 °C (32 °F)
Mode
g00784050
Illustration 72
Trip Points for a Three-Speed Fan (3406E, C-15, C-16 and C-18)
192 RENR2238-09
Troubleshooting Section
Table 144
Trip Points for a Three-Speed Fan (3406E, C-15, C-16 and C-18)
Intake Manifold Air Intake Manifold Air
Intake Manifold Air Temperature with Temperature with
Mode Coolant Temperature
Temperature Boost that is Less Boost that is Greater
Than 70 kPa (10 psi) Than 70 kPa (10 psi)
Brake Mode to Slip
90 °C (194 °F) 53 °C (127 °F)
Mode
Slip Mode to Direct
103 °C (217 °F) 81 °C (178 °F) 65 °C (149 °F)
Mode
Direct Mode to Slip
97 °C (207 °F) 53 °C (127 °F)
Mode
Slip Mode to Brake
80 °C (176 °F) 0 °C (32 °F)
Mode
The following conditions will also cause the Operation of the cooling fan control can be controlled
Three-Speed Fan to operate in Direct Mode: independently of the ECM. The OEM installed air
conditioning high pressure switch may be used for
• The engine retarder is on and the engine retarder independent cooling fan control. A cab mounted
selector switch is in the High position. The “Fan override switch in the solenoid circuit can also
with Engine Retarder in High Mode” parameter operate the cooling fan.
must be programmed to “Yes”.
Troubleshooting
• The PTO On/Off Switch is on. The “PTO Activates
Cooling Fan” parameter is programmed to “Yes”. Before troubleshooting the cooling fan circuit,
determine the type of fan drive system that is used.
• The A/C high pressure switch is active. The “A/C The fan drive can use the following controls in order
Pressure Switch Fan On-Time” is programmed to a to control the fan:
value that is greater than 0 seconds.
• Normally open with a pneumatic air solenoid
Note: There may be an initial delay before the fan is
in the Direct mode. Activation of the fan is dependent • Normally closed with a pneumatic air solenoid
on the operating conditions.
• Normally open with an electrically controlled
A/C High Pressure Switch Input Connected to solenoid
A/C Control Unit.
• Normally closed with an electrically controlled
An OEM supplied air conditioning control may be solenoid
used. The air conditioning control determines when
the cooling fan should operate. This is based on the The following OEM installed components may affect
following input information: A/C high pressure switch, the operation of the cooling fan in some applications:
low pressure switch, and evaporator thermostat. The
fan output for the air conditioning control is designed • OEM installed, normally open relay
to interface with the ECM. The fan output may be
connected to the input for the A/C high pressure • The A/C high pressure switch is connected to
switch. The input for the A/C high pressure switch is the ECM or the A/C high pressure switch is
Input 11 of the ECM Connector J1/P1:41. The fan is independent of the ECM.
in the ON position when the A/C high pressure switch
is in the OPEN position. This type of control has a • Cab mounted manual override switch
time delay. Typically, the “A/C Switch Fan On-Time” is
programmed to one second since the air conditioning • A timer that keeps the fan in the ON position
control provides an additional time delay.
• Cooling fan air solenoid valve
The Cooling Fan Control can be Operated
Independently of the ECM.
RENR2238-09 193
Troubleshooting Section
g00675576
Illustration 73
This schematic represents the ON/OFF fan with a direct solenoid connection to the ECM and the A/C Pressure Switch connected to
the ECM input.
g00675579
Illustration 74
This schematic represents the ON/OFF fan with direct solenoid connection to the ECM and the A/C High Pressure Switch not connected to
the ECM input.
194 RENR2238-09
Troubleshooting Section
g00675587
Illustration 75
This schematic represents the ON/OFF fan with direct solenoid connection to the ECM and the A/C Control Unit is connected to the ECM input.
g00675591
Illustration 76
This schematic represents the ON/OFF fan with a normally closed relay and the A/C High Pressure Switch not connected to the ECM input.
RENR2238-09 195
Troubleshooting Section
g00675623
Illustration 77
This schematic represents the ON/OFF fan with a normally open relay connection and an A/C High Pressure Switch connected to the ECM input.
g00675640
Illustration 78
This schematic represents the ON/OFF fan with a normally open relay connection and an A/C High Pressure Switch connected to the ECM input.
196 RENR2238-09
Troubleshooting Section
g00675642
Illustration 79
This schematic represents the ON/OFF fan with a normally closed relay connection and an A/C High Pressure Switch connected to
the ECM input.
g00675646
Illustration 80
Three-Speed Fan with Direct Solenoid Connection
RENR2238-09 197
Troubleshooting Section
g00675876
Illustration 81
Terminal locations for the ECM
A. Thoroughly inspect the ECM Vehicle Harness Refer to Illustration 81 for terminal locations for
Connector J1/P1, the A/C High Pressure Switch the ECM.
Connector, the connections to the Cooling Fan
Solenoid, and the firewall bulkhead connectors. Expected Result:
Refer to Troubleshooting, “ Electrical Connectors -
Inspect” for details. All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring
B. Perform a 45 N (10 lb) pull test on each of the should be free of corrosion, abrasion or pinch points.
wires in the ECM connector that are associated
with the following connections: Results:
Test Step 2. Check the Programming of • Not OK – The status of the A/C high pressure
the “Fan Control Type” Parameter switch is “Unavailable”. The ECM is not
programmed to use the A/C high pressure switch.
A. Connect Cat ET to the data link connector. Proceed to Test Step 5.
B. Check the “Fan Control Type” parameter. Ensure Test Step 4. Check the Operation of the
that the parameter is programmed to either A/C Pressure Switch
“On-Off” or to “Three-Speed Fan”, if the ECM
is used to control the fan. If the parameter is A. Connect Cat ET to the data link connector.
programmed to “None” and the ECM is connected
to the fan, then the fan will always be ON. B. Turn the key switch to the ON position.
A. Connect Cat ET to the data link connector. The status screen indicates that the “A/C High
Pressure Switch” is turning to the ON position. Then,
B. Turn the key switch to the ON position. the “A/C High Pressure Switch” is turning to the OFF
position.
C. View the following customer specified parameters.
Results:
• “Fan Control Type”
• OK – The A/C high pressure switch harness is OK.
• “A/C Switch Fan On-Time” Proceed to Test Step 6.
Ensure that the “A/C Switch Fan On-Time” is • Not OK – Proceed to Test Step 7.
programmed to a greater value than “0”. If the
“A/C Switch Fan On-Time” is programmed to “0”, Test Step 5. Check Active Codes or
then the “A/C High Pressure Switch Input” (Input Logged Codes
11) is not used.
A. Connect Cat ET to the data link connector.
Note: If the “Fan Control Type” parameter indicates
“None”, then the cooling fan driver is not used. B. Turn the key switch to the ON position.
View the “A/C High Pressure Switch” status on C. Access the “Logged Diagnostic Codes” and the
Cat ET. “Active Diagnostic Codes” on Cat ET.
The status of the A/C high pressure switch indicates • 110-00 High Coolant Temperature Warning
“ON” or “OFF”.
• 110-11 Very High Coolant Temperature
Results:
• 110-03 Coolant Temp Sensor Open Circuit
• OK – The status of the A/C high pressure switch is
on or off. Proceed to Test Step 4. • 110-04 Coolant Temp Sensor Short Circuit
RENR2238-09 199
Troubleshooting Section
Record any logged diagnostic codes. Record any Repair: Check the A/C pressure or send the
active diagnostic codes. vehicle to the OEM dealer for repairs.
Results:
STOP.
STOP.
Expected Result:
Results:
g00676088
Illustration 82
Connector for the Breakout T
A. Connect Cat ET to the data link connector. Repair: If a problem still exists, then the problem
is in the OEM wiring. Repair the problem or send
B. Turn the key switch to the OFF position. the vehicle to the OEM dealer for repair. Verify that
the repair eliminates the problem.
C. Disconnect the ECM vehicle harness connector
J1/P1. STOP.
J. Remove the jumper wire and then insert the B. Turn the key switch to the ON position.
jumper wire. At the same time, watch the “A/C
High Pressure Switch” status on Cat ET. C. Monitor the status for “Engine Coolant
Temperature” and “Intake Manifold Air
Expected Result: Temperature” in order to verify that the
temperatures are changing as the engine warms
The status screen indicates that the “A/C High up.
Pressure Switch” status is off when the jumper wire is
in place. The status screen indicates “ON” when the Expected Result:
jumper wire is removed.
The “Engine Coolant Temperature” and the “Intake
Results: Manifold Air Temperature” appear to have the correct
reading.
• OK – The ECM is OK.
RENR2238-09 201
Troubleshooting Section
Results:
STOP.
g00676097
Illustration 83
Connector for the breakout T
B. Turn the key switch to the ON position. • OK – The cooling fan circuit from the ECM to the
solenoid is functioning properly at this time.
C. Access the “On-Off Cooling Fan Special Test”
for a fan that cycles “Off” and “On”. Access Repair: If a problem still exists, then the problem is
the “Three-Speed Fan Slip Output” or the in the OEM wiring. Repair the problem or send the
“Three-Speed Fan Brake Output Special Test” for vehicle to the OEM dealer for repair.
a Three-Speed Fan. Access each menu in the
order that follows: Diagnostics, Diagnostic Tests, Verify that the repair eliminates the problem.
and Special Test.
STOP.
NOTE: If any override switches are installed, the
switch must be in the OFF position. • Not OK – Proceed to Test Step 10.
D. Cycle the “Special Test” to the ON position and to Test Step 10. Check the ECM
the OFF position. Listen for the solenoid to click.
You may need to be near the engine in order to A. Turn the key switch to the OFF position.
hear the click of the solenoid.
B. Disconnect the ECM vehicle harness connector
Expected Result: J1/P1.
An audible clicking is heard, and the solenoid C. Remove terminal 11 (Output 5) from the vehicle
appears to be operating properly. harness connector P1.
202 RENR2238-09
Troubleshooting Section
D. Connect a breakout T between the J1 and P1 Repair: Temporarily connect a test ECM. Use the
ECM connectors. special test to check the ECM cooling fan circuit. If
the problem is resolved with the test ECM, install
E. Connect a voltage test lamp between terminal 11 the suspect ECM. If the problem returns with the
(Output 5) and terminal 67 (Negative Battery) of suspect ECM, replace the ECM.
the breakout T.
Verify that the repair eliminates the problem.
F. Turn the key switch to the ON position.
STOP.
G. For a fan that cycles on and off, access the
“On/Off Cooling Fan Special Test” on Cat ET.
i02183503
Cycle the “Three-Speed Fan Slip Output” to the Use this procedure if one of the following switches is
ON position and to the OFF position. At the same suspected of preventing normal operation of cruise
time, watch the voltage test lamp. control, idle set speed, or PTO operation:
Connect the voltage test lamp to terminal 13 • Cruise control On/Off switch
(Output 4) and terminal 67 (-Battery) of the
breakout T. • Cruise control set/resume switch
Cycle the “Three-Speed Fan Brake Output” to the • Cruise control pause switch
ON position and to the OFF position. At the same
time, watch the voltage test lamp. The following switch circuits can also prevent the
correct operation of the cruise control, idle set speed
Refer to Illustration 83 for the location of Output 4 or PTO operation:
and Output 5.
• Service brake pedal position (Switch 1)
NOTE: A multimeter can not be used in place of
the voltage test lamp when the ECM output is • Service brake pedal position (Switch 2)
tested.
• Neutral switch
Expected Result:
• PTO On/Off switch
The voltage test lamp turns to the ON position when
the test is “Active”. The voltage test lamp turns to the The switches are described in the respective circuit
OFF position when the test is “Not Active”. tests in Troubleshooting.
• “PTO Kickout Vehicle Speed Limit” The adaptive cruise control is a J1939 based option.
A radar is used in order to detect vehicles. When a
The vehicle speed calibration can also affect the vehicle is detected the cruise control set speed is
cruise control, the idle set speed, and the PTO if the reduced in order to maintain a following distance.
vehicle speed calibration is incorrectly programmed. This option must be enabled with the Caterpillar
Refer to Troubleshooting, “Customer Specified Electronic Technician (ET). Customer passwords are
Parameters”. required to enable this option.
Cruise Control On/Off Switch If a problem is suspected with the adaptive cruise
control, the feature can be disabled. Toggle the
This switch must be on before cruise control or cruise control switch to the OFF position and to the
controlled idle can be activated. This switch is on ON position twice within 10 seconds.
when the switch is closed. When the switch is closed
the following terminals are connected: The following background information is related
to this procedure:
• P1-59 (cruise control On/Off switch)
The kickout switch refers to the switch that is used to
• P1-5 (AP sensor/switch sensor common) exit the cruise control, the PTO, or the idle set speed.
Note: If the vehicle is programmed to use the The operation of the Caterpillar electronic engine
dedicated PTO, the PTO On/Off switch overrides the cruise control is similar to the operation of the
cruise control On/Off switch. The PTO On/Off switch cruise controls that are installed in automobiles. The
will override the cruise control On/Off switch if the operation of idle and PTO are similar to the operation
vehicle speed is within the programmed range for the of cruise except that the idle and the PTO govern
“PTO Kickout Vehicle Speed Limit” parameter. engine rpm instead of vehicle speed.
Table 145
Switch Usage.
Setting For
Transmission Service Service
Style Brake Brake
Clutch Neutral
Parameter Switch Switch
1 2
Manual X X
Automatic
X
Option 1
Automatic
X X
Option 2
Automatic
X X X
Option 3
Automatic
X X
Option 4
Eaton Top 2 X X
• Automatic Option 1
• Automatic Option 2
• Automatic Option 3
• Automatic Option 4
A service brake pedal position (Switch 1) is required
for all configurations. The service brake pedal
position (Switch 1) connects to the ECM through
connector P1-45. The service brake pedal position
(Switch 2) connects to the ECM through connector
P1-64. The clutch pedal position switch connects to
the ECM through connector P1-22. The neutral switch
connects to the ECM through connector P1-62.
RENR2238-09 205
Troubleshooting Section
g00643881
Illustration 84
Schematic for cruise control switch, service brake pedal position switch 1 and clutch pedal position switch
• Not OK – The cruise control On/Off switch is not B. Verify that the “Cruise Control On/Off Switch”
working properly. Proceed to Test Step 3. and the “Cruise Control Set/Resume/Accel/Decel
Switch” parameters are programmed to reflect the
Test Step 2. Check the Status of the proper wiring.
Set/Resume Switch
Expected Result:
A. Put the cruise control On/Off switch in the On
position. The cruise control switches are wired directly to the
ECM.
B. Monitor the status for the “Cruise Control
Set/Resume/Accel/Decel Switch P1-35 & 44” Results:
while the set/resume switch is cycled.
• OK – The cruise control switches are wired directly
to the ECM.
206 RENR2238-09
Troubleshooting Section
Repair: Verify that the “Cruise Control Test Step 4. Inspect Electrical Connectors
On/Off Switch” and the “Cruise Control and Wiring
Set/Resume/Accel/Decel Switch” parameters are
programmed correctly.
STOP.
g01104756
Illustration 85
Terminals on the P1 ECM connector
(5) AP sensor/switch sensor common
(35) Set
(44) Input for resume switch
(59) Cruise control ON/OFF switch
Expected Result:
Results:
STOP.
A. Turn the key switch to the OFF position. F. Turn the key switch to the ON position.
B. Fabricate a jumper wire 100 mm (4 inch) long. G. While the status for the suspect switch is being
Crimp a Deutsch pin to both ends of the wires. monitored on the status screen of Cat ET,
slowly remove the jumper from terminal 5 and
C. Disconnect vehicle harness connector P1 from slowly insert the jumper from terminal 5 (AP
the ECM. Sensor/Switch Sensor Common) of the breakout
T.
D. Connect a 140-2266 Cable As (70-PIN
BREAKOUT) between the J1 and P1 ECM Refer to Table 146.
connectors.
H. Remove the breakout T and reconnect the J1 and
E. Install the jumper into the suspect switch socket P1 ECM connectors.
of the breakout T. Connect the other end of the
jumper to ECM connector P1-5 (AP Sensor/Switch
Sensor Common) of the breakout T.
208 RENR2238-09
Troubleshooting Section
Expected Result:
Results:
STOP.
B. Find the suspect switch in the vehicle. • OK – The switch status changes correctly.
C. Disconnect the wires from the suspect switch Repair: Perform the following repair:
terminals.
Replace the faulty switch.
D. Turn the key switch to the ON position.
Verify that the repair eliminates the problem.
E. While the status for the suspect switch is being
monitored on the status screen of Cat ET, connect STOP.
the suspect switch wires and disconnect the
suspect switch wires. • Not OK – There is a problem in the harness
between the switch and the ECM. Proceed to Test
Refer to Table 147. Step 7.
Expected Result:
A. Turn the key switch to the OFF position. Inspect the vehicle wiring and repair the vehicle
wiring, as required. If the problem still exists with
B. Fabricate a jumper wire 100 mm (4 inch) long. the wiring, send the vehicle to the OEM dealer.
Crimp a Deutsch pin on both ends of the wires.
STOP.
C. Find the terminal for the suspect switch and
the sensor common on the engine side of the
i02183568
bulkhead connector.
F. While the status for the suspect switch is being System Operation Description:
monitored on the status screen of Cat ET, remove
the jumper wire between the two terminals and Use this procedure under the following situation:
insert the jumper wire between the two terminals.
The circuit for the diagnostic enable switch is
Refer to Table 148. suspected of incorrect operation.
The switch status changes per the information in The diagnostic enable switch is used to prompt
Table 148. diagnostic flash codes on the check engine lamp.
For more information, refer to the “Flashing Out
Results: Diagnostic Flash Codes” section in Troubleshooting,
“Check Engine Lamp Circuit - Test”. If the “Diagnostic
• OK – The problem is in the vehicle wiring between Enable Switch” parameter is programmed to
the bulkhead connector and the switch. “None” (default), then the feature is not used. If the
“Diagnostic Enable Switch” parameter is programmed
Repair: Perform the following repair: to J1/P1:46, then the feature is available and the
switch circuit should be connected to P-46 Engine
Inspect the vehicle wiring and repair the vehicle Control Module (ECM) vehicle harness connector.
wiring, as required. If the problem still exists with
the wiring, send the vehicle to the OEM dealer.
STOP.
g00682326
Illustration 86
Schematic for Diagnostic Enable Switch
Expected Result:
Results:
STOP.
B. Turn the key switch to the On position. • OK – The diagnostic enable switch is wired directly
to the ECM. Proceed to Test Step 3.
Repair: Verify that the “Diagnostic Enable” Test Step 4. Check the Switch Circuit for
parameter is programmed to “J1939 - Body the ECM
Controller”, “J1939 - Cab Controller”, or “J1939 -
Instrument Cluster”.
STOP.
C. Check the ECM connector (Allen Head Screw) for A. Turn the key switch to the OFF position.
the proper torque of 6.0 N·m (55 lb in).
B. Install a 140-2266 Cable As (70-PIN
D. Check the harness and the wiring for abrasion and BREAKOUT) between the J1 and P1 ECM
pinch points from the battery to the ECM. Then, connectors.
check from the ignition key switch to the ECM.
C. Fabricate a jumper wire 100 mm (4 inch) long.
Refer to Illustration 87 for terminal locations for Crimp a Deutsch pin to both ends of the wire.
the ECM.
D. Insert the jumper wire into terminal 46 (Diagnostic
Expected Result: Enable Switch Input) of the breakout T. Connect
the other end of the jumper wire to terminal 5 (AP
All connectors, pins and sockets are completely Sensor/Switch Sensor Common) of the breakout
coupled and/or inserted and the harness and wiring T.
are free of corrosion, of abrasion or of pinch points.
E. Turn the key switch to the ON position.
Results:
F. While the status for “Diagnostic Enable” is
• OK – The harness and connectors appear to be monitored on Cat ET, remove the jumper wire and
OK. Proceed to Test Step 1. insert the jumper wire from terminal 5.
• Not OK – There is a problem with the connectors G. Remove the breakout T and reconnect the J1/P1
and/or wiring. ECM connector.
Verify that the repair eliminates the problem. F. While the status for “Diagnostic Enable” is
monitored, remove the jumper wire and insert the
STOP. jumper wire at the bulkhead connector.
C. Insert the jumper wire between the two terminals • OK – The status for “Diagnostic Enable” is correct.
of the diagnostic enable switch. The problem is in the vehicle wiring between the
bulkhead connector and the switch. Inspect the
D. Turn the key switch to the ON position. vehicle wiring and then repair the vehicle wiring.
Otherwise, send the vehicle to the OEM dealer for
E. While the status for “Diagnostic Enable” is repair. Verify that the original condition is resolved.
monitored, remove the jumper wire and insert the STOP.
jumper wire at the switch terminals.
• Not OK – The status for “Diagnostic Enable” is
Expected Result: not correct. The problem is in the vehicle wiring
between the bulkhead connector and the ECM.
The status for “Diagnostic Enable” is “On” when the Inspect the vehicle wiring and then repair the
jumper wire is in place. The status for “Diagnostic vehicle wiring. Otherwise, send the vehicle to
Enable” is “Off” when the jumper wire is removed. the OEM dealer for repair. Verify that the original
condition is resolved. STOP.
Results:
i02375521
• OK – The status for “Diagnostic Enable” is correct.
Repair: Replace the diagnostic enable switch.
Eaton Top 2 Transmission
Circuit - Test
Verify that the repair eliminates the problem.
SMCS Code: 3174-038
STOP.
System Operation Description:
• Not OK – The status for “Diagnostic Enable” is not
correct. There is a problem in the wire harness Use this procedure under the following situation:
between the diagnostic enable switch and the
ECM. Proceed to Test Step 6. This procedure covers the following diagnostic codes:
Test Step 6. Insert a Jumper Wire at the • 54-5 Auxiliary Output #06 current low
Bulkhead Connector
• 54-6 Auxiliary Output #06 current high
A. Turn the key switch to the OFF position.
• 55-5 Auxiliary Output #07 current low
B. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to each end of the wire. • 55-6 Auxiliary Output #07 current high
C. Locate the suspect switch socket in the engine • 191-7 Transmission Not Responding
side of the ECM bulkhead connector.
Background Information
D. Insert the wire jumper pin between the switch
socket and the sensor common connection. Install The Engine Control Module (ECM) controls shifts
the jumper wire on the engine side of the ECM between the top two gears of an Eaton Top 2
bulkhead connector. transmission. The shift points are based on engine
speed and load. When the transmission is in the Top
E. Turn the key switch to the ON position. 2 gears, the ECM will perform the following functions:
RENR2238-09 213
Troubleshooting Section
• Shift the transmission between the top 2 gears If the circuit malfunctions, the transmission will
automatically. typically default to manual operation. When the
system is in manual operation, Top 2 is inactive. For
• Increase or decrease engine speed during a Top 2 some malfunctions, the system will detect a failure.
shift. When the system detects a failure, the operator must
allow time out of the timer in the ECM. The ECM will
• Momentarily interrupt the cruise control or the complete the countdown in nine seconds. During the
engine brake during the shift. Then, the cruise countdown, the ECM will try to complete the shift.
control or the engine brake will resume. Once the ECM has completed the countdown, the
operator must place the transmission in neutral in
Note: Top gear refers to tenth gear in a ten speed order to obtain manual operation. The Top 2 function
transmission, and top gear refers to thirteenth gear in will be inactive until the vehicle is stopped and the
a thirteen speed transmission. Top gear minus one key switch is turned off.
refers to ninth gear in a ten speed transmission, and
top gear minus one refers to twelfth gear in a thirteen Wiring Connections of the ECM
speed transmission. Top gear minus two refers to
eighth gear in a ten speed transmission, and top gear The control interface between the ECM and the Eaton
minus two refers to eleventh gear in a thirteen speed Top 2 transmission consists of the following outputs:
transmission.
• Eaton Top 2 shift solenoid (No. 7 Output)
When the engine has reached the upshift point the
ECM will automatically shift the transmission into • Eaton Top 2 lockout solenoid (No. 6 Output)
Top Gear. The ECM shifts the transmission into Top
Gear by turning on the shift solenoid and turning off The ECM will turn on the Eaton Top 2 shift solenoid
the lockout solenoid. (No. 7 Output) when Top 2 is active in order to
engage top gear. The ECM will turn off the Eaton Top
When the engine has reached the shift point, the 2 shift solenoid (No. 7 Output) at all other times, if the
ECM will automatically downshift the transmission “Transmission Style” is programmed to Eaton Top 2.
from Top Gear to Top Gear Minus One. The ECM
downshifts the transmission from Top Gear to Top The ECM will turn on the Eaton Top 2 lockout
Gear Minus One by turning on the lockout solenoid solenoid (No. 6 Output) when Top 2 is active in order
and turning off the shift solenoid. to engage top gear minus one. The ECM will turn
off the Eaton Top 2 lockout solenoid (No. 6 Output)
In order to downshift from Top Gear Minus One to Top at all other times, if the “Transmission Style” is
Gear Minus Two, make sure that the shift button is in programmed to Eaton Top 2.
the forward position. Once the engine has reached
the shift point, move the gearshift lever to the next Customer Specified Parameters
lower lever position by double clutching.
The following parameters must be programmed
If the “Eaton Top 2 Override with Cruise Control per the following list in order for the Eaton Top 2
Switch” parameter is programmed to YES the cruise transmission to function properly:
control On/Off switch can be used to disable Top 2
mode. If the cruise control On/Off switch is turned to • “Transmission Style” Eaton Top 2
the OFF position and the transmission is not in Top 2
mode, the Top 2 mode will be disabled. This condition • “Top Gear Ratio” Programmed range 0.000 to
is applicable to the manual mode of operation only. If 3.750
the cruise control On/Off switch is turned to the ON
position, the Top 2 mode will be enabled and the • “Top Gear Minus One Ratio” Programmed range
transmission will be allowed to shift automatically 0.000 to 3.750
in the Top 2 gears. When the vehicle is operating
in one of the Top 2 gears and the Top 2 mode is • “Top Gear Minus Two Ratio” Programmed range
enabled, switching the cruise control On/Off switch to 0.000 to 3.750
the OFF position will place the transmission in hold
mode. When the transmission is in the hold mode, • “Eaton Top 2 Override with Cruise Switch” Yes
the transmission will not shift out of the currently or No
selected gear. When the cruise control On/Off switch
is returned to the ON position, the transmission will Note: Each gear ratio must be precisely programmed
return to Top 2 mode. When the clutch is depressed to three decimal places per the following table for the
and the transmission is in the hold mode, the manual model of transmission that is installed:
mode will be enabled and the Top 2 will be disabled.
System Problems
214 RENR2238-09
Troubleshooting Section
Table 149
Transmission Top Top Top
Model Gear Gear Gear
Minus Minus Ratio
Two One
Ratio Ratio
RTLO-XX610B-T2
1.352 1.000 0.741
10 Over
RTL-XX710B-T2
1.825 1.351 1.000
10 Direct
RTLO-XX713A-T2
1.000 0.856 0.730
13 Over
RTLO-XX718B-T2
1.000 0.856 0.730
18 Over
g00653688
Illustration 89
Schematic for the outputs for the Eaton Top 2 transmission
RENR2238-09 215
Troubleshooting Section
Expected Result:
Results:
Verify that the repair eliminates the problem. c. While you listen for the solenoid to shift, cycle
the special test for the “Lockout Solenoid” from
STOP. the ON position to the OFF position back to
the ON position.
Test Step 3. Check the Solenoids
Note: You may need to be near the transmission in
A. Turn the key switch to the ON position. order to hear the shift.
B. Access the customer specified parameters screen Note: 191-07 Transmission Not Responding may
on Cat ET. occur when one of the following diagnostic codes
occurs during vehicle operation:
C. Verify that the “Transmission Style” is programmed
to Eaton Top 2. • 54-05 Auxiliary Output #06 current low
D. Access the special tests for the “Shift Solenoid” • 54-06 Auxiliary Output #06 current high
and the “Lockout Solenoid” on Cat ET. Access the
following display screens in order: • 55-05 Auxiliary Output #07 current low
• “Diagnostics” • 55-06 Auxiliary Output #07 current high
• “Diagnostic Tests” Expected Result:
• 55-05 Auxiliary Output #07 current low Repair: Clear all logged diagnostic codes.
a. Move the splitter button to the rear position. • Not OK – The solenoid is not operating correctly
when the test is activated. Proceed to Test Step 4.
b. Ensure that the air system pressure is equal to
or greater than 620 kPa (90 psi). Test Step 4. Use the Special Test at the
Solenoid Connector
c. While you listen for the solenoid to shift, cycle
the special test for the “Shift Solenoid” from A. Turn the key switch to the OFF position.
the ON position to the OFF position back to
the ON position. B. Disconnect the Eaton Top 2 solenoid connector.
Note: You may need to be near the transmission in C. Use the following procedure for either of the
order to hear the shift. following active diagnostic codes or logged
diagnostic codes:
F. Use the following procedure for either of the
following active diagnostic codes or logged • 55-05 Auxiliary Output #07 current low
diagnostic codes:
• 55-06 Auxiliary Output #07 current high
• 54-05 Auxiliary Output #06 current low
a. Connect a voltage test lamp between terminal
• 54-06 Auxiliary Output #06 current high “B” (Sensor Common) and terminal “C” (No.
7 Output) on the ECM side of the Eaton Top
a. Move the splitter button to the forward position. 2 solenoid connector.
b. Ensure that the air system pressure is equal to D. Connect Cat ET to the data link connector.
or greater than 620 kPa (90 psi).
E. Turn the key switch to the ON position.
RENR2238-09 217
Troubleshooting Section
F. Access the special test for the “Shift Solenoid” N. Stop the special test for the “Lockout Solenoid”.
on Cat ET. Access the following display screens
in order: Note: When the key switch is turned on and the
solenoid connector is disconnected, the following
• “Diagnostics” diagnostic code will occur during performance of the
special test for the “Lockout Solenoid”:
• “Diagnostic Tests”
• 55-05 Auxiliary Output #07 current low
• “Special Test”
Clear this logged code when this step is
• “Shift Solenoid” completed.
G. While you monitor the voltage test lamp, cycle the Expected Result:
special test for the “Shift Solenoid” from the ON
position to the OFF position and back to the ON The voltage test lamp behaves in the following
position. manner:
H. Stop the special test for the “Shift Solenoid”. • The voltage test lamp turns on when the test is
active.
Note: When the key switch is turned on and the
solenoid connector is disconnected, the following • The voltage test lamp turns off when the test is
diagnostic code will occur during performance of the not active.
special test for the “Lockout Solenoid”:
Results:
• 54-05 Output #6 Open Circuit (66)
• OK – The engine harness and the ECM are OK.
Clear this logged code when this step is
completed. Repair: Temporarily connect the suspect
solenoids. Clear all logged diagnostic codes.
I. Use the following procedure for either of the Complete a test drive of the truck. If the diagnostic
following active diagnostic codes or logged code is logged after attempting to use the Top 2
diagnostic codes: feature, replace the solenoids. Repeat the test
drive in order to ensure that the problem has been
• 54-05 Auxiliary Output #06 current low corrected. Clear all logged diagnostic codes.
• 54-06 Auxiliary Output #06 current high Verify that the repair eliminates the problem.
O. Access the special test for the “Lockout Solenoid” Repair: Temporarily connect a test ECM. Remove
on Cat ET. Access the following display screens all jumpers and replace all connectors. Recheck
in order: the system for active diagnostic codes. Repeat this
test step. If the problem is resolved with the test
• “Diagnostics” ECM, reconnect the suspect ECM. If the problem
returns with the suspect ECM, replace the ECM.
• “Diagnostic Tests”
RENR2238-09 219
Troubleshooting Section
Verify that the repair eliminates the problem. The following background information is related
to this procedure:
STOP.
The engine control module (ECM) is the computer
Test Step 6. Check Gear Ratios which controls the Caterpillar electronic truck engine.
The personality module contains the software that
A. Connect Cat ET to the data link connector. controls the operation of the computer (ECM).
B. Turn the key switch to the ON position. The personality module software is the instructions
that are used by the ECM to control the engine. For
C. Access the customer specified parameters screen this reason, updating the personality module to a
on Cat ET. different version may cause some engine functions
to behave in a different manner.
D. Verify that the three parameters for gear ratios are
correctly programmed. Performance Maps
Expected Result:
Results:
Illustration 91
g00658319 • OK – Proceed to Test Step 2.
ECM and harness connectors
• Not OK
Logged Diagnostics
Repair: Repair the connectors or wiring and/or
Logged diagnostics are stored by the ECM into replace the connectors or wiring. Ensure that all of
memory so a permanent record of the diagnostic the seals are properly in place and ensure that the
code is retained. Logged faults that are not critical connectors are completely coupled.
are automatically cleared after 100 hours.
Verify that the repair eliminates the problem.
Input Circuits
STOP.
Input circuits filter electrical noise for sensor signals.
Also, input circuits protect internal circuits from Test Step 2. Check for Diagnostic Codes
potentially damaging voltage levels.
Connect the Caterpillar Electronic Technician (Cat
Output Circuits ET) and check for diagnostic codes.
A. Thoroughly inspect ECM vehicle harness Result 3 Scrambled parameters or data require
connector J1/P1 and the battery connections. troubleshooting.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details. Results:
B. Perform a 45 N (10 lb) pull test on each of the • Result 1 – Proceed to Test Step 3.
following wires in the ECM connector:
• Result 2 – Proceed to Test Step 4.
• Ignition key switch (terminal 70)
• Result 3 – Proceed to Test Step 5.
RENR2238-09 221
Troubleshooting Section
Repair: Reprogram the ECM with the correct D. Review the engine lifetime totals.
personality module. Refer to Troubleshooting,
“Flash Programming”. Expected Result:
Verify that the repair eliminates the problem. The parameters and totals are scrambled.
STOP. Results:
The ECM allows the parameters that are listed under • Not OK – The ECM is OK. STOP.
the following active diagnostic code in the active
diagnostic code screen to be programmed:
g01131276
Illustration 93
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
RENR2238-09 223
Troubleshooting Section
B. Ensure that the sealing plugs are in place. If any If moisture or corrosion is evident in the connector,
of the plugs are missing, replace the plug. Ensure the source of the moisture entry must be found and
that the plugs are inserted correctly into the the source of the moisture entry must be repaired.
connector. Refer to Illustration 93. If the source of the moisture entry is not repaired,
the problem will recur. Simply drying the connector
will not fix the problem. Check the following items
for the possible moisture entry path:
• Missing seals
• Improperly installed seals
• Nicks in exposed insulation
• Improperly mated connectors
Moisture can also travel to a connector through
the inside of a wire. If moisture is found in a
g01131019
connector, thoroughly check the connector’s
Illustration 94 harness for damage. Also check other connectors
Seal for a three-pin connector (typical example) that share the harness for moisture.
Expected Result:
Results:
STOP.
224 RENR2238-09
Troubleshooting Section
Test Step 2. Check the Wires for Damage Repair: Repair the terminals and/or replace the
to the Insulation terminals, as required.
A. Carefully inspect each wire for signs of abrasion, Verify that the repair eliminates the problem.
of nicks, and of cuts.
STOP.
Inspect the wires for the following conditions:
Test Step 4. Perform a Pull Test on Each
• Exposed insulation Wire Terminal Connection
• Rubbing of a wire against the engine
• Rubbing of a wire against a sharp point
B. Check all of the wiring harness fasteners in order
to verify that the harness is properly secured. Also
check all of the fasteners in order to verify that the
harness is not compressed. Pull back the harness
sleeves in order to check for a flattened portion
of wire. A fastener that has been overtightened
flattens the harness. This damages the wires that
are inside the harness.
• Not OK – There is damage to the harness. B. Perform the 45 N (10 lb) pull test on each wire.
Each terminal and each connector should easily
Repair: Repair the wires or replace the wires, withstand 45 N (10 lb) of tension and each wire
as required. Verify that the repair eliminates the should remain in the connector body. This test
problem. checks whether the wire was properly crimped
in the terminal and whether the terminal was
STOP. properly inserted into the connector.
The terminals are properly aligned and the terminals • Not OK – A wire has been pulled from a terminal
appear undamaged. or a terminal has been pulled from the connector.
Test Step 5. Check Individual Pin • Not OK – The connector’s locking mechanism is
Retention into the Socket damaged or missing.
STOP.
g01131604
A. Connect the ECM connectors.
Illustration 97
Diagram for testing pin retention (typical example)
Expected Result:
Results:
STOP.
The connector will securely lock. The connector and b. Torque the allen head screw for the 70
the locking mechanism are without cracks or breaks. pin ECM connector to 6.0 + 1.5 - 0.5 N·m
(55 + 13 - 4 lb in).
Results:
STOP.
c. Torque the allen head screw for the 40 pin ECM If an intermittent problem exists, the status will be
connector to 2.25 ± 0.25 N·m (20 ± 2 lb in). highlighted and an audible beep will be heard.
Expected Result:
Results:
g00692909
Illustration 102
C-10 and C-12 Pressure sensors
g00692936
Illustration 103
3406E Pressure sensors
228 RENR2238-09
Troubleshooting Section
g00693763
Illustration 104
C-15, C-16 and C-18 Pressure sensors
g00662235
Illustration 105
Schematic for engine pressure sensors
RENR2238-09 229
Troubleshooting Section
g00662237
Illustration 106
Terminal locations for ECM
Results:
B. Perform a 45 N (10 lb) pull test on each of the • Voltage Low (Short) – A “voltage low” diagnostic
wires in the ECM connector and the sensor code (short circuit) is active at this time. Proceed
connectors that are associated with the active to Test Step 4.
diagnostic code.
• Voltage High (Open) – A “voltage high” diagnostic
Refer to Illustration 106. code (open circuit) is active at this time. Proceed
to Test Step 7.
C. Check the ECM connector (Allen Head Screw) for
the proper torque of 6.0 N·m (55 lb in). Test Step 4. Disconnect the Suspect
Sensor
D. Check the harness and wiring for abrasion and
pinch points from the sensors back to the ECM. A. Turn the key switch to the OFF position.
Repair: Repair the connectors or wiring and/or A “voltage high” diagnostic code (open circuit) for the
replace the connectors or wiring. Ensure that all of disconnected sensor is now active.
the seals are properly in place and ensure that the
connectors are completely coupled. Results:
Verify that the repair eliminates the problem. • OK – A “voltage low” diagnostic code (short
circuit) was active before disconnecting the sensor.
Clear all logged diagnostic codes. A “voltage high” diagnostic code (open circuit)
became active after disconnecting the sensor.
STOP.
Repair: Temporarily connect a new sensor.
Test Step 3. Determine the Condition that
is Present Check for active diagnostic codes.
A. Turn the key switch to the ON position. Wait at If the new sensor fixes the problem, reconnect the
least 15 seconds for activation of the diagnostic suspect sensor.
codes.
If the problem returns, permanently install the new
B. Monitor the active diagnostic code screen on Cat sensor.
ET.
Verify that the repair eliminates the problem.
C. Determine if the problem is related to a “voltage
high” diagnostic code (open circuit) or a “voltage STOP.
low” diagnostic code (short circuit).
• Not OK – There is a short circuit between the
sensor and the ECM.
RENR2238-09 231
Troubleshooting Section
A. Turn the key switch to the OFF position. Repair the faulty wiring or replace the faulty wiring.
B. Remove the signal wire of the suspect sensor Verify that the repair eliminates the problem.
from the P2 ECM connector.
STOP.
C. Turn the key switch to the ON position.
• Not OK – There is a short between the pressure
D. Check for active diagnostic codes. sensor common and the signal wire.
Repair: Connect a test ECM. C. Turn the key switch to the ON position.
If the test ECM fixes the problem, reconnect the D. Measure the voltage from terminal A (Pressure
suspect ECM. Sensor +5V) to terminal B (Pressure Sensor
Common).
If the problem returns, permanently replace the
suspect ECM. Expected Result:
Verify that the repair eliminates the problem. The voltage is 5.0 ± 0.16 VDC.
STOP. Results:
Test Step 6. Check the Resistance of the • OK – The sensor supply voltage is correct.
Harness
Repair: Leave the sensor disconnected.
A. Turn the key switch to the OFF position.
Proceed to Test Step 8.
B. Verify that the suspect sensor is disconnected.
• Not OK – The sensor supply voltage is out of the
C. Measure the resistance between terminal B range.
(Pressure Sensor Common) and terminal C
(Signal) of the connector for the suspect sensor Repair: Check the 5 volt supply wire for an open
on the engine harness. circuit.
Expected Result: Repair the faulty wiring or replace the faulty wiring.
The resistance is greater than 20,000 Ohms, or “OL” Verify that the repair eliminates the problem.
is displayed on the multimeter.
STOP.
232 RENR2238-09
Troubleshooting Section
Test Step 8. Create a Short Circuit at the Note: When the P2 ECM connector is disconnected,
Sensor all of the “voltage high” diagnostic codes (open
circuit) for the pressure sensors will be active. This
A. Turn the key switch to the ON position. is normal.
B. Monitor the active diagnostic code screen. E. Install a jumper wire between the terminal for the
signal of the suspect sensor and the pressure
C. Install a jumper wire between terminal C (Signal) sensor common on the ECM. Wait at least
and terminal B (Pressure Sensor Common) of 15 seconds for activation of the “voltage low”
the sensor connector. Wait at least 15 seconds diagnostic code (short circuit).
for activation of the “voltage low” diagnostic code
(short circuit). Expected Result:
If the problem returns, permanently replace the Repair: Temporarily connect a test ECM.
suspect sensor.
If the test ECM fixes the problem, reconnect the
Verify that the repair eliminates the problem. suspect ECM.
Repair: Locate the open in the signal wire. The “Engine Running Output” activates when the
engine is running. This can be used to prevent the
Repair the faulty wiring or replace the faulty wiring. engagement of the starter motor while the engine is
running. The Engine Control Module (ECM) can be
Verify that the repair eliminates the problem. connected to a relay that disables the starter. The
relay is normally closed so cranking can be achieved
STOP. immediately at powerup. During cranking, the ECM
energizes the “Engine Running Output” once engine
• Not OK – There is a short between the 5 volt rpm reaches 50 rpm below low idle. The output is
supply and the signal wire. de-energized when the engine speed falls by 100
rpm below the programmed low idle. The low idle rpm
Repair: Locate the short between the 5 volt supply is programmable. The range for low idle is between
and the signal wire. 600 rpm and 750 rpm.
STOP.
i02185734
g00656153
Illustration 108
Circuit for engine running output
RENR2238-09 235
Troubleshooting Section
Expected Result:
Results:
STOP.
Test Step 1. Inspect Electrical Connectors The circuit is connected to the correct ECM terminal
and Wiring that is selected for the “Engine Running Output”.
C. Check the ECM connector (allen head screw) for Repair: Update the customer specified parameter
the proper torque of 6.0 N·m (55 lb in). in order to match the correct output terminal.
D. Check the harness and wiring for abrasion and for STOP.
pinch points from the sensor to the ECM.
Test Step 3. Use Caterpillar ET to Check
the Relay
A. Turn the ignition key switch to the ON position.
236 RENR2238-09
Troubleshooting Section
B. Access the “Engine Running Output Special Test” J. Cycle the corresponding “Engine Running Output
on ET. The “Engine Running Output Special Test” Special Test” to the ON position and to the OFF
will enable the “Engine Running Output” when the position and watch the voltage test lamp.
test is active.
K. Stop the special test.
C. Begin the “Engine Running Output Special Test”
and listen for the relay to click. You may need to Note: A multimeter can not be used in place of the
be near the engine in order to hear the click. voltage test lamp when the ECM outputs are being
tested.
Expected Result:
L. Turn the ignition key switch to the OFF position.
The relay will activate when the special test is turned
“On”. M. Reconnect all wires to the original configuration.
• OK – The test activated the relay. The voltage test lamp turns on when the “Engine
Running Output Special Test” is active. The voltage
Repair: The ECM and vehicle components are test lamp also turns off when the “Engine Running
operating correctly. Output Special Test” is not active.
STOP. Results:
• Not OK – The test did not activate the relay. • OK – The ECM is OK.
Proceed to Test Step 4.
Repair: The problem is in the vehicle wiring.
Test Step 4. Use Caterpillar ET to Check Inspect the vehicle wiring and then repair the
the ECM vehicle wiring. Otherwise, send the vehicle to
the OEM dealer for repair. Verify that the original
A. Connect Caterpillar ET to the cab data link condition is resolved.
connector.
STOP.
B. Turn the ignition key switch to the OFF position.
• Not OK – The voltage test lamp did not turn
C. Disconnect the ECM vehicle harness connector on. Verify that the voltage test lamp is operating
J1/P1. correctly.
D. Install a 140-2266 Cable As (70-PIN Repair: Temporarily connect a test ECM. Use the
BREAKOUT) to the ECM vehicle harness “Engine Running Output Special Test” on ET to
connector J1/P1. check the ECM. If the problem is resolved with the
test ECM, install the suspect ECM. If the problem
E. If the “Engine Running Output” is programmed returns with the suspect ECM, replace the ECM.
to P1-10, remove the wire to P1-10. Connect a Verify that the repair eliminates the problem.
voltage test lamp to terminal 10 (Output 2) and
terminal 65 (-Battery) of the breakout T. STOP.
H. Turn the ignition key switch to the ON position. This procedure checks the circuit for the engine
shutdown output for proper operation. There are no
I. Access the appropriate “Engine Running Output diagnostic codes for this output.
Special Test” on Caterpillar ET.
Background Information
RENR2238-09 237
Troubleshooting Section
g00656155
Illustration 110
Circuit for shutdown output
238 RENR2238-09
Troubleshooting Section
Expected Result:
Results:
STOP.
B. Access the “Engine Shutdown Output Special J. While you monitor the voltage test lamp, cycle the
Test” on Cat ET. The “Engine Shutdown Output “Special Test” from the ON position to the OFF
Special Test” will enable the “Engine Shutdown position back to the ON position.
Output” when the test is active.
K. Stop the “Special Test”.
C. While you listen for the relay to click, begin the
“Engine Shutdown Output Special Test”. Note: A multimeter cannot be used in place of the
voltage test lamp when the ECM outputs are being
Note: You may need to be near the relay in order to tested.
hear the click.
L. Turn the ignition key switch to the OFF position.
Expected Result:
M. Return all wiring to the original configuration.
The relay activates when the special test is enabled.
Expected Result:
Results:
The voltage test lamp turns on when the “Engine
• OK – The relay activates when the special test Shutdown Output Special Test” is active. The voltage
is enabled. test lamp turns off when the “Engine Shutdown
Output Special Test” is not active.
Repair: The ECM and vehicle components are
operating correctly. Results:
D. Install a 140-2266 Cable As (70-PIN Repair: Temporarily connect a test ECM. Use
BREAKOUT) to the ECM vehicle harness “Engine Shutdown Output Special Test” on Cat
connector J1/P1. ET to check the ECM. If the problem is resolved
with the test ECM, install the suspect ECM. If the
E. If the “Engine Shutdown Output” is programmed problem returns with the suspect ECM, replace the
to P1-10, remove the wire to P1-10. Connect a ECM. Verify that the repair eliminates the problem.
voltage test lamp to terminal 10 (Output 2) and
terminal 65 (-Battery) of the breakout T. STOP.
H. Turn the ignition key switch to the ON position. Use this procedure under the following situation:
I. Access the “Engine Shutdown Special Test” on • There is an active diagnostic code or an easily
Cat ET. repeated diagnostic code that is associated with
either the primary engine speed/timing sensor or
the secondary engine speed/timing sensor.
240 RENR2238-09
Troubleshooting Section
• You have been directed to this test from Both sensors are magnetic sensors. The two sensors
Troubleshooting, “Troubleshooting without a are not interchangeable. Do not switch the positions
Diagnostic Code”. of the sensor. If the sensors are replaced, a timing
calibration is NOT necessary for the engine. Timing
The following background information is related calibration is only necessary after replacing an
to this procedure: ECM that will not communicate.
The engine will start and the engine will run when
only one sensor signal is present from either of the
sensors. The loss of the signal from both of the
sensors during engine operation will result in the
termination of injection and the shutting down the Illustration 113
g00995766
engine by the ECM. The loss of the signal from both 3406E Engine
of the sensors during start-up will prevent the engine
Left side engine view
from starting.
RENR2238-09 241
Troubleshooting Section
• C-12 (2KS00001-15070)
• 3406E (1MM00390-00838)
• 3406E (2WS08900-20705)
If the intermittent condition occurs, the ECM will log
the following diagnostic codes:
• C-10 (3CS00001-05369)
242 RENR2238-09
Troubleshooting Section
• Remove one of the terminals of the harness socket • Do Not replace the engine speed/timing sensors.
from the connector for the engine speed/timing To check the work that has been performed, start
sensor P401 or P402. The sockets that are present the engine and disconnect the primary engine
at the sensor end of the wiring harness will be one speed/timing sensor. A slight speed burp may
of two types. The socket will be either a socket occur when the primary engine speed/timing
that is stamped and formed or a socket that is sensor is disconnected. If the engine runs properly
machined. The socket that is stamped and formed and the primary engine speed/timing sensor
will have fingers that are crimped onto the wire is disconnected, the engine repair has been
insulation. Refer to Illustration 115. The socket that accomplished without reversing the polarity of the
is machined can only be crimped onto the electrical wiring.
conductor or wire. Refer to Illustration 116.
Note: If the above installation is not performed
• If the sockets that are stamped and formed are one wire at a time, the polarity of the wiring can
present in the sensor harness connectors, the accidentally be reversed. If the polarity of the wire
sockets must be cut back at the sensor harness for the secondary engine speed/timing sensor is
ends of the sensor harness for the engine reversed, the engine may start. The engine will
speed/timing sensors, and each socket must run adequately until a failure of the primary engine
be replaced by an 8T-8730 Connector Socket speed/timing sensor occurs. At this point, the engine
that is machined. The socket terminals in the will run poorly. If the polarity of the wire for the primary
connector assembly should be removed from the engine speed/timing sensor is reversed, the engine
2-pin connector. The 2-pin connector is a Deutsch may not start. If the polarities of both the engine
DT-2 connector. The socket terminals should be speed/timing sensors are reversed, the engine will
changed, and reinserted. Perform this procedure not start.
on each wire one at a time in order to eliminate the
chance of reversing the polarity of the connection.
If machined terminals are already installed in
the sensor harness connectors for the engine
speed/timing sensors, resume troubleshooting at
Test Step 3.
g00955785
Illustration 117
Schematic for engine speed/timing sensors
g00956357
Illustration 118
P2 ECM connector
Test Step 1. Check for Diagnostic Codes • 190-12 Primary Engine Speed loss of signal
A. Connect the Caterpillar Electronic Technician (Cat Note: If the diagnostic code is logged but not active,
ET) to the data link connector. run the engine until the engine is at normal operating
temperature. The problem may only occur when the
B. Turn the key switch to the ON position. engine is at the normal operating temperature. If the
engine will not start, monitor the engine rpm on Cat
C. Check for one of the following logged diagnostic ET while the engine is being cranked. Cat ET may
codes or active diagnostic codes: need to be powered from another battery while the
engine is being cranked. This is done in order to
• 22-11 Primary to Secondary Engine Speed ensure that Cat ET does not reset.
Signal Calibration
Note: If there are occurrences of the 64-12 and
• 64-12 Secondary Engine Speed loss of signal 190-12 faults, refer to the following information in the
System Operation Section:
244 RENR2238-09
Troubleshooting Section
• Intermittent Faults That Are Due To The Wiring C. Ensure that one O-ring has been installed on
Harness Terminals the sensor, and ensure that the O-ring is free of
damage.
Expected Result:
D. If the following diagnostic code is active, there may
One or more of the diagnostic codes that are listed be a problem with the assembly of the engine:
above are logged or active.
• 22-11 Primary to Secondary Engine Speed
Note: If you have been directed here from Signal Calibration
Troubleshooting, “Troubleshooting without a
Diagnostic Code” for the following reason, select “No Refer to Illustration 119.
Engine rpm”:
Expected Result:
• The engine rpm was not indicated on Cat ET.
The sensors and the bracket are properly installed.
Results:
Results:
• 64-12, 190-12 or 22-11 – There is an active
diagnostic code or a logged diagnostic code. • OK – The sensors and the bracket are properly
Proceed to Test Step 3. installed. Proceed to Test Step 3.
STOP.
A. The flange of the sensor should be flush against B. Thoroughly inspect the J2/P2 ECM connector.
the engine in order to ensure proper operation. Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details.
B. Inspect the bracket in order to ensure that the
installation allows the flange of the sensor to be C. Perform a 45 N (10 lb) pull test on the following
flush against the engine. wires in the P2 ECM connector that are associated
with the engine speed/timing sensors:
Verify that the bracket is not bent.
• Terminal 48
Note: The bracket cannot be replaced separately.
• Terminal 49
RENR2238-09 245
Troubleshooting Section
Refer to Illustration 118. The readings agree with the values that are listed
above.
D. Ensure that the latch tab on the connector is
properly latched and ensure that the latch tab is Results:
fully latched.
• OK – Neither a short circuit nor an open circuit is
E. Check the ECM connector (allen head screw) for indicated. Proceed to Test Step 5.
the proper torque of 6.0 N·m (55 lb in).
• Not OK – The sensor resistance is not within the
F. Repair the harness or repair the connector if a acceptable range when the sensor resistance is
problem is found. measured through the engine harness. Proceed
to Test Step 4.
G. Ensure that the wiring harness is correctly routed
and secured at the proper locations. Test Step 4. Measure the Resistance of
the Sensor at the Sensor
H. Ensure that the harness wiring is not pulled
too tightly. When the harness wiring is pulled A. Turn the key switch to the OFF position.
too tightly, vibrations or movement can cause
intermittent connections. B. Check the harness and the wiring for abrasion and
pinch points from the sensor back to the ECM.
I. Inspect the harness wiring for nicks and abrasions.
C. Disconnect the suspect sensor from the engine
J. If the harness and the connector are OK, harness.
disconnect ECM connector J2/P2.
D. Thoroughly inspect J401/P401 or J402/P402
K. Primary engine speed/timing sensor connectors. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details.
Refer to Illustration 118.
E. Primary engine speed/timing sensor
a. Use a multimeter to measure the sensor
resistance (Ohms) between P2:48 (Primary a. Use a multimeter to measure the sensor
Speed/Timing Positive) and P2:49 (Primary resistance (Ohms) between J401:2 (Primary
Speed/Timing Negative). Speed/Timing Positive) and J401:1 (Primary
Speed/Timing Negative).
b. Check for an intermittent open circuit or
short circuit by moving the harness while the Resistance ....................... 75.0 to 230.0 Ohms
measurement for resistance is being taken.
Pull the wires that are directly behind the F. Secondary engine speed/timing sensor
sensors or shake the wires that are directly
behind the sensors. a. Use a multimeter to measure the sensor
resistance (Ohms) between J402:2 (Secondary
Resistance ...................... 75.0 to 230.0 Ohms Speed/Timing Positive) and J402:1 (Secondary
Speed/Timing Negative).
L. Secondary engine speed/timing sensor
Resistance ........................ 600 to 1800 Ohms
Refer to Illustration 118.
Note: Timing calibration is not necessary following
a. Use a multimeter to measure the sensor replacement of the engine speed/timing sensors.
resistance (Ohms) between P2:58 (Secondary Refer to the information in the System Operation
Speed/Timing Positive) and P2:59 (Secondary Section regarding the installation of sensors.
Speed/Timing Negative).
Expected Result:
b. Check for an intermittent open circuit or
short circuit by moving the harness while the The readings agree with the values that are listed
measurement for resistance is being taken. above.
Pull the wires that are directly behind the
sensors or shake the wires that are directly
behind the sensors.
246 RENR2238-09
Troubleshooting Section
• OK – The sensor resistance is correct. Proceed Note: Twisted pair wiring is required. Ensure that the
to Test Step 5. wires have at least one twist per inch.
• Not OK – The sensor resistance is out of the E. Reconnect the J2/P2 ECM connector.
range.
F. Start the engine in order to determine if the bypass
Repair: Perform the following procedure in order harness repairs the problem.
to check and install the new sensor:
Expected Result:
1. Before installing the new sensor, measure the
resistance of the new sensor. The problem is corrected with the installation of the
bypass harness.
If the new sensor resistance is in the correct
range, install the new sensor in the engine, as Results:
follows:
• OK
a. Loosen the bolt that holds the sensor
mounting bracket to the engine. Repair: Permanently install a new section of
harness.
b. Ensure that one O-ring is installed and free
of damage. STOP.
B. Disconnect the J2/P2 ECM connector. E. If the problem returns with the suspect ECM,
replace the ECM.
C. Use the following procedure for the primary engine
speed/timing sensor: Verify that the repair eliminates the problem.
b. Install a 16 AWG wire from J2/P2:49 to P401:1. The problem remains with the suspect ECM.
STOP.
• Not OK
Repair: Replace the sensor.
STOP.
i01907626
g00994858
Illustration 120
C-10 and C-12 Temperature sensors
g00995917
Illustration 121
3406E Temperature sensors
RENR2238-09 249
Troubleshooting Section
g00994860
Illustration 122
C-15, C-16 and C-18 Temperature sensors
g00970545
Illustration 123
Schematic for engine temperature sensors
250 RENR2238-09
Troubleshooting Section
g00970546
Illustration 124
P1 and P2 ECM connectors
All connectors, pins, and sockets should be C. Check for active diagnostic codes on the electronic
completely coupled and/or inserted and the harness service tool.
and wiring should be free of corrosion, abrasion, or
pinch points.
RENR2238-09 251
Troubleshooting Section
D. Determine if the problem is related to a “voltage Test Step 4. Disconnect the ECM
high” diagnostic code (open circuit) or a “voltage Connector
low” diagnostic code (short circuit).
A. Turn the key switch to the OFF position.
Expected Result:
B. Disconnect the J2/P2 ECM connector. Thoroughly
A “voltage high” diagnostic code (open circuit) or a inspect both halves of the connector for signs of
“voltage low” diagnostic code (short circuit) is active. corrosion or moisture.
Test Step 3. Disconnect the Suspect Note: When the J2/P2 ECM connector is
Sensor disconnected, all of the “voltage high” diagnostic
codes (open circuit) for the temperature sensors will
A. Turn the key switch to the OFF position. be active. This is normal.
A “voltage high” diagnostic code (open circuit) for the Proceed to Test Step 5.
suspect sensor is now active.
• Not OK – A “voltage low” diagnostic code (short
Results: circuit) is still active for the suspect sensor.
• OK – A “voltage high” diagnostic code (open Repair: Temporarily connect a test ECM.
circuit) for the suspect sensor is now active.
If the test ECM fixes the problem, reconnect the
Repair: Temporarily connect a new sensor. suspect ECM.
If the new sensor fixes the problem, reconnect the If the problem returns, permanently replace the
suspect sensor. suspect ECM.
If the problem returns, permanently replace the Verify that the repair eliminates the problem.
sensor.
STOP.
Verify that the repair eliminates the problem.
Test Step 5. Check the Resistance
STOP.
A. Turn the key switch to the OFF position.
• Not OK – There is a short circuit between the
sensor harness connector and the ECM. B. Verify that the suspect sensor and the ECM
connector are disconnected.
Repair: Leave the sensor disconnected.
C. Measure the resistance between terminal 1 and
Proceed to Test Step 4. terminal 2 of the sensor connector.
252 RENR2238-09
Troubleshooting Section
• OK – There is a problem with the supply wire. Repair: Remove the jumper wire.
Repair: Check the supply wire of the suspect Proceed to Test Step 7.
sensor for a short to ground.
Test Step 7. Create a Short at the ECM
Repair the faulty wiring or replace the faulty wiring.
A. Turn the key switch to the OFF position.
Verify that the repair eliminates the problem.
B. Disconnect the P2 ECM connector.
STOP.
C. Fabricate a jumper wire 150 mm (6 inch) long.
• Not OK – There is a short between the supply wire
and the common wire. D. Install the jumper wire between the terminal for
the sensor supply of the suspect sensor and the
Repair: Locate the short between the supply wire terminal for the sensor common.
and the common wire.
Expected Result:
Repair the faulty wiring or replace the faulty wiring.
A “voltage low” diagnostic code (short circuit) is
Verify that the repair eliminates the problem. active when the jumper wire is installed.
STOP. Results:
Test Step 6. Create a Short at the Sensor • OK – A “voltage low” diagnostic code (short circuit)
is active when the jumper wire is installed.
A. Fabricate a jumper wire 150 mm (6 inch) long.
Repair: Reconnect the P2 ECM connector.
B. Turn the key switch to the ON position.
• Not OK – A “voltage high” diagnostic code (open
C. Monitor the active diagnostic code screen. circuit) is still active.
D. Install the jumper wire between terminal 1 and Repair: Temporarily connect a test ECM.
terminal 2 of the sensor connector.
If the test ECM fixes the problem, reconnect the
Expected Result: suspect ECM.
A “voltage low” diagnostic code (short circuit) is If the problem returns, permanently replace the
active when the jumper wire is installed. suspect ECM.
If the voltage is below 4.5 VDC, check the supply • The “Input Sensor Common 1” is terminal 18.
wire for an open circuit.
• The “Input Sensor Common 2” is terminal 3.
Repair the faulty wiring or replace the faulty wiring.
• The “AP Sensor/Switch Sensor Common” is
Verify that the repair eliminates the problem. terminal 5.
STOP.
i02375657
• Additional cooling
254 RENR2238-09
Troubleshooting Section
g00682179
Illustration 125
Schematic for the fan override switch
Expected Result:
Results:
STOP.
Illustration 126
g01105459 • Not OK – The ECM is not reading the change in
switch status. Proceed to Test Step 2.
Terminal Locations for the ECM
(P1-5) AP sensor/switch sensor common Test Step 2. Determine the Configuration
(P1-6) Output number 6
(P1-7) Output number 4
of the Fan Override Switch
(P1-46) Output number 7
(P1-47) Output number 5 A. Determine if the fan override switch is wired
directly to the ECM or through the J1939 data link.
RENR2238-09 255
Troubleshooting Section
B. Verify that the “Fan Override Switch” parameter is Repair: Repair the connectors or wiring and/or
programmed to reflect the proper wiring. replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
Expected Result: connectors are completely coupled.
The fan override switch is wired directly to the ECM. Verify that the repair eliminates the problem.
Results: STOP.
• OK – The fan override switch is wired directly to Test Step 4. Check the Switch Circuit for
the ECM. Proceed to Test Step 3. the ECM
• Not OK – The fan override switch is wired through A. Turn the key switch to the OFF position.
the J1939 data link.
B. Remove the wire from the suspect switch socket
Repair: Verify that the “Fan Override Switch” on the P1 ECM connector.
parameter is programmed to “J1939 - Body
Controller”, to “J1939 - Cab Controller”, or to C. Install a 140-2266 Cable As (70-PIN
“J1939 - Instrument Cluster”. BREAKOUT) between the J1 and P1 ECM
connectors.
Refer to Troubleshooting, “Powertrain Data Link
Circuit - Test”. D. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to each end of the wire.
STOP.
E. Insert the jumper wire into the suspect switch
Test Step 3. Check the Electrical socket of the breakout T. Connect the other end of
Connectors and the Wiring the jumper wire to terminal 5 (AP Sensor/Switch
Sensor Common) of the breakout T.
A. Thoroughly inspect the J1/P1 ECM connector, the
connectors, and the firewall bulkhead connectors. F. Turn the key switch to the ON position.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details. G. While the status for the “Fan Override Switch”
is monitored, remove the jumper wire and then
B. Perform a 45 N (10 lb) pull test on each of the insert the jumper wire.
wires in the ECM connector that are associated
with the suspect switch circuit. H. Turn the key switch to the OFF position.
C. Check the ECM connector (allen head screw) for I. Reconnect all wires to the original configuration.
the proper torque of 6.0 N·m (55 lb in).
Expected Result:
D. Check the harness and the wiring for abrasion and
pinch points from the battery to the ECM. Then, The status for the “Fan Override Switch” is “On”
check from the key switch to the ECM. when the jumper wire is inserted. The status for the
“Fan Override Switch” is “Off” when the jumper wire
Refer to Illustration 126 for terminal locations for is removed.
the ECM.
Results:
E. Check the harness and wiring for abrasion and for
pinch points. • OK – The ECM is functioning properly at this time.
Expected Result: Repair: Remove the breakout T and reconnect the
J1 and P1 ECM connectors.
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring Proceed to Test Step 5.
are free of corrosion, of abrasion and of pinch points.
• Not OK – The ECM is not functioning properly.
Results:
Repair: Temporarily connect a test ECM. If the
• OK – The harness and connectors appear to be problem is resolved with the test ECM, install
OK. Proceed to Test Step 4. the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM.
• Not OK – There is a problem with the connectors
and/or wiring.
256 RENR2238-09
Troubleshooting Section
B. Fabricate a jumper wire 100 mm (4 inch) long. • OK – The problem is in the vehicle wiring between
Crimp a Deutsch pin to each end of the wire. the bulkhead connector and the switch.
C. Insert the jumper wire between the two switch Repair: Inspect the vehicle wiring and then repair
terminals of the fan override switch. the vehicle wiring. Otherwise, send the vehicle to
the OEM dealer for repair.
D. Turn the key switch to the ON position.
Verify that the original condition is resolved.
E. While the status for the “Fan Override Switch”
is monitored, remove the jumper wire and then STOP.
insert the jumper wire.
• Not OK – The problem is in the vehicle wiring
Expected Result: between the bulkhead connector and the ECM.
The status for the “Fan Override Switch” is “On” Repair: Inspect the vehicle wiring and then repair
when the jumper wire is inserted. The status for the the vehicle wiring. Otherwise, send the vehicle to
“Fan Override Switch” is “Off” when the jumper wire the OEM dealer for repair.
is removed.
Verify that the original condition is resolved.
Results:
STOP.
• OK – The harness wiring is OK.
i01815718
Repair: Replace the fan override switch.
• The engine is not in “Cold Mode” or “Dedicated The “Idle Shutdown Timer” feature can be temporarily
PTO Mode”. disabled by the use of the Caterpillar Electronic
Technician (ET). The “Idle Shutdown Timer” feature
• The engine is not under load. can be temporarily disabled through the “System
Troubleshooting Settings” screen in order to help
The timer can be reset by moving the vehicle or troubleshoot other problems. Temporarily disabling
the timer can be reset by quickly depressing the this feature avoids engine shutdowns when you
accelerator pedal and releasing the accelerator are troubleshooting other systems. The use of this
pedal. method eliminates the need to temporarily alter the
customer specified parameter of “Idle Shutdown
The check engine lamp will begin to rapidly flash 90 Timer”.
seconds before the programmed time expires. During
this 90 second time period, the following conditions Note: If the following diagnostic code is active, the
can disable the timer: “Idle Shutdown Timer” will not operate.
• The driver moves the clutch pedal. • 84-08 Vehicle Speed Out Of Range (36)
• The driver moves the service brake pedal. Note: The timer will be overridden if the following
conditions exist.
The following event code will be logged when the
driver overrides the timer by the use of the clutch • The “Allow Idle Shutdown Timer Override” is
pedal or the brake pedal during the 90 second period: programmed to “Outside Temperature Based” or
“J1587 Outside Temperature Based”.
• 71-00 Idle Shutdown Override (01)
• The temperature that is being sensed by the ECM
If the parameter for the “Allow Idle Shutdown is below the minimum air temperature that is
Override” is programmed to “NO”, the timer can not programmed or the air temperature is above the
be overridden by the use of the clutch pedal or the maximum air temperature that is programmed.
brake pedal during the final 90 second period. “YES”
is the factory default that is programmed for the Test Step 1. Verify Activation of the “Idle
parameter for the “Allow Idle Shutdown Override”. Shutdown Timer”
The allowance of the override is the default.
A. Connect ET to the cab data link connector.
With OCT99 and newer software, an additional
parameter can be programmed to allow the timer to B. Access the “Customer Parameters” on ET.
be reset above a specified engine speed. When the
“Idle Shutdown Timer Maximum RPM” parameter is a. Access the following display screens in order:
programmed to a value below the Top Engine Limit,
the timer can be reset by increasing engine rpm • “Service”
above a programmed limit. The timer will be reset
until engine rpm drops below the programmed value. • “Configuration”
The timer will begin counting again. The factory
default of 2120 rpm disables this feature. The “Top b. Record the programmed time for the “Idle
Engine Limit” is 2120 rpm. Shutdown Timer”. The “Idle Shutdown Timer”
must be between 3 and 1440 minutes. If the
If the timer is activated and the timer is allowed to “Idle Shutdown Timer” is programmed to 0,
shut down the engine the following event code will then the timer is disabled.
be generated:
c. Record the programmed status of the
• 71-01 Idle Shutdown Occurrence (47) parameter for the “Allow Idle Shutdown
Override” and the “Idle Shutdown Timer
Code 71-01 records the event and the code does Maximum RPM”.
not indicate an electrical system malfunction or an
electronic system malfunction. Disable the timer by C. Start the engine. Allow the engine to warm up until
programming “Idle Shutdown Timer” to 0 (Caterpillar the coolant temperature is 38 °C (100 °F). Allow
Factory Default). the engine to operate at the programmed low idle
and turn off any unnecessary accessory devices.
The ECM will shut down the engine but not the
vehicle electrical system when the “Idle Shutdown D. Ensure that all unnecessary loads are turned off.
Timer” time expires. The “Engine Shutdown Output”
can be used to shut down the vehicle electrical
system after the “Idle Shutdown Timer” time has
expired.
258 RENR2238-09
Troubleshooting Section
With OCT99 and newer software, the “Idle c. Reprogram the “Idle Shutdown Timer” to 3
Shutdown Timer Maximum RPM” can be minutes for this test.
programmed to allow the timer to be reset
by increasing the engine RPM above the C. Observe the following items during the 90 second
programmed limit. Ensure that the accelerator is period before the programmed shutdown time:
not being depressed so that the rpm increases
beyond the programmed limit. • Check Engine Lamp
a. Park the vehicle. • Idle Shutdown Status
b. Ensure that the “Vehicle Speed” on the status D. If the customer parameter of “Allow Idle Shutdown
screen on ET is 0 km/h (0 mph). Override” is programmed to “YES”, perform either
of the following actions in order to override the
c. Ensure that the engine speed on the status shutdown:
screen is at “Low Idle”.
• Press the clutch pedal.
d. Ensure that the clutch pedal is not depressed.
Ensure that the brake pedal is not depressed. • Press the service brake pedal.
e. Ensure that the status of the PTO On/Off Note: This action must be accomplished while the
Switch is off. check engine lamp is flashing. The check engine
lamp flashes during the 90 second period before the
f. Observe the “Idle Shutdown Status”. programmed shutdown time.
Result 2 The “Idle Shutdown Status” indicates “Not During the 90 second period before the scheduled
Active”. shutdown, the status should change from “Counting”
to “Driver Alert” and the check engine lamp should
Results: flash rapidly. If the “Allow Idle Shutdown Override” is
programmed to “YES”, the “Idle Shutdown Status”
• Result 1 – The ECM is reading the proper should change to “Override” after the pedals are
conditions for the activation of the “Idle Shutdown depressed.
Timer”. Proceed to Test Step 2.
Result 1 The “Idle Shutdown Timer” behaves in the
• Result 2 – The ECM is not reading the proper manner that is described above.
conditions for activation of the “Idle Shutdown
Timer”. Proceed to Test Step 3. Result 2 The check engine lamp did not flash during
the alert.
Test Step 2. Verify the Driver Alert
Function for Idle Shutdown and the Result 3 The ECM did not sense a change in the
Override Function for Idle Shutdown status of the service brake.
A. Connect ET to the cab data link connector. Result 4 The ECM did not sense a change in the
status of the clutch.
B. Access the “Customer Parameters” on ET.
Results:
a. Access the following display screens in order:
• Result 1 – The “Idle Shutdown Timer” is operating
• “Service” properly. STOP.
Repair: Perform the following diagnostic Repair: Perform the following diagnostic
procedure: Troubleshooting, “Check Engine Lamp procedure: Troubleshooting, “Vehicle Speed Circuit
Circuit - Test” - Test”
STOP. STOP.
• Result 3 – The ECM did not sense a change in the • Result 2 – The status screen on ET indicates that
status of the service brake. the engine is in cold mode.
Repair: Perform the following diagnostic Repair: The engine must not be in “Cold Mode”
procedure: Troubleshooting, “Service Brake Pedal operation while this test procedure is being
Position (Switch 1) Circuit - Test” performed. Allow the engine to run until the coolant
temperature exceeds 20 °C (68 °F). Troubleshoot
STOP. and repair any related conditions.
g00779064
Illustration 127
Schematic for ECM battery circuit
g00640974
Illustration 128
Terminal locations for ECM
262 RENR2238-09
Troubleshooting Section
Test Step 1. Inspect Electrical Connectors C. Monitor the status for “Ignition Key Switch” while
and Wiring the key switch is being cycled slowly from the ON
position to the OFF position.
A. Thoroughly inspect the J1/P1 ECM connector, the
battery connections and the connections to the Note: Cat ET may indicate that a new ECM has
key switch. Refer to Troubleshooting, “Electrical been detected. This condition is normal, due to a
Connectors - Inspect” for details. powerdown of the ECM with the key switch in the
OFF position.
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated Note: Cycling the key switch several times may
with the following connections: cause additional 43-02 faults to be logged. This is
normal. Clear any logged faults.
• J1/P1:52 & 53 (Unswitched +Battery)
Expected Result:
• J1/P1:65 & 67 (−Battery)
The status for “Ignition Key Switch” changes from
• J1/P1:70 (Ignition Key Switch) “On” with the key switch in the ON position to “Off”
with the key switch in the OFF position.
C. Check the allen head screws on the ECM
connector for the proper torque. Refer to Results:
Troubleshooting, “Electrical Connectors - Inspect”
for details. • OK – The key switch input is functioning properly
at this time.
D. Check the harness and wiring for abrasion and
for pinch points from the battery to the ECM, and Repair: If an intermittent connection is suspected,
from the key switch to the ECM. refer to Troubleshooting, “Electrical Connectors -
Inspect”. Excessive cycling of the key switch can
Expected Result: cause this fault to be logged. This is normal. Clear
any logged faults.
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring STOP.
are free of corrosion, of abrasion and of pinch points.
• Not OK – The key switch input is not functioning
Results: properly. Proceed to Test Step 3.
• OK – The connectors and wiring are OK but there Test Step 3. Check the Battery Voltage at
may be a problem with the keyswitch. Proceed to the ECM
Test Step 2.
Perform Steps A, B, and C if the following
• OK – The connectors and wiring are OK but diagnostic code is active or logged:
there may be a problem with the battery voltage.
Proceed to Test Step 3. • 168-02 ECM Battery Power Intermittent
• Not OK – There is a problem with the connectors A. Insert a 140-2266 Cable (Seventy-Pin Breakout)
and/or wiring. between the J1 and P1 ECM connector.
Repair: Repair the connectors or wiring and/or B. Measure the voltage between P1:52 (Unswitched
replace the connectors or wiring. Ensure that all of +Battery) and P1:65 (-Battery).
the seals are properly in place and ensure that the
connectors are completely coupled.
STOP.
g00640981
Illustration 129
ECM Breakout T-connector
C. Measure the voltage between P1:53 (Unswitched Repair: Trace the wiring for the key switch from the
+Battery) and P1:67 (-Battery). ECM through the key switch circuit to the batteries.
Find the problem and repair the problem. Check
Refer to Illustration 129. the circuit protection for the circuit and the wiring.
Refer to the vehicle service manual for instructions
Perform Steps D, E, and F if the following on troubleshooting the circuit for the key switch.
diagnostic code is active or logged:
Verify that the repairs eliminate the problem.
• 43-02 Key Switch Fault
STOP.
D. Insert a 140-2266 Cable (Seventy-Pin Breakout)
between the J1 and P1 ECM connector. Test Step 4. Check the Batteries
E. Turn the key switch to the ON position. A. Measure no-load battery voltage at the battery
posts.
F. Measure the voltage between P1:70 (Ignition Key
Switch) and P1:65 (-Battery). B. Load test the batteries. Use the 4C-4911
Battery Load Tester. Refer to Special Instruction,
Refer to Illustration 129. SEHS9249, “Use of 4C-4911 Battery Load Tester
for 6, 8 and 12 Volt Lead Acid Batteries” and
Expected Result: Special Instruction, SEHS7633, “Battery Test
Procedure”.
For 12 Volt Systems, the measured voltage is
a constant 11.0 to 13.5 VDC with no suspected Expected Result:
intermittent problems at this time.
The batteries pass the load test. For 12 Volt systems,
For 24 Volt Systems, the measured voltage is the measured voltage is at least 11.0. For 24 Volt
a constant 22.0 to 27.0 VDC with no suspected systems, the measured voltage is at least 22.0.
intermittent problems at this time.
Results:
Results:
• OK – The voltage is within the acceptable range.
• OK – The ECM is receiving the correct voltage.
Repair: Refer to the vehicle service manual for
Repair: If an intermittent condition is suspected, instructions on troubleshooting the vehicle wiring
refer to Troubleshooting, “Electrical Connectors harness. Troubleshoot the vehicle wiring harness
- Inspect”. and repair the vehicle wiring harness, as required.
Verify that the repairs eliminate the problem.
STOP.
STOP.
• Not OK – The battery voltage is intermittent or
there is no voltage. Proceed to Test Step 5. • Not OK – The voltage is out of the acceptable
range.
• – The voltage for the key switch is out of the
acceptable range.
264 RENR2238-09
Troubleshooting Section
Repair: Recharge or replace the faulty batteries. If the problem still exists, temporarily connect
Verify that the repair eliminates the problem. a test ECM. Remove all jumpers and replace
all connectors. Recheck the system for active
STOP. diagnostic codes and repeat the Test Step. If the
problem is resolved with the test ECM, reconnect
Test Step 5. Bypass the Vehicle Harness the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM.
D. Connect Cat ET to the data link connector of the The following background information is related
bypass harness and verify that communication to this procedure:
is established.
The Engine Control Module (ECM) can use various
E. Restore all wiring to the original condition after inputs in a number of ways. The inputs depend
testing. on the parameter programming. Certain features
are available on several different inputs. The
Expected Result: configuration for the switch must match the actual
switch installation in order for the switch to function
Installing the bypass eliminates the problem. properly.
Note: The status for “Ignition Key Switch” will always Ignore Brake/Clutch Switch
indicate “On” while the bypass harness is installed.
The ignore brake/clutch switch is typically used
Results: with a “Cab Switches PTO Configuration” which
requires mobile use of the vehicle during PTO
• OK – The symptoms disappear when the bypass operation. When the ignore brake/clutch switch
harness is installed. Also, the symptoms return is on, depressing the brake or the clutch will not
when the bypass harness is removed. The problem disengage PTO operation or a set engine speed.
is in the vehicle wiring that supplies power to the If the “Ignore/Brake Clutch Switch” parameter is
ECM. Check for aftermarket engine protection programmed to “None” (default), this feature is not
switches that interrupt power. Send the vehicle to used. If the “Ignore/Brake Clutch Switch” parameter
the OEM dealer to repair. STOP. is programmed to J1/P1:47, then the feature is
available and the switch circuit should be connected
• Not OK – The symptoms did not disappear. to P1-47 of the P1 ECM vehicle harness connector.
Repair: Connect the bypass to another battery and Note: The wiring for your particular application
verify if the problem is resolved. If the problem is may be slightly different. The circuits for the sensor
resolved, the problem is with the vehicle batteries. common are used interchangeably by the OEM of
the vehicle. The following circuits are common within
the ECM:
g00682286
Illustration 130
Terminal Locations for ECM
Expected Result:
Results:
Illustration 131
g01105610 Verify that the repair eliminates the problem.
Schematic for ignore brake/clutch switch
STOP.
(18) Input number 1 sensor common
(47) Input number 5 (ignore brake/clutch switch
Test Step 2. Check the Status of the
Ignore Brake/Clutch Switch on Caterpillar
Test Step 1. Check the Electrical Electronic Technician (ET)
Connectors and the Wiring
A. Connect Cat ET at the cab data link connector.
A. Thoroughly inspect the ECM vehicle harness
connector J1/P1, the connectors, and the firewall B. Turn the ignition key switch to the ON position.
bulkhead connectors. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details. C. View the “Ignore Brake/Clutch Switch” status on
Cat ET.
266 RENR2238-09
Troubleshooting Section
E. If the “Ignore Brake/Clutch Switch” status indicates • OK – The ECM is functioning properly at this time.
“Not Installed”, then the “Ignore Brake/Clutch Proceed to Test Step 4.
Switch” parameter has not been programmed.
• Not OK – The ECM is not functioning properly.
Expected Result:
Repair: Perform the following repair:
The “Status” screen indicates “On” if the switch is
turned on. The “Status” screen indicates “Off” if the 1. Temporarily connect a test ECM.
switch is turned off.
2. Recheck the system for active diagnostic codes.
Results:
3. Repeat this Test Step.
• OK – The switch is operating normally. Continue
troubleshooting if the original condition is not 4. If the problem is resolved with the test ECM,
resolved. STOP. reconnect the suspect ECM.
• Not OK – The ECM is not reading the change in 5. If the problem returns with the suspect ECM,
switch status. Proceed to Test Step 3. replace the ECM.
Test Step 3. Check the Switch Circuit at 6. Verify that the repair eliminates the problem.
the ECM
STOP.
A. Turn the ignition key switch to the OFF position.
Test Step 4. Insert a Jumper Wire at the
B. Remove the wire in P1-47 Ignore Brake/Clutch Switch
Switch from the ECM connector P1.
A. Turn the ignition key switch to the OFF position.
C. Install a 140-2266 Cable As (70-PIN
BREAKOUT) to the ECM vehicle harness B. Reconnect the ECM vehicle harness connector
connector J1/P1. J1/P1.
D. Fabricate a jumper wire 100 mm (4 inch) long. C. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wire. Crimp a Deutsch pin to both ends of the wire.
E. Insert the jumper wire into terminal 18 (Input D. Insert the jumper wire between the two terminals
Sensor Common #1) of the breakout T. Insert of the ignore brake/clutch switch.
the other end of the jumper wire into terminal 47
(Ignore Brake/Clutch Switch) of the breakout T. E. Turn the ignition key switch to the ON position.
F. Connect Cat ET to the cab data link connector. F. Alternately remove the jumper wire and then insert
the jumper wire at the switch terminals. At the
G. Turn the ignition key switch to the ON position. same time, watch the status screen on Cat ET.
H. Alternately remove the jumper wire and insert the Expected Result:
jumper wire at terminal 18 while you monitor the
status screen on Cat ET. The switch status changes to “ON” with the jumper
wire in place to “OFF” when the jumper wire is
I. Turn the ignition key switch to the OFF position. removed.
Test Step 5. Insert a Jumper Wire at the Perform this procedure under conditions that are
Bulkhead Connector identical to the conditions that exist when the problem
occurs. Typically, problems with the injector solenoid
A. Turn the ignition key switch to the OFF position. occur when the engine is warmed up and/or when
the engine is under vibration (heavy loads).
B. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wire. The following background information is related
to this procedure:
C. Insert the jumper wire between the two terminals
for the ignore brake/clutch switch on the engine These engines have Electronic Unit Injectors that are
side of the ECM bulkhead connector. mechanically actuated and electronically energized.
The engine control module sends a 105 volt pulse
D. Turn the ignition key switch to the ON position. to each injector solenoid. The pulse is sent at the
proper time and at the correct duration for a given
E. Alternately connect and then disconnect the engine load and speed. The solenoid is mounted
jumper wire. At the same time, monitor the status on top of the fuel injector body. The 105 volt pulse
screen on Cat ET. can be individually cut out to aid in troubleshooting
misfire problems.
Expected Result:
If an open is detected in the solenoid circuit, a
The switch status changes from “ON” with the jumper diagnostic code is generated. The ECM continues
wire in place to “OFF” when the jumper wire is to try to fire the injector. If a short is detected, a
removed. diagnostic code is generated. The ECM will disable
the solenoid circuit. The ECM will then enable the
Results: solenoid. If the short circuit remains this sequence of
events will be repeated until the problem is corrected.
• OK – The switch status changes from “ON” with
the jumper wire in place to “OFF” when the jumper Some personality modules require the injector
wire is removed. The problem is in the vehicle codes to be programmed. Injector codes allow each
wiring between the bulkhead connector and the individual injector to be fine tuned for optimum
switch. performance. The ECM will generate the following
diagnostic code if the injector codes are not
Repair: Inspect the vehicle wiring and then repair programmed:
the vehicle wiring. Otherwise, send the vehicle to
the OEM dealer for repair. • 253-02 Check Customer or System Parameters
Verify that the original condition is resolved. When an injector is replaced, program the injector
code that is etched on the injector. The injector code
STOP. is a four digit number. If the ECM is replaced, all six
injector codes must be programmed into the new
• Not OK – The problem is in the vehicle wiring ECM. Refer to Troubleshooting, “Injector Code -
between the bulkhead connector and the ECM. Calibrate”.
STOP.
268 RENR2238-09
Troubleshooting Section
g00735975
Illustration 132
Electronic Unit Injector
g00927316
Illustration 133
Schematic for electronic unit injector
RENR2238-09 269
Troubleshooting Section
g00663571
Illustration 134
P2 ECM connector
Test Step 1. Inspect Electrical Connectors F. Check the harness and wiring for abrasion and
and Wiring pinch points from the injectors to the ECM.
Expected Result:
C. Perform a 45 N (10 lb) pull test on each of Repair the connectors or wiring and/or replace
the wires in the J2/P2 ECM connector and the connectors or wiring. Ensure that all of the
the J300/P300 valve cover connector that are seals are properly in place and ensure that the
associated with injector solenoids. connectors are completely coupled.
Refer to Illustration 134. Verify that the repair eliminates the problem.
Expected Result:
Results:
g00663575
Illustration 135
“Automated Cylinder Cutout Test” screen in Caterpillar Electronic Technician (Cat ET)
Expected Result:
Results:
• OK
Repair: If the engine is misfiring or if the
engine has low power, refer to Troubleshooting,
“Engine Misfires, Runs Rough or Is Unstable”
and Troubleshooting, “Low Power/Poor or No
Response to Throttle”.
g00663576
Illustration 136
“Injector Solenoid Test” screen in Caterpillar Electronic Technician (Cat ET)
A. Start the engine. Note: Do not confuse the Injector Solenoid Test with
the Cylinder Cutout Test. The Cylinder Cutout Test is
B. Allow the engine to warm up to 77 °C (171 °F) used to shut off fuel to a specific cylinder while the
which is the normal operating temperature. engine is running. The Injector Solenoid Test is used
in order to actuate the injector solenoids. This allows
C. Turn the key switch to the OFF position. the click of the injector solenoids to be heard when
the engine is not running in order to determine that
D. Connect Cat ET to the data link connector. the circuit is functioning properly.
E. Turn the key switch to the ON position. H. As each solenoid is energized by the ECM an
audible click can be heard at the valve cover.
F. After the engine is warmed to operating Listen for a click at each valve cover. A black
temperature, access the “Injector Solenoid Test” square will appear over the cylinder number when
by accessing the following display screens in the cylinder is being fired.
order:
I. Perform the Injector Solenoid Test at least two
• “Diagnostics” times.
STOP.
Expected Result:
Results:
g00663572
Illustration 137
Injector connector for Engine harness
Expected Result:
G. Repeat this test for each suspect Injector. Ensure D. Perform the Injector Solenoid Test at least two
that the Injector Solenoid Test is disabled before times.
handling the jumper wires.
RENR2238-09 275
Troubleshooting Section
All cylinders indicate “OPEN” when the P2 ECM • Result 1 – Proceed to Test Step 10.
connector is disconnected from the ECM.
• Result 2 – Proceed to Test Step 11.
Note: When the engine harness is disconnected
all of the diagnostic codes for supply voltage to the • Result 3 – Proceed to Test Step 12.
sensors will be active. This is normal. Clear all of
these diagnostic codes after completing this test step. Test Step 9. Check the ECM for an Open
Circuit
Results:
Repair: Perform the following repair: C. Use a jumper wire to short between the socket of
the injector and the common socket of the suspect
1. Temporarily connect a test ECM. injector.
2. Remove all jumpers and replace all connectors. D. Turn the key switch to the ON position.
3. Recheck the system for active diagnostic codes. E. Perform the Injector Solenoid Test at least two
times.
4. Repeat the Test Step.
Expected Result:
5. If the problem is resolved with the test ECM,
reconnect the suspect ECM. ET displays “SHORT” for the cylinder with the jumper
wire.
6. If the problem returns with the suspect ECM,
replace the ECM. Note: When the engine harness is disconnected
all of the diagnostic codes for supply voltage to the
7. Verify that the repair eliminates the problem. sensors will be active. This is normal. Clear all of
these diagnostic codes after completing this test step.
STOP.
Results:
Test Step 8. Evaluate the Symptoms
• OK – The ECM is OK.
Expected Result:
Repair: Perform the following repair:
Choose from these possible results:
Replace the engine harness or repair the engine
Result 1 Test Step 6 indicated that only one injector harness, as required.
had an “OPEN” or “SHORT”, or that one injector
had an “OPEN” but the other injector on the injector Verify that the repair eliminates the problem.
common line had a “SHORT”.
STOP.
Result 2 Test Step 6 indicated that two injectors that
share an injector common line are open. • Not OK
Result 3 Test Step 6 indicated that two injectors that Repair: Perform the following repair:
share an injector common line are shorted.
1. Temporarily connect a test ECM.
276 RENR2238-09
Troubleshooting Section
2. Remove all jumpers and replace all connectors. Verify that the repair eliminates the problem.
STOP.
Expected Result:
Results:
• OK
Repair: Perform the following repair:
g00663574
Illustration 138
Harness terminals of Electronic Unit Injector
F. Perform the Injector Solenoid Test at least two Test Step 12. Check the Engine Harness
times. Under the Valve Cover for Short Circuits
in the Injector Wires
Expected Result:
• OK
278 RENR2238-09
Troubleshooting Section
Test Step 13. Check for a Short Circuit in The reconnected injector indicates a “SHORT”.
the Injector Common Line to the Engine
Results:
• OK
Electrical shock hazard. The electronic unit injec-
Repair: Perform the following repair:
tor system uses 90-120 volts.
Replace the Injector.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch Verify that the repair eliminates the problem.
is not turned off.
STOP.
B. Disconnect the J2/P2 ECM connector.
• Not OK – The injector is OK. Proceed to Test Step
C. Locate the common line for the problem injector 15.
in the P2 connector. Measure the resistance from
the terminal to the engine ground stud connection.
Expected Result:
Test Step 15. Check for a Short Circuit The multitorque feature is an optional feature. This
in the Other Injector feature requires unique software. The multitorque
feature provides an otherwise standard engine with
two different torque curves. The torque curve for the
lower gears functions as a standard engine. The
torque curve for the top gears provides additional
Electrical shock hazard. The electronic unit injec- torque. The transmission ratio determines the top
tor system uses 90-120 volts. gears. In the top gears, the engine provides additional
torque. This additional torque is typically 136 N·m
A. Turn the key switch to the OFF position. A strong (100 lb ft).
electrical shock hazard is present if the key switch
is not turned off. The ECM determines when the vehicle is in the top
gears by sensing the ratio of engine speed to vehicle
B. Reconnect the other disconnected injector. speed. The engine will operate with the higher torque
curve if the ratio of engine speed to vehicle speed is
C. Turn the key switch to the ON position. within the specified range.
D. Perform the Injector Solenoid Test at least two The engine ratings are based on the trip point.
times. Additional torque is made available at the trip points.
The three options are listed below.
Expected Result:
• MT-4 ratio is 71.5 rpm/mph & below (Top 4 Gears)
The reconnected injector indicates a “SHORT”.
• MT-2 ratio is 37.6 rpm/mph & below (Top 2 Gears)
Results:
• MT-1 ratio is 27.9 rpm/mph & below (Top 1 Gear)
• OK –
With OCT99 and newer software, the “Multitorque
Repair: Perform the following repair: Ratio” parameter was added. This allows the
selection of the desired ratio turn on trip point (MT-1,
Replace the faulty injector. Restore the wiring to MT-2, or MT-4). “Multitorque Ratio” is used rather
the proper injectors. than requiring three different ratings that are based
only on the different ratio trip points. With older
Verify that the repair eliminates the problem. software, the engine rating determined the specific
ratio that was used for the vehicle application.
STOP.
The multitorque feature differs from the PTO torque
• Not OK – This injector is OK. STOP. limit. The PTO torque limit requires a torque limit
switch. Multitorque software provides a second
torque curve. The engine will not exceed the PTO
i01815762 torque limit. The ECM essentially removes the top
of the torque curve at the programmed PTO torque
Multi-Torque - Test limit. The PTO torque limit is used only for temporary
protection of equipment.
SMCS Code: 1901-038
Test Step 1. Repair all Diagnostic Codes
System Operation Description: and Other Problems
Use this procedure under the following situation: A. Make sure that there are no active diagnostic
codes and make sure that there are no logged
The multitorque software is suspected of operating
diagnostic codes that affect engine performance.
incorrectly. Access the Instantaneous Screen if
the vehicle is equipped with the (CAT ID) Driver B. Refer to the procedure that best describes
Information Display. This screen will show the status
the symptom if there are any other complaints
of the multitorque feature in order to determine if the or symptoms. Refer to Troubleshooting for
multitorque feature is activating. troubleshooting information on specific symptoms,
or the relationship between diagnostic codes and
Background of the multitorque feature possible performance related complaints.
Expected Result:
Test Step 2. Verify that the Software is With OCT99 and newer software, verify that the
Installed “Multitorque Ratio” parameter is programmed to
the correct setting.
A. Connect the Caterpillar Electronic Technician (ET)
to the cab data link connector. Verify that the repair eliminates the problem.
Expected Result:
i02049755
g00646460
Illustration 139
Schematic for transmission neutral switch
Idle Parameters
• “PTO Configuration”
• “PTO Vehicle Speed Limit”
• “Transmission Neutral Switch”
D. Ensure that the vehicle is not experiencing
a problem due to one of these parameters.
Refer to Troubleshooting, “Customer Specified
Parameters” for a description of the parameters, if
necessary.
• Cruise Kickout
• Idle Kickout
• PTO Kickout
RENR2238-09 283
Troubleshooting Section
g00705233
Illustration 140
Expected Result:
Results:
A. Access the status screen on the electronic service Take the vehicle for a road test in order to
tool. duplicate these conditions and set the cruise
control. Operate the vehicle in cruise control until
B. Turn the key switch to the ON position. the problem reoccurs.
C. Shift the transmission into the Neutral position B. For an intermittent idle kickout, talk to the driver
while the status for the “Transmission Neutral in order to determine the conditions when the
Switch” is being observed. Also, shift out of neutral kickout occurs. A topic of examination could be
while the status for the “Transmission Neutral the following example:
Switch” is being observed.
• Specific engine rpm
Note: If the status indicates “Not Installed”, check the
programming of the “Transmission Style” parameter. Start the engine. Duplicate these conditions and
The “Transmission Style” must be programmed to set the idle rpm. Operate the vehicle in idle until
“Automatic Option 3” or “Automatic Option 4”. With the problem reoccurs.
DEC03 and later software, the “Transmission Style”
parameter must be programmed to NONE, J1/P1:62, Note: The status screen on the electronic service tool
or J1939. will only indicate the last kickout. The status screen
on the electronic service tool will lose this information
Expected Result: if the key switch is turned OFF.
The switch status changes per the information in C. Connect the electronic service tool and check the
Table 151. status screen for the last cause of the kickout.
• “Brake”
RENR2238-09 285
Troubleshooting Section
RESULT 4 The status for the kickout displays the Troubleshooting, “PTO Switch Circuit - Test”
following result:
STOP.
• “Vehicle Speed < Limit”
• Result 6
• “Bad Vehicle Speed”
Repair: Perform the following diagnostic
• “Vehicle Speed ≥ Limit” procedure:
RESULT 5 The status for the kickout displays the Troubleshooting, “Clutch Pedal Position Switch
following result: Circuit - Test”
RESULT 7 The status for the kickout displays the Troubleshooting, “Engine Speed/Timing Circuit -
following result: Test”
Troubleshooting, “Service Brake Pedal Position F. Turn the key switch to the ON position.
(Switch 1) Circuit - Test”
G. Connect the electronic service tool to the data link
STOP. connector.
Repair: Perform the following diagnostic When the jumper wire is installed, the status for
procedure: the “Transmission Neutral Switch” is “On”. When
the jumper wire is removed, the status for the
“Transmission Neutral Switch” is “Off”.
286 RENR2238-09
Troubleshooting Section
Results: Results:
• OK – The ECM is functioning properly. Proceed • OK – The switch is not functioning properly.
to Test Step 6.
Repair: Perform the following repair:
• Not OK – The ECM is not functioning properly.
Replace the faulty switch.
Repair: Perform the following repair:
Verify that the repair eliminates the problem.
1. Temporarily connect a test ECM.
STOP.
2. Remove all jumpers and replace all connectors.
• Not OK – There is a problem in the harness
3. Recheck the system for active diagnostic codes. between the switch and the ECM. Proceed to Test
Step 7.
4. Repeat the Test Step.
Test Step 7. Insert a Jumper at the
5. If the problem is resolved with the test ECM, Bulkhead Connector
reconnect the suspect ECM.
A. Turn the key switch to the OFF position.
6. If the problem returns with the suspect ECM,
replace the ECM. B. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to each end of the wires.
7. Verify that the repair eliminates the problem.
C. Find the neutral switch terminal and the +Battery
STOP. connection in the engine side of the bulkhead
connector for the vehicle harness.
Test Step 6. Insert a Jumper at the Neutral
Switch D. Insert the jumper wire between the two terminals
in the engine side of the bulkhead connector.
A. Turn the key switch to the OFF position.
E. Turn the key switch to the ON position.
B. Ensure that the J1/P1 ECM connector is
connected. F. Connect the electronic service tool to the data link
connector.
C. Find the neutral switch in the vehicle.
G. Access the status screen on the electronic service
D. Disconnect the wires from the neutral switch tool.
terminals.
H. While the switch status is being monitored,
E. Turn the key switch to the ON position. alternately remove the jumper wire between the
two terminals, and alternately insert the jumper
F. Connect the electronic service tool to the data link wire between the two terminals.
connector.
Expected Result:
G. Access the status screen on the electronic service
tool. When the jumper wire is installed, the status for
the “Transmission Neutral Switch” is “On”. When
H. While the status for the “Transmission Neutral the jumper wire is removed, the status for the
Switch” is being monitored, connect the switch “Transmission Neutral Switch” is “Off”.
wires and disconnect the switch wires.
Results:
Expected Result:
• OK – The problem is in the vehicle wiring between
When the switch wires are connected, the status for the bulkhead connector and the switch.
the “Transmission Neutral Switch” is “On”. When the
switch wires are disconnected, the status for the Repair: Perform the following repair:
“Transmission Neutral Switch” is “Off”.
RENR2238-09 287
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Inspect the vehicle wiring and repair the vehicle The J1922 and J1939 refers to the standard
wiring, as required. If the problem still exists with for data link communications of the Society of
the wiring, send the vehicle to the OEM dealer. Automotive Engineers Inc.. The ECM has a customer
programmable parameter that is called “Powertrain
STOP. Data Link” which can be programmed to any one of
the following options:
• Not OK – The problem is in the vehicle wiring
between the bulkhead connector and the ECM. • J1922
Repair: Perform the following repair: • J1939
Inspect the vehicle wiring and repair the vehicle • J1922 and J1939
wiring, as required. If the problem still exists with
the wiring, send the vehicle to the OEM dealer. • None
STOP. Anti-Lock Brake Systems (ABS)
• SAE J1922
• SAE J1939
288 RENR2238-09
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g00652190
Illustration 141
Schematic for Power train data link
RENR2238-09 289
Troubleshooting Section
g00714306
Illustration 142
ECM pin locations
Note: The “Powertrain Data Link” parameter is a • No – The ECM is not receiving messages from the
customer parameter that must not be programmed to devices that are installed on the vehicle.
J1939, or J1922 and J1939, unless the J1939 data
link is being used. Repair: The devices that can be programmed to
use the J1939 data link can be circuits with two
Results: wires or circuits with three wires. Bad connections
are the most frequent problem. Repair the suspect
• J1939 – Proceed to Test Step 3. component or replace the suspect component.
This may include the connectors, the wiring, and/or
• J1922 – Proceed to Test Step 5. the device. Ensure that the connectors are free of
corrosion.
• Not OK – Proceed to Test Step 4.
STOP.
Test Step 3. Check the Devices on the
J1939 Data Link.
A. Connect Cat ET to the data link connector.
Expected Result:
Results:
g00714416
Illustration 143
Table 152
A. Connect Cat ET to the data link connector. B. While the vehicle is being driven by someone else,
monitor Cat ET. Use the following procedure:
RENR2238-09 293
Troubleshooting Section
Expected Result:
Results:
• Not OK
Repair: Perform the following diagnostic
procedure:
STOP.
294 RENR2238-09
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g00652192
Illustration 144
Terminal locations for ECM
C. Reconnect vehicle harness connector P1 to the 1. Use the following procedure if the vehicle is not
ECM when the wires are disconnected. using the J1922 data link for power train control:
D. Turn the key switch to the ON position. a. Leave the pins for the data link disconnected
from the ECM.
E. Monitor the active diagnostic code screen on Cat
ET. Check and record active diagnostic codes. b. Fill the unused cavities of connector P1 with
Deutsch plugs.
Expected Result:
c. Program the parameter for the “Powertrain
The following diagnostic code is active: Data Link” to “None”.
• 249-11 J1922 Data Link Fault (58) 2. Use the following procedure if the vehicle is
using the J1922 data link for power train control:
Note: If the J1922 data link is not being used for the
vehicle’s power train control, program the “Powertrain a. Temporarily connect a test ECM.
Data Link” parameter to “None”. After the “Powertrain
Data Link” parameter is programmed to “None”, the b. Repeat the Test Step.
following active diagnostic code should be repaired:
c. If the problem is resolved with the test ECM,
• 249-11 J1922 Data Link Fault (58) reconnect the suspect ECM.
RENR2238-09 295
Troubleshooting Section
d. If the problem returns with the suspect ECM, Switch for “PTO Engine RPM Set Speed Input A”
replace the ECM.
The switch for the “PTO Engine RPM Set Speed
STOP. Input A” is used to control engine RPM during
PTO operation. The “PTO Engine RPM Set Speed
• Not OK – The ECM is OK. A” parameter requires an engine RPM to be
programmed. The “PTO Engine RPM Set Speed
Repair: Perform the following diagnostic A” parameter is located in the “Dedicated PTO
procedure: Parameter Group”. The “PTO Engine RPM Set Speed
Input A” status is located in the “Input Selections
1. Use the following procedure if the vehicle is not Parameter Group”. The engine will ramp up to the
using the J1922 data link for power train control: engine rpm that is programmed under the following
conditions:
a. Leave the pins of the data link disconnected
from the ECM. • The switch for the “PTO Engine RPM Set Speed
Input A” is in the ON position and the PTO On/Off
b. Fill the unused cavities of connector P1 with switch is then turned on.
Deutsch plugs.
• The switch for the “PTO Engine RPM Set Speed
c. Program the parameter for the “Powertrain Input A” is turned to the ON position when the PTO
Data Link” to “OFF”. On/Off switch is on.
d. Verify that the repair eliminates the problem. The “PTO Configuration” must be programmed to
“Cab Switches”, “Remote Switches”, or “Remote
2. Use the following procedure if the vehicle is Throttle” for this feature to function. The PTO On/Off
using the J1922 data link for power train control: switch or the switch for the “PTO Engine RPM
Set Speed Input A” must be cycled from the OFF
a. Send the vehicle to the OEM dealer for position to the ON position in order to return to the
repair. programmed engine rpm if the PTO operation is
disabled. If the “PTO Engine RPM Set Speed Input
b. Verify that the repair eliminates the problem. A” parameter is programmed to None (default), this
feature is not used. If the “PTO Engine RPM Set
STOP. Speed Input A” parameter is programmed to one of
the available inputs (J1/P1:6, J1/P1:46, J1/P1:58,
J1/P1:60), the feature is available. Also, the switch
i01625471
circuit should be connected to the same input.
PTO Engine RPM Set Speed Switch for the “PTO Engine RPM Set Speed Input
(Input A and Input B) Circuit - B”
Test The switch for the “PTO Engine RPM Set Speed
Input B” is used to control engine RPM during
SMCS Code: 1901-038
PTO operation. The “PTO Engine RPM Set Speed
System Operation Description: B” parameter requires an engine RPM to be
programmed. The “PTO Engine RPM Set Speed
B” parameter is located in the “Dedicated PTO
Use this procedure under the following situation:
Parameter Group”. The “PTO Engine RPM Set Speed
Input B” status is located in the “Input Selections
Use this procedure to determine if the circuit for the
Parameter Group”. The function of the switch for the
PTO Engine RPM Set Speed “Input A” and “Input
B” is operating correctly. This feature is available on “PTO Engine RPM Set Speed Input B” is similar to
the function of the switch for the “PTO Engine RPM
NOV99 and newer software.
Set Speed Input A”. The engine will operate at set
The following background information is related speed “A” when both of the switches are on. If the
“PTO Engine RPM Set Speed Input B” parameter
to this procedure:
is programmed to “None” (default), this feature is
The ECM can use various inputs in a number of ways. not used. If the “PTO Engine RPM Set Speed Input
B” parameter is programmed to one of the available
The inputs depend on the parameter programming.
inputs (J1/P1:6, J1/P1:46, J1/P1:58, J1/P1:60), then
Certain features are available on several different
inputs. The configuration for the switch must match the feature is available. Also, the switch circuit should
be connected to the same input option.
the actual switch installation in order for the switch
to function properly.
296 RENR2238-09
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g00683014
Illustration 145
This illustration represents the schematic for the “PTO Engine RPM Set Speed Input A” switch circuit.
g00683021
Illustration 146
This illustration represents the schematic for the “PTO Engine RPM Set Speed Input B” switch circuit.
RENR2238-09 297
Troubleshooting Section
g00683028
Illustration 147
Terminal Locations for ECM
All connectors, pins, and sockets are completely E. If the “PTO Engine RPM Set Speed Input A” status
coupled and/or inserted, and the harness and wiring indicates “Not Installed”, then the parameter has
should be free of corrosion, abrasion or pinch points. not been programmed. If the “PTO Engine RPM
Set Speed Input B” status indicates “Not Installed”,
Results: then the parameter has not been programmed.
Expected Result:
Results:
g00683037
Illustration 148
Connector for Breakout T
B. Install a 70 terminal breakout T to the ECM vehicle • OK – The ECM is functioning properly at this time.
harness connector J1/P1. Proceed to Test Step 4.
C. Fabricate a jumper wire 100 mm (4 inch) long. • Not OK – The ECM is not functioning properly.
Crimp a Deutsch pin to both ends of the wire.
Repair: Perform the following repair:
D. Insert the jumper wire into the suspect switch
socket of the breakout T. Connect the other end of 1. Temporarily connect a test ECM. Only connect
the jumper wire to terminal 5 (AP Sensor/Switch ECM harness J1/P1.
Common) in the breakout T.
2. Recheck for an +5 V diagnostic code when the
E. Connect ET to the cab data link connector. engine harness is disconnected.
F. Turn the ignition key switch to the ON position. 3. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
G. Alternately remove the jumper wire and then insert
the jumper wire from terminal 5. At the same time, 4. If the problem returns with the suspect ECM,
monitor the status screen on ET. replace the ECM.
C. Fabricate a jumper wire 100 mm (4 inch) long. • OK – The problem is in the vehicle wiring between
Crimp a Deutsch pin to both ends of the wire. the bulkhead connector and the switch. Inspect the
vehicle wiring and then repair the vehicle wiring.
D. Insert the jumper wire between the two switch Otherwise, send the vehicle to the OEM dealer for
terminals. repair. Verify that the original condition is resolved.
STOP.
E. Turn the ignition key switch to the ON position.
• Not OK – The problem is in the vehicle wiring
F. Alternately remove the jumper wire and then insert between the bulkhead connector and the ECM.
the jumper wire at the switch terminals. At the Inspect the vehicle wiring and then repair the
same time, watch the status screen on ET. vehicle wiring. Otherwise, send the vehicle to
the OEM dealer for repair. Verify that the original
Expected Result: condition is resolved. STOP.
If the PTO shutdown timer is activated and the timer c. Ensure that the status of the PTO on/off switch
stops the engine, the following event code will be is on.
generated.
d. Observe the status of the PTO shutdown.
• 71-14 (47)
Note: The following note pertains to the heavy-duty
Note: Fuel rates are not monitored while the PTO engines (C-10, C11, C-12, C13, 3406E, C15, C-15,
shutdown timer is active. Shutdown will occur C-16, and C-18). With OCT99 and newer software,
regardless of load. Unlike the idle shutdown timer, a “PTO Shutdown Timer Maximum RPM” can be
the PTO shutdown timer cannot be overridden by programmed in order to allow the timer to be reset by
using the clutch pedal or the brake pedal. increasing engine RPM above the programmed limit.
Ensure that the accelerator is not being depressed in
The following note pertains to the heavy-duty engines order to increase rpm beyond the programmed limit.
(C-10, C11, C-12, C13, 3406E, C15, C-15, C-16,
and C-18). Expected Result:
Note: With OCT99 and newer software, an additional Result 1 The status of the parameter for PTO
parameter can be programmed to allow the timer to shutdown indicates “COUNTING”.
be reset above a specified engine speed. When the
parameter for the “PTO Shutdown Timer Maximum Result 2 The ECM is not reading the proper
RPM” is programmed to a value below the top engine conditions for activation of the timer.
limit, the timer can be reset by increasing engine rpm
above a programmed limit. The timer will stay reset Results:
until engine rpm drops below the programmed value.
At this point, the timer will begin to count again. The • Result 1 – The ECM is reading the proper
factory default setting of 2120 rpm (top engine limit) conditions for the activation of the PTO shutdown
disables this feature. timer. Proceed to Test Step 2.
Test Step 1. Verify Activation of the PTO • Result 2 – The ECM is not reading the proper
Shutdown Timer conditions for activation of the timer. Proceed to
Test Step 3.
A. Connect Caterpillar Electronic Technician (ET) to
the data link connector. Test Step 2. Verify the Driver Alert
Function of the PTO Shutdown
B. Access the customer parameters on Cat ET.
Access the following display screens in order: A. Verify that Cat ET is connected to the data link
connector.
• “Service”
B. Use the following procedure in order to activate
• “Configuration” the PTO shutdown timer:
a. Record the programmed PTO shutdown time. a. Access the customer parameters on Cat ET.
The PTO shutdown time must be between 3 Access the following display screens in order:
and 1440 minutes. If the PTO shutdown time is
programmed to zero, the timer is disabled. • “Service”
C. Start the engine. Allow the engine to warm up until • “Configuration”
the coolant temperature is 38 °C (100 °F). Allow
the engine to operate at the programmed low idle b. Record the programmed PTO shutdown time.
and turn off any unnecessary accessory devices. The PTO shutdown time must be between 3
and 1440 minutes. If the PTO shutdown time is
D. Ensure that all unnecessary loads are turned off. programmed to zero, the timer is disabled.
E. Use the following procedure in order to check the c. Reprogram the PTO shutdown time to three
operation of the PTO shutdown: minutes for this test.
a. Park the vehicle. C. Observe the following items during the 90 second
period before the programmed shutdown time:
b. Ensure that the PTO configuration is
programmed to cab switches, remote switches • Check engine lamp
or remote throttle.
RENR2238-09 301
Troubleshooting Section
• Status of the PTO shutdown timer Note: The status screen on Cat ET will indicate if
the cold mode is active.
• PTO switch on lamp
c. Ensure that the PTO on/off switch is on.
While the engine is in the last 90 second period
before the scheduled shutdown, the status should Expected Result:
change from “COUNTING” to “DRIVER ALERT”
and the check engine lamp and the PTO switch on Result 1 Vehicle speed is not indicated as 0 km/h
lamp should flash rapidly. (0 mph).
Note: A PTO switch on lamp is an optional feature Result 2 The status screen on Cat ET indicates that
and the PTO switch on lamp may not be installed. the engine is in the cold mode.
D. Reprogram the PTO shutdown timer to the value Result 3 The PTO on/off switch is not on.
that was recorded earlier for this test.
Results:
Expected Result:
• Result 1 – Vehicle speed is not indicated as
Result 1 The driver alert function of the PTO 0 km/h (0 mph). Continue by testing the vehicle
shutdown operates in the manner that is described speed circuit.
above.
Repair: Perform the following diagnostic
Result 2 The PTO switch on lamp did not flash. procedure: Troubleshooting, “Vehicle Speed Circuit
- Test”
Result 3 The check engine lamp did not flash.
STOP.
Results:
• Result 2 – The status screen on Cat ET indicates
• Result 1 – The PTO shutdown timer is operating that the engine is in the cold mode. The engine
properly. Clear all diagnostic codes. STOP. must not be in cold mode operation while this test
procedure is being performed. Allow the engine to
• Result 2 – “PTO Switch On Lamp” did not flash run until the coolant temperature exceeds 38 °C
during the driver alert. (100 °F). Troubleshoot and repair any related
conditions. STOP.
Repair: Perform the following diagnostic
procedure: Troubleshooting, “PTO Switch ON • Result 3 – The PTO on/off switch is not on.
Lamp Circuit - Test” Continue by testing the circuit for the PTO on/off
switch.
STOP.
Repair: Perform the following diagnostic
• Result 3 – The check engine lamp did not flash procedure: Troubleshooting, “PTO Switch Circuit -
during the driver alert. Test”
• The engine is not in the Cold Mode. Result 1 The status of the parameter for “PTO
Shutdown” indicates “COUNTING”.
During the last 90 seconds of the PTO Shutdown
Timer, the check engine lamp will begin flashing. If Result 2 The ECM is not reading the proper
the vehicle is equipped with a PTO switch on lamp, conditions for activation of the timer.
the PTO switch on lamp will begin flashing during
the last 90 seconds. Results:
If the PTO shutdown timer is activated and the timer • Result 1 – The ECM is reading the proper
stops the engine, the following event code will be conditions for the activation of the PTO shutdown
generated. timer. Proceed to Test Step 2.
During the 90 second period before the scheduled c. Ensure that the PTO on/off switch is on.
shutdown, the status should change from
“COUNTING” to “DRIVER ALERT”. The check Expected Result:
engine lamp and the PTO switch on lamp should
flash rapidly. Result 1 Vehicle speed is not indicated as 0 km/h
(0 mph).
Note: A PTO switch on lamp is an optional feature
and the PTO switch on lamp may not be installed. Result 2 The electronic service tool status screen
indicates that the engine is in the cold mode.
D. Reprogram the PTO shutdown timer to the value
that was recorded earlier for this test. Result 3 The PTO on/off switch is not on.
Result 1 The driver alert function of the PTO • Result 1 – Continue by testing the vehicle speed
shutdown operates in the manner that is described circuit.
above.
Repair: Perform the following diagnostic
Result 2 The PTO switch on lamp did not flash. procedure: Troubleshooting, “Vehicle Speed Circuit
- Test”
Result 3 The check engine lamp did not flash.
STOP.
Results:
• Result 2 – The engine must not be in cold mode
• Result 1 – The PTO shutdown timer is operating operation while this test procedure is being
properly. Clear all diagnostic codes. STOP. performed. Allow the engine to run until the coolant
temperature exceeds 38 °C (100 °F). Troubleshoot
• Result 2 – The PTO switch on lamp did not flash and repair any related conditions. STOP.
during the driver alert.
• Result 3 – Continue by testing the circuit for the
Repair: Perform the following diagnostic PTO on/off switch.
procedure: Troubleshooting, “PTO Switch ON
Lamp Circuit - Test” Repair: Perform the following diagnostic
procedure: Troubleshooting, “PTO Switch Circuit -
STOP. Test”
When the PTO on/off switch is on, the ECM will be • Service brake pedal position switch 2
in dedicated PTO mode.
• Clutch pedal position switch
When the ECM is in the dedicated PTO mode the
PTO Top Engine Limit (TEL) is activated. The engine • Neutral switch
may proceed directly to the PTO engine rpm set
speed if the parameter is programmed. If a PTO • Cruise control pause switch
switch on lamp is connected to the P1-30 output 1,
the PTO switch on lamp will turn on whenever the When the “PTO Configuration” is programmed to
PTO on/off circuit is on. “Cab Switches” and the PTO on/off switch is on, the
accelerator pedal position sensor that is located in the
If the problem is with undetermined PTO kickouts, cab can be limited to one of the following settings by
use the following procedure: using the “PTO Cab Throttle RPM Limit” parameter:
Table 153
Table For The PTO Kickout Status Screen On Cat ET
Cat ET Meaning or Possible Cause Troubleshooting
Intermittent engine speed signal or lost Refer to Troubleshooting, “Speed/Timing
“No Engine Speed”
engine speed signal. Circuit - Test”.
The PTO on/off switch is turned off or the Proceed with this test procedure.
“Switch Turned Off”
switch circuit has an open circuit condition.
The cruise control pause switch is Refer to Troubleshooting, “Powertrain Data
“Cruise Control PAUSE
depressed or there is an illegal message on Link Circuit - Test”.
Switch”
the J1939 data link.
The service brake pedal is depressed or the Refer to Troubleshooting, “Service Brake
“Brake Pedal Depressed” circuit for the service brake switch has an Pedal Position Switch 1 Circuit - Test”.
open circuit condition.
The clutch pedal is depressed or the circuit Refer to Troubleshooting, “Clutch Pedal
for the clutch pedal position switch has an Position Switch Circuit - Test”.
“Clutch Pedal Depressed”
open circuit condition. Also, the switch could
be incorrectly adjusted.
The vehicle speed has exceeded the speed Refer to Troubleshooting, “Vehicle Speed
that is programmed into the “PTO vehicle and Speedometer Circuit - Test” if a problem
“Vehicle Speed ≥ Limit”
speed limit” parameter or the vehicle speed with the signal exists.
signal is erratic or intermittent.
The transmission is not in neutral or the Refer to Troubleshooting, “Neutral Switch
“Neutral” transmission neutral switch circuit has an Circuit - Test”.
open circuit condition.
The PTO has not been enabled since the Operate the vehicle in the PTO mode in
“Not Kicked Out”
ECM has been powered up. order to create the problem again.
g00644420
Illustration 149
Typical circuit schematic for “Cab Switches” configuration
The return wire may be connected to P1-3, P1-5, or P1-18.
306 RENR2238-09
Troubleshooting Section
g00644427
Illustration 150
Typical circuit schematic for “Remote Switches” configuration
The return wire may be connected to P1-3, P1-5, or P1-18.
g00644448
Illustration 151
Typical circuit schematic for “Remote Throttle” configuration
The return wire may be connected to P1-3, P1-5, or P1-18.
C. Access the “Dedicated PTO Parameters” on Cat • OK – The “PTO Configuration” is programmed.
ET. Note the programming of the parameter “PTO Proceed to Test Step 2.
Configuration”.
RENR2238-09 307
Troubleshooting Section
• Not OK – The Dedicated PTO features are not Test Step 3. Inspect the Electrical
programmed for this engine. If PTO operation Connectors and the Wiring
is desired, the “PTO Configuration” must be
programmed to “Cab Switches”, to “Remote
Switches”, or to “Remote Throttle”. STOP.
Expected Result:
D. Check the allen head screw on each of the Result 2 The status of the PTO on/off switch on
ECM connectors for the proper torque. Refer to Cat ET changes from “OFF” to “ON” when the PTO
Troubleshooting, “Electrical Connectors - Inspect” on/off switch is turned to the OFF position and the
for details. ON position. However, the remote accelerator is not
operating correctly.
E. Check the harness and wiring for abrasion and for
pinch points from the switch to the ECM. Result 3 The status of the PTO on/off switch on Cat
ET does not change from “OFF” to “ON” when the
Expected Result: PTO on/off switch is turned to the OFF position and
to the ON position.
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring Results:
are free of corrosion, of abrasion and of pinch points.
• Result 1 – The status of the PTO on/off switch
Results: correctly changes but the set/resume switch is not
operating correctly. Proceed to Test Step 5.
• OK – The harness and connectors appear to be
OK. Proceed to Test Step 4. • Result 2 – The status of the PTO on/off switch
correctly changes but the remote accelerator is not
• Not OK – There is a problem with the connectors operating correctly.
and/or wiring.
Repair: Perform the following diagnostic
Repair: Repair the connectors or wiring and/or procedure: Troubleshooting, “Remote PTO
replace the connectors or wiring. Ensure that all of Accelerator Position Sensor Circuit - Test”
the seals are properly in place and ensure that the
connectors are completely coupled. STOP.
Verify that the repair eliminates the problem. • Result 3 – The status of the PTO on/off switch
does not change. Proceed to Test Step 6.
STOP.
Test Step 5. Use Cat ET to Check the
Test Step 4. Use Cat ET to Check the Status of the Set/Resume Input
Circuit for the PTO On/Off Switch
Note: The set/resume input increases the engine rpm
A. Turn the ignition key switch to the ON position. and the set/resume input decreases the engine rpm.
B. For the input 1 (PTO on/off switch), access the A. Find the PTO set switch. If the “PTO Configuration”
Cat ET status screens that display the following is programmed to “Cab Switches”, the cruise
status parameters: control set/resume switch will be used. If the
“PTO Configuration” is programmed to “Remote
• “PTO Config” Switches” or to “Remote Throttle”, a dedicated
PTO set switch will be used.
• “PTO On/Off Switch”
The “PTO Configuration” is programmed to
C. Verify that each of the interlocks for the PTO are “Cab Switches”.
set. Then, while the Cat ET status screen is being
monitored move the PTO on/off switch to the ON Look at the status for the “Cruise Control
position and move the PTO on/off switch to the Set/Resume Switch” parameter on Cat ET. The
OFF position. parameter is located on the same status screen
as the idle switch.
An example of an interlock for the PTO would be
a parking brake that is intended to allow the PTO B. Monitor the status screen of Cat ET. Perform the
to control the engine under specific conditions. following procedure in order:
• Put the cruise control set/resume switch in the • The status of the remote PTO set switch changes
Resume position. from “OFF” to set switch “ON” when the remote
PTO set switch is moved to the SET position.
• Release the cruise control set/resume switch
from the Resume position. • The status of the remote PTO resume switch
changes from “OFF” to resume switch “ON” when
The “PTO Configuration” is programmed to the remote PTO resume switch is moved to the
“Remote Switches” or to “Remote Throttle”. RESUME position.
• Put the remote PTO set/resume switch in the Test Step 6. Use Cat ET to Check the
Resume position. Status of the PTO On/Off Switch
• Release the remote PTO set/resume switch
from the Resume position.
Expected Result:
• The status screen for the remote PTO set switch D. Remove the wire P1-56 (input 1) from ECM
displays “OFF” when the remote PTO set switch connector P1.
is released.
E. Install a 140-2266 Cable As (70-PIN
• The status of the remote PTO resume switch BREAKOUT) to the ECM vehicle harness
displays “OFF” when the remote PTO resume connector J1/P1.
switch is released.
F. Verify that Cat ET is connected to the data link
connector.
310 RENR2238-09
Troubleshooting Section
G. Turn the ignition key switch to the ON position. 5. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
H. Access the “PTO On/Off Switch” status on Cat ET.
6. If the problem returns with the suspect ECM,
I. While the switch status is being observed on Cat replace the ECM.
ET, install the jumper into the breakout T between
P1-56 (input 1) and P1-3 (input sensor common 7. Verify that the repair eliminates the problem.
2).
STOP.
The input 1 is the PTO on/off switch.
Test Step 7. Use Cat ET to Check the
Refer to Illustration 153. Status of the Cruise Control Set/Resume
Switch
J. Turn the key switch to the OFF position.
Expected Result:
Verify that the repair eliminates the problem. D. Remove the wire P1-35 (cruise control set) from
the P1 ECM connector.
STOP.
E. Remove the wire P1-44 (cruise control resume)
• Not OK – The ECM is not reading the switch from the P1 ECM connector.
status change.
F. Install a 140-2266 Cable As (70-PIN
Repair: Perform the following diagnostic BREAKOUT) to the ECM vehicle harness
procedure: connector J1/P1.
1. Temporarily connect a test ECM. G. Verify that Cat ET is connected to the data link
connector.
2. Ensure that the “PTO Configuration” of the test
ECM matches the “PTO Configuration” of the H. Turn the ignition key switch to the ON position,
suspect ECM. while the engine is off.
3. Recheck the system for active diagnostic codes. I. Access the status of the cruise control set/resume
switch on Cat ET.
4. Repeat the test step.
RENR2238-09 311
Troubleshooting Section
J. While the switch status is being observed on Cat • Not OK – The ECM is not reading the switch
ET, install the jumper into the breakout T in order status change.
to connect P1-35 (cruise control set) to P1-5
(AP sensor/switch sensor common). Also, while Repair: Perform the following diagnostic
the switch status is being observed on Cat ET procedure:
remove the jumper from the breakout T in order
to disconnect P1-35 (cruise control set) from P1-5 1. Temporarily connect a test ECM.
(AP sensor/switch sensor common).
2. Ensure that the “PTO Configuration” of the test
K. While the switch status is being observed on Cat ECM matches the “PTO Configuration” of the
ET, install the jumper into the breakout T. This suspect ECM.
connects P1-44 (cruise control resume) to P1-5
(AP sensor/switch sensor common). Also, while 3. Recheck the system for active diagnostic codes.
the switch status is being observed on Cat ET,
remove the jumper from the breakout T. This will 4. Repeat the test step.
disconnect P1-44 (cruise control resume) from
P1-5 (AP sensor/switch sensor common). 5. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
Refer to Illustration 154.
6. If the problem returns with the suspect ECM,
L. Turn the key switch to the OFF position. replace the ECM.
M. Reconnect all wires to the original configuration. 7. Verify that the repair eliminates the problem.
The switch status of the cruise control set/resume Test Step 8. Use Cat ET to Check the
switch on Cat ET behaves in the following manner: Status of the Remote PTO Set Switch and
the Remote PTO Resume Switch
• The switch status of the cruise control set/resume
switch changes from “OFF” to set switch “ON”
when the jumper is connected from P1-35 (cruise
control set) to P1-5 (AP sensor/switch sensor
common).
Verify that the repair eliminates the problem. D. Remove the wire P1-58 (input number 2 (remote
PTO set)) from ECM connector P1.
STOP.
E. Remove the wire P1-60 (input number 3 (remote
PTO resume)) from ECM connector P1.
312 RENR2238-09
Troubleshooting Section
F. Install a 140-2266 Cable As (70-PIN • The switch status of the “Remote PTO Resume
BREAKOUT) to the ECM vehicle harness Switch” changes from “OFF” to resume switch
connector J1/P1. “ON” when the jumper is connected from P1-60
(input number 3 (remote PTO resume)) to P1-3
G. Verify that CatET is connected to the data link (input sensor common 2).
connector.
Results:
H. Turn the ignition key switch to the ON position.
• OK – Input 2 (“remote PTO set switch”) and input
I. Access the “Remote PTO Set Switch” and 3 (“remote PTO resume switch”) of the ECM
“Remote PTO Resume Switch” status on Cat ET. are functioning correctly. The problem is in the
switches of the vehicle or the problem is in the
J. While the status of the “Remote PTO Set Switch” wiring of the vehicle.
is being observed on Cat ET, install the jumper
into the breakout T in order to connect P1-58 Repair: Inspect the wiring. Select one of the
(input number 2 (remote PTO set)) to P1-3 (iInput following options:
sensor common 2). Also, while the switch status
is being observed on Cat ET remove the jumper • Repair the wiring or replace the wiring.
from the breakout T in order to disconnect P1-58
(input number 2 (remote PTO set)) from P1-3 • Send the vehicle to the OEM dealer for repair.
(input sensor common 2).
Verify that the repair eliminates the problem.
K. While the status of the “Remote PTO Resume
Switch” is being observed on Cat ET, install the STOP.
jumper into the breakout T in order to connect
P1-60 (Input number 3 (remote PTO resume)) • No – The ECM is not reading the switch status
to P1-3 (input sensor common 2). Also, while change.
the switch status is being observed on Cat ET
remove the jumper from the breakout T in order to Repair: Perform the following diagnostic
disconnect P1-60 (input number 3 (remote PTO procedure:
resume)) from P1-3 (input sensor common 2).
1. Temporarily connect a test ECM.
Refer to Illustration 155.
2. Ensure that the “PTO Configuration” of the test
L. Turn the key switch to the OFF position. ECM matches the “PTO Configuration” of the
suspect ECM.
M. Reconnect all wires to the original configuration.
3. Recheck the system for active diagnostic codes.
Expected Result:
4. Repeat the test step.
The switch status of the “Remote PTO Set Switch” on
Cat ET behaves in the following manner: 5. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
• The switch status of the “Remote PTO Set Switch”
is “OFF” when the jumper is removed. 6. If the problem returns with the suspect ECM,
replace the ECM.
• The switch status of the “Remote PTO Set Switch”
changes from “OFF” to set switch “ON” when the 7. Verify that the repair eliminates the problem.
jumper is connected from P1-58 (input number 2
(remote PTO set)) to P1-3 (input sensor common STOP.
2).
i02336554
Terminal 30 (Output 1)
g00703413
Illustration 156
Typical circuit schematic for PTO switch on lamp
g00834964
Illustration 157
Optional circuit for PTO switch on lamp
The return wire may be connected to P1-3, P1-5, or P1-18.
RENR2238-09 315
Troubleshooting Section
Results:
STOP.
Expected Result:
Test Step 3. Test the Circuit for the PTO Result 2 The suspect lamp does not turn on while
Switch On Lamp the jumper is connected to both sockets.
Results:
• P1-63 -Battery
• P1-65 -Battery
• P1-67 -Battery
• P1-69 -Battery
g01152466
E. Turn the ignition key switch to the ON position. Illustration 160
ECM breakout T-connector
F. While the lamp is being watched, insert the jumper (30) Output #1 (PTO switch on lamp)
wire and remove the jumper wire. (48) Unswitched +Battery
(52) Unswitched +Battery
(53) Unswitched +Battery
Refer to Illustration 159. (55) Unswitched +Battery
(63) -Battery
Expected Result: (65) -Battery
(67) -Battery
Result 1 The PTO switch on lamp turns on while the (69) -Battery
jumper is connected to both sockets. Also, the PTO
switch on lamp turns off when the jumper is removed A. Disconnect ECM connector J1/P1.
from one of the sockets.
B. Insert a breakout T at the J1/P1 ECM connector.
RENR2238-09 317
Troubleshooting Section
C. Connect one probe of the voltage test lamp to Repair: Temporarily connect a test ECM. Ensure
terminal 63 (-Battery). Connect the other probe of that the “PTO Configuration” of the test ECM
the voltage test lamp to terminal 48 (unswitched matches the “PTO Configuration” of the suspect
+Battery) of the breakout T. ECM. Check the ECM output for the PTO Switch
On Lamp when the test ECM is installed. If the
D. The test lamp should turn on. If the test lamp does problem is resolved with the test ECM, reconnect
not turn on, either the test lamp is faulty or the the suspect ECM. If the problem returns with
wiring to the ECM is faulty. Continue with this step the suspect ECM, replace the ECM. Refer to
if the lamp turns ON. Troubleshooting, “Replacing the ECM”.
Refer to Illustration 160. Use this procedure if any of the following diagnostic
codes are indicated:
G. Verify that Cat ET is connected. Access the
following display screens in order: • 30-08 PTO Throttle signal invalid (29)
• “Diagnostics” • 30-13 PTO Throttle out of calibration (29)
• “Diagnostic Test” Also, use this procedure if the remote accelerator
position sensor is suspected of improper operation.
• “Special Test”
Remote Accelerator Position Sensor
H. Activate the special test for the PTO switch on
lamp. Observe the voltage test lamp. The lamp A remote accelerator position sensor may be used
should turn on when the test is active. Also, the for PTO purposes. The remote accelerator position
lamp should turn off when the test is inactive. sensor should be connected to terminal J1/P1-68
of the Engine Control Module (ECM). Before the
Note: Perform the same test procedure with terminals ECM will respond to the remote accelerator position
P1-52, P1-53, and P1-55 unswitched +Batt. sensor, the ECM “PTO Configuration” must be
programmed to “Remote Throttle”, and the “PTO
Expected Result: On/Off Switch” must be in the ON position.
The test lamp turns on and the test lamp turns off The remote accelerator position sensor must be
per the above description. powered from the vehicle battery (+12 V). A +12 V
version of the accelerator position sensor must be
Results: used for the remote accelerator position sensor, and
the +8 V version for the accelerator pedal position
• OK – The ECM is operating correctly. There is a sensor must be used in the cab.
problem in the vehicle wiring or the lamp. STOP.
The ECM will not respond to the remote accelerator
• Not OK – The test lamp does not turn on and the position sensor while 253-02 diagnostic code is
test lamp does not turn off. active. Refer to Troubleshooting, “ECM Memory -
Test” if 253-02 diagnostic code is active.
318 RENR2238-09
Troubleshooting Section
g01042360
Illustration 161
Typical schematic for remote accelerator pedal position sensor
The return wire may be connected to P1-3, P1-5, or P1-18.
320 RENR2238-09
Troubleshooting Section
Expected Result:
Results:
STOP.
g01152475
Illustration 162
Pin locations on ECM connector Test Step 2. Check for Active Diagnostic
(P1-3) Input sensor common #2 Codes
(P1-5) AP sensor/switch sensor common
(P1-68) Input #8 (remote accelerator position sensor) A. Ensure that Cat ET is connected to the data link
connector.
Test Step 1. Inspect the Electrical
Connectors and the Wiring B. Turn the ignition key switch to the ON position.
A. Connect Cat ET to the data link connector. Turn C. Monitor the active diagnostic code screen on Cat
the ignition key switch to the ON position. Verify ET. Check and record active diagnostic codes.
that the parameter for the PTO configuration is
programmed to the “Remote Throttle”.
Note: When the ECM automatically calibrates new Test Step 4. Check the Duty Cycle of
duty cycle values for the low idle throttle position the Remote Accelerator Pedal Position
and the high idle throttle position, the ECM assumes Sensor
22 percent duty cycle at low idle and 75 percent
duty cycle at high idle. As a result, you may notice A. Verify that the ignition key switch is in the ON
that the status of the throttle position reaches 100 position.
percent well before the remote accelerator position
sensor is fully actuated. This is normal. After cycling B. Monitor the duty cycle of the PTO throttle sensor
the accelerator pedal to the high idle position, the on Cat ET. Access the following display screen
ECM will adjust the calibration automatically. The in order:
ECM will adjust the calibration automatically provided
that the high idle stop position is within the 75 to 90 • “Service”
percent duty cycle range, and the low idle is in the
10 to 22 percent duty cycle range. During normal • “Calibrations”
operation, you may notice that more movement of
the remote accelerator position sensor is required for • “Monitor Throttle Position Sensor”
the status of the throttle position to increase above
three percent. You may also observe that the status Expected Result:
reaches the 100 percent value prior to the limit of the
high idle position. This is done in order to ensure that The duty cycle is between 10 and 22 percent with the
the accelerator reaches these two critical points for accelerator pedal assembly in the low idle position,
engine operation. and the duty cycle is between 75 and 90 percent
with the accelerator pedal assembly in the high idle
Expected Result: position.
Result 2 There are no active diagnostic codes that • OK – The remote accelerator position sensor is
are related to the remote accelerator position sensor operating correctly. Proceed to Test Step 5.
at this time, but a problem is suspected.
• Not OK – The remote accelerator position sensor
Results: is not operating correctly. Proceed to Test Step 6.
• Result 1 – 30-08 or 30-13 are active. Proceed to Test Step 5. Check the Status of the
Test Step 3. Power Train Data Link on Cat ET
• Result 2 – There are no active diagnostic codes at A. Start the engine. While the status of the “PTO
this time. Proceed to Test Step 3. Throttle Position” is being monitored on Cat ET,
actuate the remote throttle. The throttle position
Test Step 3. Check the Supply Voltage for status and the engine should respond to the
the Remote Accelerator Position Sensor change in the throttle position.
A. Verify that the ignition key switch is in the ON B. Go to the “System Troubleshooting Settings”
position. section of Cat ET and turn off the power train data
link.
B. Measure the voltage between terminal “A” (+12 V)
and terminal “B” (sensor common) at J406 remote C. While the status of the “PTO Throttle Position” is
accelerator position sensorconnector. being monitored on Cat ET, actuate the remote
throttle. Also, actuate the remote throttle while the
Expected Result: engine response is being monitored.
• Result 2 – If the engine responds with the power B. Remove terminal P1-68 (sensor signal) from the
train data link in the OFF position, but not with ECM connector.
the power train data link in the ON position,
a component of the power train data link is C. Connect the multimeter’s probes between the wire
causing the response problem of the remote for the remote accelerator position sensor and the
accelerator position sensor. Send the truck to the sensor common.
vehicle manufacturer in order to repair the faulty
component of the power train data link. STOP. D. Turn the ignition key switch to the ON position.
Test Step 6. Check the Duty Cycle of the E. Use the multimeter in order to display the duty
Remote Accelerator Position Sensor at cycle output of the remote accelerator position
the Sensor sensor. While the duty cycle output of the remote
accelerator position sensor is being monitored
A. Turn the ignition key switch to the OFF position. on the multimeter, actuate the remote throttle
from the low idle position to the high idle position.
B. Remove terminal J406-C (throttle position signal) Record the results.
from the connector for the remote accelerator
position sensor. This is the vehicle harness side F. Turn the ignition key switch to the OFF position.
of the connector.
Expected Result:
C. Install a breakout T at connector J406/P406.
The duty cycle is between 10 and 22 percent with the
D. Connect the multimeter probes to terminal “C” accelerator pedal assembly in the low idle position,
(throttle position signal) and terminal “B” (sensor and the duty cycle is between 75 and 90 percent
common) of the breakout T. with the accelerator pedal assembly in the high idle
position.
E. Turn the ignition key switch to the ON position.
Results:
F. While the duty cycle is being monitored on
the multimeter, actuate the remote accelerator • OK – A good signal from the remote accelerator
position sensor. position sensor is reaching the ECM. Verify that
the ECM is receiving the proper battery voltage. If
Expected Result: the ECM is receiving the proper battery voltage,
temporarily connect a test ECM and verify that the
The duty cycle is between 10 and 22 percent with problem is resolved. If the problem disappears with
the remote accelerator position sensor in the low idle the test ECM, reconnect the suspect ECM. If the
position, and the duty cycle is between 75 and 90 problem returns with the suspect ECM, replace the
percent with the remote accelerator position sensor suspect ECM. STOP.
in the high idle position.
• Not OK – There is a problem with signal wire
Results: for the remote accelerator position sensor in the
vehicle wiring harness. Proceed to Test Step 9.
• OK – Return the J406/P406 to the original
configuration. The sensor is working correctly. Test Step 8. Remove the Remote
Proceed to Test Step 7. Accelerator Position Sensor from the
Throttle Assembly
• Not OK – Leave the PWM probe connected to the
breakout T. Insert wire C into the J406 connector. A. Turn the ignition key switch to the OFF position.
The sensor or the accelerator control is faulty.
Proceed to Test Step 8. B. Remove the remote accelerator position sensor
from the throttle assembly. Note the orientation
of the sensor in the accelerator pedal assembly,
and the sensor pigtail routing prior to sensor
removal. Thoroughly inspect the pigtail for signs
of abrasion.
RENR2238-09 323
Troubleshooting Section
g00642019
Illustration 163
(1) Mounting screw holes (3) Sensor housing (5) Accelerator pedal assembly
(2) Sensor slot (4) Mounting surface for sensor (6) Accelerator block assembly
324 RENR2238-09
Troubleshooting Section
Results:
Retarder (Compression Brake)
Solenoid Circuit - Test
• OK – The remote accelerator position sensor is
working correctly. Clear any diagnostic codes that SMCS Code: 1129-038
were caused by performing this test procedure.
Refer to the OEM dealer for correct replacement of System Operation Description:
the accelerator pedal assembly. STOP.
The engine retarder solenoids are usually factory
• Not OK – The remote accelerator position sensor installed at Caterpillar and the switches are installed
is faulty. Check the accelerator pedal assembly by the vehicle OEM. The ECM directly drives the
in order to ensure that the accelerator pedal retarder solenoids, eliminating OEM installed relays
assembly is not causing damage to the sensor. If and circuit protection. The ECM reads the status of
the accelerator pedal assembly is causing damage the OEM installed engine retarder switches in order
to the sensor, refer to the OEM dealer for correct to determine the following modes of operation:
replacement of the accelerator pedal assembly.
STOP. • OFF
Test Step 9. Route the Supply Bypass • Low
Wires to the Remote Accelerator Pedal
Position Sensor • Medium
A. Turn the ignition key switch to the OFF position. • High
B. Remove P1-66 (remote accelerator position Operation of the retarder solenoids is inhibited during
sensor) from the ECM connector. undesirable engine operating conditions.
C. Remove terminal “C” (sensor signal) from the All of the following conditions must be met in order
connector for the remote accelerator position to ensure the proper retarder operation regardless of
sensor. the settings of the customer specified parameters:
D. Route new wiring from the ECM to the remote • Engine speed is above 800 rpm.
accelerator position sensor.
• The “Accelerator Pedal Position” is less than 8
E. Turn the ignition key switch to the ON position. percent.
F. Check the duty cycle of the remote accelerator • The clutch pedal is released.
position sensor with Cat ET while the accelerator
pedal assembly is being moved over the full range. Additional factors may affect retarder operation. The
additional factors are based on the programming of
Expected Result: certain customer specified parameters. The following
parameters may affect retarder operation:
The duty cycle is between 10 and 22 percent with the
accelerator pedal assembly in the low idle position, • “Engine Retarder Mode”
and the duty cycle is between 75 and 90 percent
with the accelerator pedal assembly in the high idle • “Auto Retarder In Cruise”
position.
• “Auto Retarder In Cruise Increment”
Results:
• “Engine Retarder Minimum Vehicle Speed”
• OK – The wiring from the ECM to the accelerator
position sensor appears faulty. Permanently install • “Engine Retarder Minimum Vehicle Speed Type”
new wiring. Verify that the repair eliminates the
problem. STOP. • “Engine Retarder Delay”
RENR2238-09 325
Troubleshooting Section
Note: If the “PTO Configuration” is programmed to This parameter allows the engine retarder to activate
Cab Switches, Remote Switches, or Remote Throttle, while the engine is in cruise control in order to
the engine retarder is disabled whenever the PTO maintain the cruise set speed. The “Auto Retarder
On/Off circuit is on. in Cruise” option still requires the engine retarder
switches to be in the ON position. The “Auto Retarder
When the Cruise Control On/Off Switch is in the in Cruise” option will only activate the engine retarder
ON position, the following conditions exist: to the level of braking that is determined by the switch
setting. The “Auto Retarder in Cruise” parameter is
“Engine Retarder Mode” a vehicle speed above the cruise set speed. When
the vehicle speed that is above the cruise set speed
When the cruise control On/Off switch is on, this is met, the ECM will send a signal in order to begin
parameter provides two special options that allow engaging the engine retarder.
the engine retarder to be operated only after the
driver has depressed the service brake pedal. The At this vehicle speed, the engine retarder will activate
two modes of operation that follow are customer at the low level. The Medium and High braking levels
programmable: will be activated at the programmed “Auto Retarder
in Cruise Increment”. This assumes that the engine
• The “Coast” mode engages the engine retarder retarder switches are set at the high level. The
when the driver depresses the service brake pedal. “Auto Retarder in Cruise” affects the engine retarder
The retarder disengages when the driver releases solenoids that are driven directly from the ECM
the service brake pedal. engine harness connector P2 terminal 9, terminal 10
and terminal 11.
• The “Latch” mode engages the retarder when the
driver depresses the service brake pedal. The “Auto Retarder In Cruise Increment”
retarder remains engaged until the control detects
a change in a control input. The following actions The “Auto Retarder in Cruise Increment” parameter
are examples of a change in a control input: determines the increment in kilometers per hour
(km/h) or miles per hour (mph) when the higher
• The throttle is depressed. levels of engine retarder will activate. This feature
requires the “Auto Retarder in Cruise ” parameter to
• The clutch pedal is depressed. be programmed above 0 mph.
• The engine speed drops below 800 rpm. “Engine Retarder Minimum Vehicle Speed”
The third option for the engine retarder parameter is This parameter determines the minimum vehicle
“Manual”. The Manual mode operates in the same speed limit for the engine retarders to turn ON. When
manner regardless of the position of the cruise this parameter is programmed to “0” the retarder will
control On/Off switch. The driver is not required to operate at all vehicle speeds.
depress the service brake pedal in order to initiate
the engine retarder. This is required in the Latch “Engine Retarder Minimum VSL Type”
mode and the Coast mode.
The “Engine Retarder Minimum VSL Type” defines
Note: The Latch mode and the Coast mode are the use of the “Engine Retarder Minimum Vehicle
customer programmable options. The Latch mode Speed” parameter. The “Engine Retarder Minimum
and the Coast mode determine engine retarder VSL Type” provides the following two options:
operation only when the cruise control switch is in the
ON position. The Latch mode and the Coast mode • Hard Limit
do not determine engine retarder operation when
the engine is active in cruise control. Latch mode • Soft Limit
and Coast mode require the initiation of the service
brake before acting. The action of the service brake If the “Engine Retarder Minimum VSL Type” is
disengages the cruise control. programmed to the Hard Limit, the engine retarder
will turn off when the value that is programmed into
“Auto Retarder In Cruise” the “Engine Retarder Minimum Vehicle Speed” is
reached.
326 RENR2238-09
Troubleshooting Section
If the “Engine Retarder Minimum VSL Type” is The “Retarder Brake Test” should be used to assist in
programmed to the Soft Limit, the engine retarder troubleshooting problems in the circuit for the engine
will remain in the ON position below the value that retarder. The ECM will only detect shorts in the
is programmed in the “Engine Retarder Minimum circuit for the engine retarder when the test is active.
Vehicle Speed”. The engine retarder will remain in the “Current high” diagnostic codes (short circuits) will be
ON position until the parameters that would normally logged once the test has been deactivated. The ECM
turn off the engine retarder are met. The retarder will only detect opens in the circuit for the engine
cannot be activated when the vehicle speed is below retarder when the test is not active. The test must be
the “Engine Retarder Minimum Vehicle Speed”. activated and then deactivated before the ECM will
detect an open circuit. “Current low” diagnostic codes
This parameter requires the “Engine Retarder (open circuits) will be active once the test has been
Minimum Vehicle Speed” parameter to be deactivated.
programmed above 0 mph.
g00645615
Illustration 164
Schematic for engine retarder (compression brake)
g00645629
Illustration 165
Terminal locations for ECM
328 RENR2238-09
Troubleshooting Section
D. Turn the key switch to the ON position. A “current high” diagnostic code (short circuit) is
active when the jumper wire is in place and the
E. Access the “Retarder Brake Test” in the “Special “Retarder Brake Test” is active.
Tests” under the “Diagnostics” menu.
Note: A “current low” diagnostic code (open circuit)
F. Start the test. will be active when the jumper wire is removed and
the test is not active.
G. Check for active diagnostic codes that are related
to the engine retarder. Results:
Test Step 4. Create a Short Circuit at the Repeat this Test Step.
Engine Retarder Solenoid
If there is still a “current low” diagnostic code (open
A. Turn the key switch to the OFF position. circuit), the problem is the supply wire.
B. Remove the valve cover(s). If there is a “current high” diagnostic code (short
circuit), the problem is the common wire.
C. Disconnect the wires for the suspect solenoid.
Insert a jumper wire between the two wires for the Repair the wiring or replace the wiring.
suspect solenoid.
Verify that the repair eliminates the problem.
D. Turn the key switch to the ON position.
STOP.
E. Access the “Retarder Brake Test” in the “Special
Tests” under the “Diagnostics” menu. Test Step 5. Create a Short Circuit at the
ECM
F. Start the test.
A. Turn the key switch to the OFF position.
G. Check for active diagnostic codes that are related
to the engine retarder. B. Disconnect the J2/P2 ECM connector.
D. Connect a jumper wire between the terminal for Verify that the repair eliminates the problem.
the suspect circuit on the breakout T and Terminal
9 (Retarder Solenoid Common). STOP.
• Terminal 11 (LOW/HI Retarder Solenoid) • Not OK – There may be a problem with the ECM.
• Terminal 10 (MED/HI Retarder Solenoid) Repair: Temporarily connect a test ECM.
E. Turn the key switch to the ON position. If the test ECM fixes the problem, reconnect the
suspect ECM.
F. Access the “Retarder Brake Test” in the “Special
Tests” under the “Diagnostics” menu. If the problem returns, permanently replace the
ECM.
G. Start the test.
Verify that the repair eliminates the problem.
H. Check for active diagnostic codes that are related
to the engine retarder. STOP.
Note: A “current low” diagnostic code (open circuit) D. Check for active diagnostic codes that are related
will be active when the jumper wire is removed and to the engine retarder.
the test is not active.
E. Stop the test.
Results:
F. Check for active diagnostic codes that are related
• OK – There is a problem in the harness between to the engine retarder.
the ECM and the valve cover base.
Expected Result:
Repair: Remove the breakout T and reconnect the
J1/P1 ECM connector. A “current low” diagnostic code (open circuit) is
active.
Inspect the wiring between the ECM and the valve
cover base. Results:
Disconnect the P300 connector. • OK – The harness between the ECM and the
valve cover base is OK. Proceed to Test Step 7.
Insert a jumper wire between the terminal on the
P300 connector for the suspect solenoid and • Not OK – There is a problem between the valve
chassis ground. cover base and the ECM. Proceed to Test Step 8.
Repeat this Test Step. Test Step 7. Create an Open Circuit at the
Retarder Solenoids
If there is still a “current low” diagnostic code (open
circuit), the problem is the supply wire. A. Turn the key switch to the OFF position.
If there is a “current high” diagnostic code (short B. Remove the valve cover(s).
circuit), the problem is the common wire.
C. Disconnect the wires from each engine retarder
Repair the wiring or replace the wiring. solenoid. Ensure that the wires are not touching
any metal parts.
RENR2238-09 331
Troubleshooting Section
D. Turn the key switch to the ON position. D. Access the “Retarder Brake Test” in the “Special
Tests” under the “Diagnostics” menu.
E. Access the “Retarder Brake Test” in the “Special
Tests” under the “Diagnostics” menu. E. Start the test.
F. Start the test. F. Check for active diagnostic codes that are related
to the engine retarder.
G. Check for active diagnostic codes that are related
to the engine retarder. G. Stop the test.
H. Stop the test. H. Check for active diagnostic codes that are related
to the engine retarder.
I. Check for active diagnostic codes that are related
to the engine retarder. Expected Result:
Temporarily connect a new engine retarder Verify that the repair eliminates the problem.
solenoid.
STOP.
If the new solenoid fixes the problem, reconnect
the suspect solenoid. • Not OK – There may be a problem with the ECM.
If the problem returns, permanently replace the Repair: Temporarily connect a test ECM.
solenoid.
If the test ECM fixes the problem, reconnect the
Verify that the repair eliminates the problem. suspect ECM.
The status for “Retarder Off/Low/Med/High Switch” • OK – The status changed accordingly. There is a
correlates to the position of the engine retarder problem in the vehicle harness in the cab.
switch.
Repair: Repair the harness or replace the harness
Results: in the cab.
• OK – The engine retarder switch is operating Reconnect all wires and connectors.
correctly. Proceed to Test Step 11.
Verify that the repair eliminates the problem.
• Not OK – There is a problem in the circuit for the
engine retarder switch. STOP. STOP.
Test Step 10. Check the Switch Circuits • Not OK – There is a problem between the ECM
at the Firewall Bulkhead Connector and the firewall bulkhead connector.
A. Turn the key switch to the OFF position. Repair: Repair the harness or replace the harness
between the ECM and the bulkhead connector.
B. Disconnect the firewall bulkhead connector.
Remove the three wires for the retarder Reconnect all wires and connectors.
off/low/medium/high switch from the firewall
bulkhead connector. Verify that the repair eliminates the problem.
D. Turn the key switch to ON position. B. Access the “Configuration” screen on Cat
ET. Review the programming of the following
E. Check the status for “Retarder Off/Low/Med/High parameters:
Switch” on Cat ET. Remove the jumper wire.
• “Engine Retarder Mode”
F. Turn the key switch to OFF position.
• “Engine Retarder Minimum VSL Type”
G. Insert a jumper wire between the following wires
on the vehicle harness: • “Engine Retarder Minimum Vehicle Speed”
• AP Sensor/Switch Sensor Common • “Engine Retarder Delay”
• Retarder Solenoid Med/Hi Switch C. Use the following information when the parameter
for the “Engine Retarder Mode” is being reviewed:
H. Turn the key switch to ON position.
a. If the parameter is programmed to Latch mode
I. Check the status for “Retarder Off/Low/Med/High or Coast mode, the engine retarder will not turn
Switch” on Cat ET. on unless the following conditions are met:
a. This parameter has no effect on engine retarder C. While the status is monitored, depress the
operation when the “Engine Retarder Minimum accelerator pedal.
Vehicle Speed” is programmed to 0 mph.
Expected Result:
b. When this parameter is programmed to the
Hard Limit and the vehicle speed drops below The status for “Accelerator Pedal Position” is less
the Engine Retarder Minimum Vehicle Speed, than 8% when the accelerator pedal is fully released.
the engine retarder turns off. The status changes as the accelerator is depressed.
E. Use the following information when the parameter • Not OK – The accelerator pedal position sensor is
for the “Engine Retarder Minimum Vehicle Speed” not operating correctly.
is being reviewed:
Repair: Refer to Troubleshooting, “Accelerator
a. When the programmed value is more than 0 Pedal (Throttle) Position Sensor Circuit - Test”.
mph, the engine retarder will not turn on below
the programmed value. STOP.
Note: The retarder will not turn on if the vehicle speed Test Step 13. Check the Clutch Switch
is already below the “Engine Retarder Minimum
Vehicle Speed”. A. Turn the key switch to the ON position.
F. Use the following information when the parameter B. Monitor the status for “Clutch Pedal Position
for the “Engine Retarder Delay” is being reviewed: Switch” while the clutch pedal is fully released.
a. This parameter provides a programmable C. While the status is monitored, depress the clutch
delay once the conditions are met in order to pedal.
turn the engine retarder.
Expected Result:
Expected Result:
The status for “Clutch Pedal Position Switch” is “Off”
The problem is due to the programming of any of the when the clutch pedal is fully released. The status is
listed parameters. “On” when the clutch pedal is depressed.
• OK Results:
Repair: Perform the following diagnostic • OK – The clutch pedal position switch is operating
procedure: correctly. There may be a mechanical problem with
the engine retarder.
Program parameters for desired operation.
Repair: Refer to Testing and Adjusting,
Refer to Troubleshooting, “Customer Specified “Compression Brake”.
Parameters” for additional information on the listed
parameters. STOP.
Use this procedure under the following situation: The service brake pedal position switches, the
neutral switch and the clutch switch are used in the
Use this procedure to determine if the Service Brake cruise control mode, the PTO mode and the Idle
Pedal Position (Switch 1) is preventing normal mode in order to discontinue the cruise operation, the
operation of cruise control, idle set speed, or PTO PTO operation, or the idle operation. The capability to
operation: override the idle shutdown timer is determined by the
“Allow Idle Shutdown Override” parameter setting.
The following switch circuits can also prevent the The “Allow Idle Shutdown Override” is a customer
correct operation of the cruise control, idle set speed parameter.
or PTO operation:
Usage of Transmission Style Switches
• Service Brake Pedal Position (Switch 1)
Note: With DEC03 software, the Transmission
• Service Brake Pedal Position (Switch 2) neutral Switch can be used with all transmission
styles.
• Neutral Switch
The “Transmission Style” parameter determines the
• Cruise Control Set/Resume Switch switches that will be used. The following switches
can be used with being dependent on the parameter
• Cruise Control On/Off Switch setting:
Table 154
Setting For Switch Usage.
Transmission
Style Service Service
Clutch Neutral
Parameter Brake 1 Brake 2
Manual
X X
Option 1
Automatic
X
Option 1
Automatic
X X
Option 2
Automatic
X X X
Option 3
Automatic
X X
Option 4
Eaton Top 2 X X
g00643881
Illustration 167
Schematic for cruise control switch, service brake pedal position (switch 1) and clutch pedal position switch
Test Step 1. Check the Status for the C. Access the status for the “Service Brake Pedal
“Service Brake Pedal Position Switch #1” Position Switch #1” on the electronic service tool.
A. Connect the electronic service tool to the data link D. While the status for the “Service Brake Pedal
connector. Position Switch #1” is monitored, depress the
brake and release the brake.
B. Turn the key switch to the ON position.
336 RENR2238-09
Troubleshooting Section
Expected Result:
Results:
Expected Result:
Results:
STOP.
RENR2238-09 337
Troubleshooting Section
g00702676
Illustration 168
D. Install the jumper into terminal 45 (Service Brake D. Turn the key switch to the ON position.
Pedal Position Switch) of the breakout T. Connect
the other end of the jumper to terminal 5 (AP E. Access the status for the “Service Brake Pedal
Sensor/Switch Sensor Common) of the breakout Position Switch #1”.
T.
F. While the status for the “Service Brake Pedal
E. Turn the key switch to the ON position. Position Switch #1” is monitored, connect the
wires for the service brake pedal position (Switch
F. Access the status for the “Service Brake Pedal 1) and disconnect the wires for the service brake
Position Switch #1”. pedal position (Switch 1).
G. While the status for the “Service Brake Pedal Expected Result:
Position Switch #1” is monitored, remove the
jumper from terminal 5 and insert the jumper into The status for the “Service Brake Pedal Position
terminal 5 (AP Sensor/Switch Sensor Common). Switch #1” is “Off” when the wires are disconnected.
The status for the “Service Brake Pedal Position
Expected Result: Switch #1” is “On” when the wires are connected.
• Not OK – The ECM is not functioning properly. Test Step 6. Insert a Jumper at the
Bulkhead Connector
Repair: Perform the following repair:
A. Turn the key switch to the OFF position.
1. Temporarily connect a test ECM.
B. Fabricate a jumper wire 100 mm (4 inch) long.
2. Remove the breakout T and reconnect the J1 Crimp a Deutsch pin to each end of the wire.
and P1 ECM connectors.
C. Locate the terminal for the “Service Brake Pedal
3. If the problem is resolved with the test ECM, Position (Switch 1)” and the “AP Sensor/Switch
reconnect the suspect ECM. Sensor Common” on the engine side of the
bulkhead connector.
4. If the problem returns with the suspect ECM,
replace the ECM. D. Insert the jumper wire between the two terminals
in the engine side of the bulkhead connector.
5. Verify that the repair eliminates the problem.
E. Turn the key switch to the ON position.
STOP.
F. Access the status for the “Service Brake Pedal
Test Step 5. Insert a Jumper at the Position Switch #1”.
Service Brake Pedal Position (Switch 1)
G. While the status for the “Service Brake Pedal
A. Turn the key switch to the OFF position. Position Switch #1” is monitored, remove the
jumper from one of the terminals and insert the
B. Find the switch for the Service Brake Pedal jumper wire into the terminal.
Position (Switch 1) in the vehicle.
STOP.
i01626422
g00646450
Illustration 169
Schematic for service brake pedal position (switch 2)
g00704926
Illustration 170
Terminal locations for ECM
A. Thoroughly inspect ECM vehicle harness D. Check the harness and wiring for abrasion and
connector J1/P1 and the firewall bulkhead pinch points from the sensor to the ECM.
connector.
Expected Result:
Refer to Troubleshooting, “ Electrical Connectors -
Inspect” for details. All connectors, pins, and sockets should be
completely coupled and/or inserted and the harness
B. Perform a 45 N (10 lb) pull test on each of the and wiring should be free of corrosion, abrasion, or
wires in the ECM connector that are associated pinch points.
with the switches.
Results:
Refer to Illustration 170.
• OK – Proceed to Test Step 2.
C. Check the ECM connector (allen head screw) for
the proper torque of 6.0 N·m (55 lb in). • Not OK
Repair: Perform the following repair:
RENR2238-09 341
Troubleshooting Section
STOP.
Expected Result:
Results:
STOP.
A. Turn the ignition key switch to the OFF position. 5. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
B. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wire. 6. If the problem returns with the suspect ECM,
replace the ECM.
C. Disconnect vehicle harness connector P1 from
the ECM. 7. Verify that the repair eliminates the problem.
Expected Result:
Results:
Expected Result:
Results:
• OK
Repair: Perform the following repair:
STOP.
Table for Input Status of the Service Brake Pedal Position (Switch 2)
Switch Position or Pedal Position Switch Status Circuit
Switch wires are disconnected. OFF Open
Switch wires are connected. ON Shorted
STOP.
STOP.
RENR2238-09 345
Troubleshooting Section
g00681335
Illustration 171
Schematic for Starting Aid Output
346 RENR2238-09
Troubleshooting Section
Expected Result:
Results:
STOP.
Results:
Test Step 1. Inspect Electrical Connectors
and Wiring
• OK – The circuit is connected to the correct ECM
terminal that is selected for the starting aid output.
A. Thoroughly inspect the ECM vehicle harness
Proceed to Test Step 3.
connector J1/P1, and the firewall bulkhead
connectors. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details. • Not OK – The parameter is programmed
incorrectly. Update the customer specified
parameter in order to match the correct output
B. Perform a 45 N (10 lb) pull test on terminal 10,
terminal. Proceed to Test Step 3.
terminal 12, or terminal 13 in the ECM connector.
Test Step 3. Check the Relay on Cat ET F. If the starting aid output is programmed to
J1/P1:12, remove the wire for the starting aid
output from P1-12. Connect a voltage test lamp to
terminal 12 (Output 3) and terminal 65 (-Battery)
of the breakout T.
Personal injury or death can result from not fol-
lowing the proper procedures. G. If the starting aid output is programmed to
J1/P1:13, remove the wire for the starting aid
To avoid the possibility of injury or death, follow output from P1-13. Connect a voltage test lamp to
the established procedure. terminal 13 (Output 4) and terminal 65 (-Battery)
of the breakout T.
A. Access the “Starting Aid Output Special Test” on
Cat ET. The “Starting Aid Output Special Test” H. Turn the key switch to the ON position.
will enable the starting aid output when the test
is active. I. Access the “Starting Aid Output Special Test” on
Cat ET.
Disconnect the starting aid canister in order to
prevent accidental discharge. J. Cycle the corresponding “Starting Aid Output
Special Test” to the ON position and to the OFF
B. Begin the “Starting Aid Output Special Test” and position and watch the voltage test lamp.
listen for the solenoid or the relay to “click”. You
may need to be near the engine in order to hear K. Stop the “Starting Aid Output Special Test”.
the “click”.
Note: A multimeter can not be used in place of the
Expected Result: voltage test lamp when the ECM outputs are being
tested.
The solenoid or the relay activates when the special
test is enabled. Note: The “Starting Aid Output Special Test” will only
remain active for one second in order to prevent
Results: accidental discharge. The test lamp will turn off when
the “Starting Aid Output Special Test” is disabled.
• OK – The solenoid or the relay activates when the
special test is enabled. L. Turn the key switch to the OFF position.
Repair: The ECM and vehicle components are M. Return the wiring to the original configuration.
operating correctly. Ensure that the ether canister
is not empty. Expected Result:
B. Turn the key switch to the OFF position. Repair: The problem is in the vehicle wiring.
Inspect the vehicle wiring and then repair the
C. Disconnect the P1 connector. vehicle wiring. Otherwise, send the vehicle to the
OEM dealer for repair. Verify that the problem is
D. Install a 140-2266 Cable As (70-PIN resolved.
BREAKOUT) to the ECM vehicle harness
connector J1/P1. STOP.
E. If the starting aid output is programmed to • Not OK – The test lamp’s output is incorrect. The
J1/P1:10, remove the wire for the starting aid ECM output did not operate correctly.
output from P1-10. Connect a voltage test lamp to
terminal 10 (Output 2) and terminal 65 (-Battery)
of the breakout T.
348 RENR2238-09
Troubleshooting Section
Repair: Temporarily connect a test ECM. Use the Note: The wiring for your particular application may
“Starting Aid Output Special Test” on Cat ET to be slightly different. The sensor common circuits are
check the ECM. If the problem is resolved with the used interchangeably by the OEM of the vehicle. The
test ECM, install the suspect ECM. If the problem following circuits are common within the ECM:
returns with the suspect ECM, replace the ECM.
Verify that the repair eliminates the problem. • The “Input Sensor Common 1” is terminal 18.
STOP. • The “Input Sensor Common 2” is terminal 3.
i01627841
• The “AP Sensor/Switch Sensor Common” is
terminal 5.
Starting Aid Switch Circuit -
Test
SMCS Code: 7332-038
g00682699
Illustration 173
Schematic for the Starting Aid Switch
g00682618
Illustration 174
Terminal Locations for the ECM
Test Step 1. Check the Electrical D. Check the harness and the wiring for abrasion and
Connectors and the Wiring pinch points from the battery to the ECM. Then,
check from the ignition key switch to the ECM.
A. Thoroughly inspect the ECM vehicle harness
connector J1/P1, the connectors, and the firewall Refer to Illustration 174 for terminal locations for
bulkhead connectors. Refer to Troubleshooting, the ECM.
“Electrical Connectors - Inspect” for details.
Expected Result:
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated All connectors, pins, and sockets are completely
with the circuit for the starting aid switch. coupled and/or inserted, and the harness and wiring
should be free of corrosion, abrasion or pinch points.
C. Check the ECM connector (allen head screw) for
the proper torque of 6.0 N·m (55 lb in).
350 RENR2238-09
Troubleshooting Section
Results:
Expected Result:
Results:
g00682624
Illustration 175
Connector for the Breakout T
B. Install a 70 terminal breakout T to the ECM vehicle C. Fabricate a jumper wire 100 mm (4 inch) long.
harness connector J1/P1. Crimp a Deutsch pin to both ends of the wire.
C. Fabricate a jumper wire 100 mm (4 inch) long. D. Insert the jumper wire between the two switch
Crimp a Deutsch pin to both ends of the wire. terminals of the starting aid switch.
D. Insert the jumper wire into the input terminal for E. Turn the ignition key switch to the ON position.
the starting aid switch of the breakout T. Connect
the other end of the jumper wire to terminal 5 in F. Alternately remove the jumper wire and then insert
the breakout T. Terminal 5 is AP Sensor/Switch the jumper wire at the switch terminals. At the
Common. same time, watch the status screen on ET.
• Not OK – The ECM is not functioning properly. Test Step 5. Insert a Jumper Wire at the
Bulkhead Connector
Repair: Perform the following diagnostic
procedure: A. Turn the ignition key switch to the OFF position.
1. Temporarily connect a test ECM. Only connect B. Fabricate a jumper wire 100 mm (4 inch) long.
ECM harness J1/P1. Crimp a Deutsch pin to both ends of the wire.
2. Recheck for an +5 V diagnostic code when the C. Locate the socket for the starting aid switch that is
engine harness is disconnected. suspect in the engine side of the ECM bulkhead
connector.
3. If the problem is resolved with the test ECM,
reconnect the suspect ECM. D. Insert the wire jumper pin between the switch
socket and the sensor common connection. Install
4. If the problem returns with the suspect ECM, the jumper wire on the engine side of the ECM
replace the ECM. bulkhead connector.
Test Step 4. Insert a Jumper Wire at the F. Alternately connect and then disconnect the
Switch jumper wire. At the same time, monitor the status
screen on ET.
A. Turn the ignition key switch to the OFF position.
Expected Result:
B. Reconnect the ECM vehicle harness connector
J1/P1. The switch status changes from “ON” with the jumper
wire in place. The switch status changes to “OFF”
when the jumper wire is removed.
352 RENR2238-09
Troubleshooting Section
g00649121
Illustration 176
Schematic No. 1 for tachometer
g00649123
Illustration 177
Schematic No. 2 for tachometer
• “Diagnostics”
• “Diagnostic Tests”
• “Special Test”
D. While the dash tachometer is being monitored,
begin the test.
Expected Result:
Results:
Repair: Refer to Troubleshooting, “Powertrain Verify that the repair eliminates the problem.
Data Link Circuit - Test”.
STOP.
STOP.
Test Step 4. Check the ECM Connection
• J1587 data link – The tachometer is wired through to the Tachometer
the J1587 data link.
A. Inspect the J1/P1 ECM connector. Verify that the
Repair: Refer to Troubleshooting, “ATA (SAE connections are present at P1-39 Tachometer −
J1587 / J1708) Data Link Circuit - Test”. and/or P1-38 Tachometer +.
C. Check the ECM connector (allen head screw) for Repair: Send the vehicle to the OEM dealer in
the proper torque of 6.0 N·m (55 lb in). order to repair the tachometer circuit.
D. Check the harness and wiring for abrasion and for STOP.
pinch points from the battery to the ECM.
RENR2238-09 355
Troubleshooting Section
Test Step 5. Check the Tachometer Signal Repair: Perform the following repair:
at ECM
1. Temporarily connect a test ECM.
Note: Performing certain steps within this procedure
requires the use of a multimeter that is capable of 2. Remove all jumpers and replace all connectors.
measuring a PWM Duty Cycle.
3. Recheck the system for active diagnostic codes.
A. Turn the key switch to the OFF position.
4. Repeat the test step.
B. Disconnect the J1/P1 ECM connector.
5. If the problem is resolved with the test ECM,
C. Remove the wire in P1-38 Tachometer + from the reconnect the suspect ECM.
ECM connector P1.
6. If the problem returns with the suspect ECM,
D. Remove the wire in P1-39 Tachometer − from the replace the ECM.
ECM connector P1.
7. Verify that the repair eliminates the problem.
E. Fabricate two jumper wires 100 mm (4 inch) long.
Crimp a Deutsch Pin to one end of each wire. STOP.
H. Access the “Tachometer Circuit Test”. Access the B. Connect Cat ET to the data link connector.
following display screens in order:
C. Check the “Tachometer Calibration” parameter on
• “Diagnostics” the “Configuration” screen.
J. Attach the negative lead of the multimeter to the • OK – The tachometer is correctly calibrated.
jumper wire from P1-39.
Repair: If the tachometer is correctly calibrated
K. While the “Tachometer Circuit Test” is being run, but the tachometer does not work, replace the
observe the reading on the multimeter. tachometer or send the tachometer to the OEM
dealer for repair. Verify that the repair eliminates
L. Turn the key switch to the OFF position. the problem.
a. If the tachometer calibration is known and B. Check the positive battery connections and the
the tachometer calibration is within 12.0 to negative battery connections to the tachometer.
500.0 pulses per revolution, change the Include the fuses and the circuit protection.
Customer Programmable Parameter of the
ECM “Tachometer Calibration” in order to Expected Result:
match the tachometer.
The tachometer is receiving the correct battery
2. Verify that the repair eliminates the problem. supply voltage.
STOP. Results:
Test Step 7. Check the ECM Connection • OK – The battery supply voltage is OK.
to the Tachometer
Repair: Perform the following repair:
A. Find the tachometer signal connections to the
tachometer. If the tachometer is receiving the correct battery
supply voltage but the tachometer does not work,
B. Disconnect the wires from the ECM to the replace the tachometer or send the tachometer to
tachometer at the ECM connector and at the the OEM dealer for repair.
tachometer.
STOP.
Refer to Illustration 176 or refer to Illustration 177.
• Not OK – The battery supply voltage is incorrect.
C. Check for continuity through the wires to the
ECM connector P1-39 (Tachometer −) and P1-38 Repair: Perform the following repair:
(Tachometer +).
1. Repair the wiring for the battery connection.
Note: Some of the tachometers require only one
signal line to be connected. Either of the ECM 2. Verify that the repair eliminates the problem.
terminals can be used for this type of tachometer.
The other wire should be left disconnected. If both STOP.
wires are connected, and one indicates an open
circuit, repair this line.
i02186711
Either repair the wiring or send the vehicle to the The following background information is related
OEM dealer. Verify that the repair eliminates the to this procedure:
problem.
The Engine Control Module (ECM) can use various
STOP. inputs in a number of ways. The inputs depend
on the parameter programming. Certain features
Test Step 8. Check the Supply Voltage to are available on several different inputs. The
the Tachometer configuration for the switch must match the actual
switch installation in order for the switch to function
A. Connect the tachometer lines to the ECM and the properly.
tachometer.
Torque Limit Switch
RENR2238-09 357
Troubleshooting Section
g00682363
Illustration 179
Schematic for torque limit switch
358 RENR2238-09
Troubleshooting Section
Expected Result:
Results:
STOP.
Illustration 180
g01105866 A. Connect Cat ET to the cab data link connector.
Terminal locations for ECM
B. Turn the ignition key switch to the ON position.
(P1-7) Input number 4 (Torque limit switch)
(P1-18) Input number 1 (Sensor common)
C. Operate the switch in the ON position and the
OFF position.
Test Step 1. Inspect Electrical Connectors
and Wiring D. View the status of the “Torque Limit Switch” on
Cat ET.
A. Thoroughly inspect the ECM vehicle harness
connector J1/P1, the connectors, and the firewall E. If the status of the “Torque Limit Switch” indicates
bulkhead connectors. Refer to Troubleshooting,
“Not Installed”, then the “Torque Limit Switch”
“Electrical Connectors - Inspect” for details. parameter has not been programmed.
B. Perform a 45 N (10 lb) pull test on each of the
Expected Result:
wires in the ECM connector that are associated
with the circuit for the torque limit switch. The status screen indicates “ON” if the switch is
turned on. The status screen indicates “OFF” if the
The wires are on the following terminals: switch is off.
• P1-7 Results:
• P1-18 • OK – The switch is operating normally. STOP.
C. Check the ECM connector (allen head screw) for
the proper torque of 6.0 N·m (55 lb in). • Not OK – The ECM is not reading the change in
the status of the switch. Proceed to Test Step 3.
RENR2238-09 359
Troubleshooting Section
Test Step 3. Check the Switch Circuit at Test Step 4. Insert a Jumper Wire at the
the ECM Switch
A. Turn the ignition key switch to the OFF position. A. Turn the ignition key switch to the OFF position.
B. Fabricate a jumper wire 100 mm (4 inch) long. B. Reconnect the ECM vehicle harness connector
Crimp a Deutsch pin to both ends of the wire. J1/P1.
C. Remove the wire in P1-7 Torque limit switch from C. Fabricate a jumper wire 100 mm (4 inch) long.
the ECM connector P1. Crimp a Deutsch pin to both ends of the wire.
D. Install a 140-2266 Cable As (70-PIN D. Insert the jumper wire between the two switch
BREAKOUT) to the ECM vehicle harness terminals of the torque limit switch.
connector J1/P1.
E. Turn the ignition key switch to the ON position.
E. Insert the jumper wire into terminal 7 (Torque limit
switch) of the breakout T. Connect the other end of F. Alternately remove the jumper wire and then insert
the jumper wire to terminal 18 (sensor common). the jumper wire at the switch terminals. At the
same time, watch the status screen on Cat ET.
F. Connect Cat ET to the cab data link connector.
Expected Result:
G. Turn the ignition key switch to the ON position.
The switch status changes to “ON” with the jumper
H. Alternately remove the jumper wire and then insert wire in place. The switch status changes to “OFF”
the jumper wire from terminal 5. At the same time, when the jumper wire is removed.
monitor the status screen on Cat ET.
Results:
I. Turn the ignition key switch to the OFF position.
• OK – The switch status changes to “ON” with the
J. Reconnect all wire to the original configuration. jumper wire in place. The switch status changes to
“OFF” when the jumper wire is removed.
Expected Result:
Repair: Replace the torque limit switch.
The switch status changes to “ON” with the jumper
wire in place. The switch status changes to “OFF” Verify that the repair eliminates the problem.
when the jumper wire is removed.
STOP.
Results:
• Not OK – There is a problem in the wire harness
• OK – The ECM is functioning properly at this time. between the torque limit switch and the ECM.
Proceed to Test Step 4. Proceed to Test Step 5.
• Not OK – The ECM is not functioning properly. Test Step 5. Insert a Jumper Wire at the
Bulkhead Connector
Repair: Perform the following repair:
A. Turn the ignition key switch to the OFF position.
1. Temporarily connect a test ECM.
B. Fabricate a jumper wire 100 mm (4 inch) long.
2. Recheck the system for active diagnostic codes. Crimp a Deutsch pin to both ends of the wire.
3. Repeat the Test Step. C. Locate the torque limit switch socket in the engine
side of the ECM bulkhead connector.
4. If the problem is resolved with the test ECM,
reconnect the suspect ECM. D. Insert the wire jumper pin between the switch
socket and the sensor common connection. Install
5. If the problem returns with the suspect ECM, the jumper wire on the Engine side of the ECM
replace the ECM. bulkhead connector.
6. Verify that the repair eliminates the problem. E. Turn the ignition key switch to the ON position.
• Not OK – The problem is in the vehicle wiring Note: The wiring for your particular application may
between the bulkhead connector and the ECM. be slightly different. The sensor common circuits are
used interchangeably by the OEM of the vehicle. The
Repair: Inspect the vehicle wiring and then repair following circuits are common within the ECM:
the vehicle wiring. Otherwise, send the vehicle to
the OEM dealer for repair. Verify that the original • The “Input Sensor Common 1” is terminal 18.
condition is resolved.
• The “Input Sensor Common 2” is terminal 3.
STOP.
• The “AP Sensor/Switch Sensor Common” is
terminal 5.
i01871027
g00682705
Illustration 181
Schematic for Two Speed Axle Switch Circuit
g00682684
Illustration 182
Terminal Locations for the ECM
B. Turn the key switch to the ON position. • Not OK – The ECM is not reading the “Switch
Status” change. Proceed to Test Step 2.
C. Monitor the status for the “Two Speed Axle Switch”
while the switch is operated in the ON and OFF Test Step 2. Determine the Configuration
positions. of the Switch
D. If the “Two Speed Axle Switch” status indicates A. Determine if the wiring for the switch is wired
“Not Installed”, then the “Two Speed Axle Switch” directly to the ECM or through the J1939 data link.
parameter has not been programmed.
B. Verify that the “Two-Speed Axle Switch” parameter
Expected Result: is programmed to reflect the proper wiring.
The status screen should indicate “ON” if the switch Expected Result:
is turned on. The status screen should indicate “OFF”
if the switch is off. The switch is wired directly to the ECM.
362 RENR2238-09
Troubleshooting Section
Results:
STOP.
• terminal 6
• terminal 5
C. Check the ECM connector (allen head screw) for
the proper torque of 6.0 N·m (55 lb in).
Expected Result:
Results:
g00682687
Illustration 183
Connector for Breakout T
A. Turn the key switch to the OFF position. 2. Remove the breakout T and reconnect the J1
and P1 ECM connectors.
B. Install a 140-2266 Cable (Seventy-Pin Breakout)
between the J1 and P1 ECM connector. 3. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
C. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to each end of the wire. 4. If the problem returns with the suspect ECM,
replace the ECM.
D. Insert the jumper wire into terminal 6 of the
breakout T. Connect the other end of the jumper 5. Verify that the repair eliminates the problem.
wire to terminal 5 (AP Sensor/Switch Common)
of the breakout T. STOP.
E. Connect the electronic service tool to the data link Test Step 5. Insert a Jumper Wire at the
connector. Switch
F. Turn the key switch to the ON position. A. Turn the key switch to the OFF position.
G. Alternately remove the jumper wire and then insert B. Fabricate a jumper wire 100 mm (4 inch) long.
the jumper wire from terminal 5. At the same time, Crimp a Deutsch pin to both ends of the wire.
monitor the status screen on the electronic service
tool. C. Locate the switch for the Two-Speed Axle. Insert
the jumper wire between the two switch terminals.
Expected Result:
D. Turn the key switch to the ON position.
The switch status changes to “ON” with the jumper
wire in place. The switch status changes to “OFF” E. Alternately remove the jumper wire and then
when the jumper wire is removed. insert the jumper wire at the switch terminals. At
the same time, watch the status screen on the
Results: electronic service tool.
Repair: Remove the breakout T and reconnect the The switch status changes to “ON” with the jumper
J1 and P1 ECM connectors. wire in place. The switch status changes to “OFF”
when the jumper wire is removed.
Proceed to Test Step 5.
Results:
• Not OK – The ECM is not functioning properly.
• OK – Replace the switch. Verify that the repair
Repair: Perform the following repair: solves the problem. STOP.
• Not OK – There is a problem in the wire harness • There is an easily repeated diagnostic code that is
between the switch for the two-speed axle and the associated with the vehicle speed circuit.
ECM. Proceed to Test Step 6.
Refer to Troubleshooting, “Vehicle Speed Circuit -
Test Step 6. Insert a Jumper Wire at the Calibrate” if the vehicle speed is being calibrated
Bulkhead Connector in ppm (pulses per mile) or PPKM (pulses per
kilometer).
A. Turn the key switch to the OFF position.
The following background information is related
B. Fabricate a jumper wire 100 mm (4 inch) long. to this procedure:
Crimp a Deutsch pin to both ends of the wire.
The vehicle speed circuit consists of the vehicle
C. Locate the two speed axle switch socket in the speed source and associated wiring. The vehicle
engine side of the ECM bulkhead connector. speed source is installed by the vehicle OEM. Usually,
a sensor reads movement of the transmission output
D. Insert the wire jumper pin between the switch shaft from the teeth on a chopper wheel. The Engine
socket and the sensor common connection. Install Control Module (ECM) converts the signal from the
the jumper wire on the engine side of the ECM vehicle speed source into vehicle speed for the
bulkhead connector. following functions:
If the problem is related to vehicle speed calibration, • The speedometer is operating properly.
refer to Troubleshooting, “Vehicle Speed Circuit -
Calibration” for calibrating the vehicle speed in PPKM Note: While the test is active, the odometer will
(pulses per kilometer) or ppm (pulses per mile). The increment mileage.
ECM speedometer output signal is set to 18,600
PPKM (30,000 ppm) and the ECM speedometer Magnetic Sensors
output signal cannot be changed. All speedometers
that are driven by the ECM output (P1-36 & 37) must A magnetic pickup will have only two wires if the
match the ECM (30,000 ppm) in order to operate magnetic pickup is a single coil magnetic sensor.
properly. Also, a magnetic pickup will have four wires if the
magnetic pickup is a dual coil magnetic sensor. The
The type of vehicle speed sensor that is installed on magnetic pickup sensor does not require a power
the vehicle must be determined. connection or a ground connection.
Both single coil magnetic sensors and dual coil Vehicles with Electronic Vehicle Speed Sources
magnetic sensors are commonly used. Caterpillar
recommends single coil magnetic sensors. Some of For these vehicles, the vehicle speed signal is
the vehicles may provide the vehicle speed through provided by an electronic source. The signal is
the transmission ECM. received over a single wire that is connected to P1-32
(Vehicle Speed In +). No other connection should be
You must determine if the vehicle speedometer is made to this line. A speedometer is an example of
driven from the ECM. a connection that should not be made to this line.
For this type of signal, the P1-33 (Vehicle Speed In
The ECM can drive the speedometer through the −) should not be connected to the ECM in order to
connection to P1-36 (Speedometer +) and/or P1-37 prevent introducing electrical noise into the circuit.
(Speedometer −).
For vehicle speed problems on trucks that are
Note: The ECM may also drive the speedometer equipped with either of these vehicle speed sources,
by a connection to the J1587 ATA data link or the first inspect the wiring from the electronic source to
J1939 data link, if the instrument cluster is capable the engine ECM for open circuits or short circuits.
of interpreting the signal.
Speedometer Connection
• P1-36 (Speedometer +)
• P1-37 (Speedometer −)
Note: Some speedometers require only one of the
ECM signal lines to operate. Other speedometers
may require both of the ECM signal lines to operate.
g00643046
Illustration 184
Schematic for a single coil speed sensor and an ECM driven speedometer
g00643048
Illustration 185
Schematic for a single coil speed sensor and a second single coil sensor for a speedometer
g00643050
Illustration 186
Schematic for a single coil speed sensor and a data link driven speedometer
RENR2238-09 367
Troubleshooting Section
g00643051
Illustration 187
Schematic for an electronic vehicle speed source and an ECM driven speedometer
g00643052
Illustration 188
Schematic for an electronic vehicle speed source and a speedometer
368 RENR2238-09
Troubleshooting Section
STOP.
STOP.
B. Verify that the “Vehicle Speed Input” parameter is Repair: Repair the connectors or wiring and/or
programmed to reflect the proper wiring. replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
Expected Result: connectors are completely coupled.
The suspect input is wired directly to the ECM. Verify that the repair eliminates the problem.
Results: STOP.
Result 2 The status screen and speed is stable, but Expected Result:
incorrect.
The speedometer indicates 80 to 96 km/h (50 to 60
Result 3 The status screen agrees with the actual mph).
speed, but the ECM driven speedometer is incorrect
or inoperable. Results:
Result 4 The speed that is displayed on the status • OK – The speedometer indicates 80 to 96 km/h
screen is not present, unstable, or erratic. (50 to 60 mph).
STOP.
370 RENR2238-09
Troubleshooting Section
If the ECM is not connected to the OEM Test Step 6. Measure Vehicle Speed
speedometer, send the vehicle to the OEM dealer Sensor Resistance at the Sensor
for repair of the speedometer.
A. Disconnect the vehicle speed sensor from the
STOP. vehicle harness.
• Not OK – The speedometer does not show any B. Thoroughly inspect the connector. Ensure that
vehicle speed. the connector terminals are free of corrosion
and ensure that the connector terminals are fully
Repair: If OEM truck wiring diagrams are available, seated into the housing of the connector. Repair
trace the wiring to the speedometer and repair the the connector terminals or replace the connector
speedometer, as required. terminals, as required.
Compare the vehicle speed circuit with the • OK – The sensor resistance is correct. Reconnect
detailed circuit schematics: the sensor to the vehicle harness. Proceed to Test
Step 7.
Schematic 1 Refer to Illustration 184.
• Not OK – The sensor resistance is incorrect.
Schematic 2 Refer to Illustration 185.
Repair: Perform the following repair:
Schematic 3 Refer to Illustration 186.
If the sensor is damaged, replace the damaged
Schematic 4 Refer to Illustration 187. sensor or send the vehicle to the OEM dealer for
repairs.
Schematic 5 Refer to Illustration 188.
Verify that any repair eliminates the problem.
Select the schematic that is similar to the circuit
that is being repaired. STOP.
• OK – The vehicle speed circuit is similar to Note: Shavings and debris on the sensor may occur
Schematic 1, 2, or 3. Proceed to Test Step 6. unless the transmission fluid is drained and replaced
according to the maintenance schedule.
• Not OK – The vehicle speed circuit is similar to
Schematic 4 or 5. Proceed to Test Step 8. B. Wipe off the sensor until the sensor is clean.
Test the sensor according to the manufacturer’s
instructions. The sensor is OEM supplied.
RENR2238-09 371
Troubleshooting Section
Expected Result:
Results:
STOP.
g00643436
Illustration 190
Jumper wire locations for breakout T
A. Turn the key switch to the OFF position. C. Remove the wire in P1-32 Vehicle Speed In +
from the ECM connector P1.
B. Fabricate two jumper wires 100 mm (4 inch) long.
Crimp a Deutsch pin to each end of the wires. D. Remove the wire in P1-33 Vehicle Speed In −
from the ECM connector P1.
372 RENR2238-09
Troubleshooting Section
E. Remove the wire in P1-36 Speedometer + from • Not OK – Cat ET does not indicate a constant
the ECM connector P1. vehicle speed between 80 to 96 km/h (50 to 60 mph)
when the jumper wires from the speedometer
F. Remove the wire in P1-37 Speedometer − from circuit are connected. Recheck the connections
the ECM connector P1. of the jumper wires. Leave the speedometer and
the vehicle speed wires disconnected. Leave the
G. Install a 140-2266 Cable As (70-PIN jumper wires installed in the breakout T. Disconnect
BREAKOUT) to the ECM vehicle harness the breakout T. Proceed to Test Step 9.
connector J1/P1.
Test Step 9. Test the ECM Vehicle Speed
H. Install one jumper into the breakout T in order to Inputs when the Test ECM is Installed
connect terminal 36 (Speedometer +) to terminal
32 (Vehicle Speed In +). Install the other jumper A. Connect a test ECM and reconnect the breakout T.
into the breakout T in order to connect terminal 37
(Speedometer −) to terminal 33 (Vehicle Speed B. Install one jumper into the breakout T in order to
In −). connect terminal 36 (Speedometer +) to terminal
32 (Vehicle Speed In +). Install the other jumper
Refer to Illustration 190. into the breakout T in order to connect terminal 37
(Speedometer −) to terminal 33 (Vehicle Speed
I. Turn the key switch to the ON position. In −).
K. Access the “55 mph VSP/Speedometer Test” by C. Turn the key switch to the ON position.
accessing the following display screens in order:
D. Access the “55 mph VSP/Speedometer Test” by
• “Diagnostics” accessing the following display screens in order:
Cat ET indicates a constant vehicle speed between G. Reconnect all wiring to the original configuration.
80 to 96 km/h (50 to 60 mph) when the jumper wires
from the speedometer circuit are connected. Expected Result:
If the sensor is damaged, replace the damaged Repair: Perform the following repair:
sensor or send the vehicle to the OEM dealer for
repairs. Reconnect the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM.
Verify that any repair eliminates the problem.
STOP.
STOP.
RENR2238-09 373
Troubleshooting Section
• Not OK – Cat ET does not indicate a constant When the ECM has detected an engine condition
vehicle speed between 80 to 96 km/h (50 to 60 mph) that exceeds the acceptable limits, the warning lamp
when the jumper wires from the speedometer will turn on. The activation of the lamp depends on
circuit are connected. the existing conditions and the programming of the
parameter for “Engine Monitoring”. The lamp will
Repair: Recheck the connectors. Continue activate in one of the following modes:
troubleshooting until original condition is resolved.
• The lamp not only turns on, but the lamp stays on.
STOP.
• The lamp will flash on and off.
i01624592
If the lamp turns on continuously, the engine is in
Warning Lamp Circuit - Test warning mode. If the lamp begins to flash, the ECM
has begun to derate engine speed, vehicle speed,
SMCS Code: 7431-038 or power.
g00676476
Illustration 191
RENR2238-09 375
Troubleshooting Section
g00676565
Illustration 192
Test Step 1. Inspect Electrical Connectors Repair: Repair the connectors or wiring and/or
and Wiring replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
A. Thoroughly inspect ECM vehicle harness connectors are completely coupled.
connector J1/P1, the firewall bulkhead connector,
and the suspect terminal for the lamp. Refer STOP.
to Illustration 192. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details. Test Step 2. Check for Normal Operation
of the Warning Lamp(s)
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that is associated with A. Monitor the check engine lamp. Turn the ignition
the suspect terminal for the lamp. key switch to the ON position, while the engine
is off. The lamp should turn on for five seconds.
Refer to Illustration 192. Then, the lamp should turn off.
C. Check the ECM connector (allen head screw) for The lamp will continue flashing if there is an active
the proper torque of 6.0 N·m (55 lb in). diagnostic code. If there is an active diagnostic
code, connect the Caterpillar Electronic Technician
D. Check the harness and wiring for abrasion and (ET) in order to read the active diagnostic code.
pinch points from the battery to the ECM. Troubleshoot the problem.
Expected Result: Note: The warning lamp will not turn on until the
engine is cranked.
All connectors, pins, and sockets should be
completely coupled and/or inserted and the harness B. Connect ET in order to verify that the “Engine
and wiring should be free of corrosion, abrasion, or Monitoring” has been programmed to “Warning”,
pinch points. “Derate”, or “Shutdown”. If “Engine Monitoring” is
programmed to “Off”, the warning lamp is not used
Results: and the ECM will not turn on the lamp.
Expected Result:
Results:
g00676787
Illustration 193
Vehicle harness connector P1
A. Disconnect ECM vehicle harness connector B. Fabricate a jumper wire 100 mm (4 inch) long.
J1/P1. Crimp a Deutsch pin to both ends of the wire.
RENR2238-09 377
Troubleshooting Section
Expected Result:
Results:
• Result 3
Repair: Perform the following diagnostic
procedure:
STOP.
378 RENR2238-09
Troubleshooting Section
g00676787
Illustration 194
ECM Breakout T-connector
A. Disconnect ECM vehicle harness connector • Not OK – Temporarily connect a test ECM. Ensure
J1/P1. that the “Engine Monitoring” of the test ECM
matches the “Engine Monitoring” of the suspect
B. Insert a 70-Terminal breakout T between the ECM ECM. Check the ECM operation of the Lamp when
vehicle harness connectors J1 and P1. the test ECM is installed. If the problem is resolved
with the test ECM, reconnect the suspect ECM. If
C. Connect a voltage test lamp probe to terminal 65 the problem returns with the suspect ECM, replace
(-Battery) and connect the other probe to terminal the ECM. STOP.
52 (Unswitched +Battery) of the breakout T.
D. The test lamp should turn on. If the test lamp does
not turn on, either the test lamp is faulty or the
wiring to the ECM is faulty. Continue with this step
if the lamp turns on.
Expected Result:
Results:
Calibration Procedures
i01907628
• 60 Degrees
C. Use the following procedure for a C-10 or C-12
engine:
380 RENR2238-09
Troubleshooting Section
a. Remove the timing calibration plug from the Test Step 3. Start the Engine and
right side of the cylinder block as the engine is Allow the Coolant to Reach Operating
viewed from the flywheel. The timing calibration Temperature
plug is located on the No. 4 cylinder rod pocket.
A. Start the engine and run at low idle until the
b. Install the 7X-1171 Transducer Adapter into engine has warmed up enough to exit cold mode
the hole for the plug. operation. The status screen on Cat ET will display
“COLD MODE” in the upper corner when cold
D. Use the following procedure for a 3406E, C-15, mode operation exists. The engine will adjust idle
C-16 or C-18 Engine: rpm from cold mode idle to the programmed low
idle rpm when cold mode operation is complete.
a. Remove the timing calibration plug from the
left side of the cylinder block as the engine is B. Check for active diagnostic codes. Use the
viewed from the flywheel. procedures in this manual to troubleshoot
and repair any active diagnostic codes before
b. Install the 7X-1171 Transducer Adapter into attempting a calibration check. The engine must
the hole for the plug. not have any diagnostic fault conditions that are
present during the timing calibration except the
Results: following condition:
Results:
A. Put a 2D-6392 O-Ring Seal on the end of the
magnetic transducer. • OK – Proceed to Test Step 4.
Note: A small amount of clean engine oil will allow Test Step 4. Connect Cat ET
the seal to slide onto the transducer more easily.
A. Connect Cat ET to the data link connector.
B. Push the magnetic transducer through the adapter
until the magnetic transducer comes in contact B. After the engine has exited cold mode operation,
with the outermost portion of the crankshaft access the “Timing Calibration Screen” on Cat ET.
counterweight. Move the O-ring seal downward Access the following display screens in order:
against the adapter.
• “Service”
C. Withdraw the magnetic transducer 1.0 mm
(0.04 inch) and hand tighten the nut on the adapter • “Calibrations”
sleeve in order to secure the magnetic transducer
in place. • “Timing Calibration”
D. Connect the 6V-2197 Magnetic Transducer to Note: To perform a timing calibration, the engine rpm
the 7X-1695 Cable. must remain as steady as possible at approximately
1100 rpm. This can be performed by the use of
Results: the cruise control switches or a steady foot on the
accelerator pedal. Any changes to engine rpm that
• OK – Proceed to Test Step 3. are more than 100 rpm will slow down the procedure.
These changes will also reduce the accuracy of the
procedure.
D. Ensure that all of the connections are made Test Step 6. Disconnect the 6V-2197
correctly. Magnetic Transducer Before Exiting the
“Monitor/Calibrate Timing” Screen
Results:
A. Disconnect the 6V-2197 Magnetic Transducer
• OK – Proceed to Test Step 5. from the P400 Speed/Timing Calibration
Connector.
Test Step 5. Calibrate the Speed/Timing
Sensor B. Exit the timing calibration screen on Cat ET.
A. To calibrate the timing to the correct setting, select Note: Exiting the timing calibration screen on Cat ET
“Continue” on Cat ET. Wait until Cat ET indicates will drop the engine rpm to the programmed low idle
that the timing is “CALIBRATED”. if the cruise control switches were used to maintain
engine rpm during calibration. This is normal.
Note: If Cat ET displays “CALIBRATION
UNSUCCESSFUL”, the electronic injection timing Expected Result:
has not been set. Recheck the tool installation and
tool operation and try again to calibrate electronic The magnetic transducer was disconnected before
injection timing. If the crankshaft and camshaft gears exiting the timing calibration screen on Cat ET.
have been reassembled incorrectly, the engine will
not calibrate. Results:
Results:
i02149153
4 • OK – STOP.
5
i02186893
6
Vehicle Speed Circuit -
Note: If the ECM is replaced, all injector trim codes
must be recorded. The injector trim codes can be
Calibrate
found in “Calibrations” under the “Service” menu on
SMCS Code: 7463-524
the Caterpillar Electronic Technician (ET).
System Operation Description:
Expected Result:
The Engine Control Module (ECM) uses vehicle
All injector trim codes were obtained.
speed information for the following features:
Results:
• Cruise control
• OK – All injector trim codes were obtained. • Fast idle control
Proceed to Test Step 2.
• Not OK – The injector trim codes were not • Idle speed control
obtained.
• PTO operation
Repair: Remove the valve cover and record the
injector trim code and the corresponding cylinder • Vehicle speed limiting
number for each unit injector.
• Speedometer
Proceed to Test Step 2.
• Progressive shift
Test Step 2. Replace Hardware
• Idle shutdown
A. Replace the suspect unit injectors and/or the ECM.
• Operation of the air inlet heater
B. Record the injector trim code and the
corresponding cylinder number for each unit • Secure idle theft deterrent
injector.
• Trip data
Expected Result:
• Maintenance data
All hardware was successfully replaced and the new
There are three different methods that can be used
injector trim codes were recorded.
to obtain the information for the ECM to use for
calculating vehicle speed. The ECM can calculate
Results:
vehicle speed by either of the following means:
• OK – The hardware was successfully replaced. • The ECM monitors the signal from a vehicle speed
Proceed to Test Step 3.
sensor in pulses per kilometer (mile). The vehicle
speed sensor is connected to the vehicle speed
Test Step 3. Enter Injector Trim Codes input circuit (terminals 32 and 33 of the ECM). This
into the ECM is the “Vehicle Speed Calibration” option.
A. Connect Cat ET to the service tool connector.
RENR2238-09 383
Troubleshooting Section
• The ECM receives a message over the J1939 The variable for the tire revolution could be affected
data link from the Transmission ECU that indicates by changing from bias ply tires to radial tires and
revolutions per kilometer (mile) of the transmission vice versa. Also, changing to radial tires that have
output shaft. This is the “Vehicle Speed Cal a low profile could affect the variable for the tire
(J1939-Trans)” option. revolution. This result may change the actual vehicle
speed which could result in performance complaints
• The ECM receives a message over the J1939 data or complaints about fuel consumption. If the tire
link from the Anti-lock Brake System (ABS) that configuration has been changed, determine the new
contains information about the wheel speed. This variable for the tire revolution. Enter the new value
is the “Vehicle Speed Cal (J1939-ABS)” option. in pulses per km (PPKM) or pulses per mile (PPM).
The preferred method is obtaining the data from the
Each of these methods require a specific calibration individual tire manufacturers for the specific tire that
number to be programmed into the ECM to calculate is being used.
vehicle speed.
Note: The ECM speedometer signal is set to
For the “Vehicle Speed Calibration” option that uses 18,600 pulses per km (PPKM) or 30,000 pulses per
the vehicle speed sensor, the ECM must know the mile (PPM). This setting cannot be changed. All
number of pulses that are produced by the vehicle speedometers that are driven by the ECM output
speed sensor during each kilometer (mile) of travel (J1/P1 terminal 36 and terminal 37) must match the
by the vehicle. In order to find the number of pulses fixed output of the ECM for proper operation.
that are produced by the sensor, multiply the tire
size by the axle ratio. Multiply the number that was Test Step 1. Use Caterpillar Electronic
obtained in the previous calculation by the number of Technician (ET) to Determine the
teeth on the output shaft that is used by the sensor Configuration for the Vehicle Speed Input
to obtain the pulses. to the ECM
For the “Vehicle Speed Cal (J1939-Trans)” option, A. Connect Cat ET to the cab data link connector.
the ECM must know the number of times that the
output shaft revolves per kilometer (mile) of travel B. Access the “Configuration Parameter List”. View
by the vehicle. This can be calculated by one of the the “Vehicle Speed Parameters”. Determine if
following methods: the vehicle is configured to use the “Vehicle
Speed Calibration” option,the “Vehicle Speed Cal
• Divide the pulses per kilometer (mile) of the sensor (J1939-Trans)” option, or the “Vehicle Speed Cal
on the transmission output shaft by the number of (J1939-ABS)” option.
teeth on the transmission output shaft.
Expected Result:
• Multiply the axle ratio by the number of revolutions
per kilometer (mile) of the tire. RESULT 1 The ECM is configured for the “Vehicle
Speed Calibration” option.
For the “Vehicle Speed Cal (J1939-ABS)” option, the
ECM must know a calibration number. The number is RESULT 2 The ECM is configured to use the “Vehicle
calculated by dividing the actual tire revolutions per Speed Cal (J1939-Trans)” option.
kilometer (mile) by the tire revolutions per kilometer
(mile) that is programmed into the ABS. RESULT 3 The ECM is configured to use the “Vehicle
Speed Cal (J1939-ABS)” option.
The ECM calculates vehicle speed by converting the
vehicle speed signal to kilometers per hour (km/h) Results:
or miles per hour (mph). The conversion factor is
customer programmable and the conversion factor is • RESULT 1 – Proceed to Test Step 2.
stored in pulses per km (PPKM) or pulses per mile
(PPM). • RESULT 2 – Proceed to Test Step 3.
• RESULT 3 – Proceed to Test Step 4.
Test Step 2. Calculating Pulses Per
Kilometer (Mile) When all the Variables
are Known.
A. Calculate pulses per kilometer (PPKM) or pulses
per mile (PPM).
PPKM = K X Ra X N.
384 RENR2238-09
Troubleshooting Section
K – This symbol represents the tire revolutions The value is within the valid range of the ECM.
per kilometer. This is a constant that is divided by
the tire static loaded radius. Results:
M – This symbol represents the tire revolutions • Yes – Once the value is entered, verify that the
per mile. This is a constant that is divided by the ECM is accurately measuring vehicle speed.
tire static loaded radius. Proceed to Test Step 5.
Ra – This symbol represents the rear axle ratio. • No – Recalculate the value and re-enter the
The rear axle ratio can typically be found on the correct value into the ECM. STOP.
housing of the rear axle, or the rear axle ratio can
typically be found on the specification sheet for Test Step 4. Calculate Tire Revolutions
the vehicle. Per Kilometer (Mile) When all the
Variables are Known
N – This symbol represents the number of
chopper teeth on the transmission drive shaft. A. The correct calibration number must be entered
The magnetic pickup sensor is mounted here. for the “Vehicle Speed Cal J1939-ABS” setting. If
The number of chopper teeth is usually 16. Some this value is unknown, the following calculation
transmissions have 11 tooth chopper wheels. can be used to obtain the correct setting.
B. Use Cat ET to enter pulses per km (PPKM) or Divide the actual tire revolutions per kilometer
pulses per mile (PPM) into the ECM. (mile) by the tire revolutions per kilometer (mile)
that is broadcast by theABS.
Expected Result:
For example, the actual tire revolutions per
This value is within the valid range of the ECM. kilometer (mile) could equal 400 revolutions per
kilometer (mile). The tire revolutions per kilometer
Results: (mile) that is broadcast by the ABS could equal
500 revolutions per kilometer (mile).
• OK – Once the value is entered, verify that the
ECM is accurately measuring vehicle speed. The formula would be 400 / 500 = 0.800.
Proceed to Test Step 5.
Therefore, 0.800 would be the value that would be
• Not OK – Recalculate the value and re-enter the entered into the ECM.
correct value into the ECM. STOP.
B. Use Cat ET to enter the calculated value into the
Test Step 3. Calculate the Revolutions ECM.
Per Kilometer (Mile) of the Transmission
Output Shaft Expected Result:
A. The correct revolutions per kilometer (mile) of This value is within the valid range of the ECM.
the transmission output shaft must be entered
for the “Vehicle Speed Cal J1939-Trans” setting. Results:
If this value is unknown, either of the following
calculations can be used to obtain the correct • OK – Once the value is entered, verify that the
setting: ECM is accurately measuring vehicle speed.
Proceed to Test Step 5.
• Divide the pulses per kilometer (mile) of the
sensor on the transmission output shaft by the • Not OK – Recalculate the value and re-enter the
number of teeth on the transmission output correct value into the ECM. STOP.
shaft.
Test Step 5. Inspect the Speedometer
• Multiply the axle ratio by the number of Calibration.
revolutions per kilometer (mile) of the tire.
Determine the speedometer’s vehicle speed
B. Use Cat ET to enter the calculated value into the calibration setting.
ECM.
RENR2238-09 385
Troubleshooting Section
Expected Result:
Results:
• Not OK
Repair: Perform the following diagnostic
procedure:
STOP.
386 RENR2238-09
Index Section
Index
Numerics 0111-01 Low Coolant Level Warning (62)............ 126
0111-02 Coolant Level signal invalid (12) ............ 127
0001-11 Cylinder #1 Injector current fault (72) .... 101 0111-03 Coolant Level voltage high (12) ............. 128
0002-11 Cylinder #2 Injector current fault (72) .... 101 0111-04 Coolant Level voltage low (12) .............. 128
0003-11 Cylinder #3 Injector current fault (73) .... 102 0111-11 Very Low Coolant Level (62) .................. 128
0004-11 Cylinder #4 Injector current fault (73) .... 102 0121-05 Low/High Retarder current low (14) ...... 129
0005-11 Cylinder #5 Injector current fault (74) .... 103 0121-06 Low/High Retarder current high (14) ..... 130
0006-11 Cylinder #6 Injector current fault (74) .... 103 0122-05 Med/High Retarder current low (14) ...... 130
0022-11 Primary to Secondary Engine Speed Signal 0122-06 Med/High Retarder current high (14)..... 130
Calibration (42) .................................................. 103 0168-01 Low ECM Battery Power (17)................ 131
0022-13 Engine Speed Signal Calibration Not 0168-02 ECM Battery Power Intermittent (51) .... 131
Performed (42)................................................... 105 0171-03 Ambient Air Temperature voltage high .. 131
0030-08 PTO Throttle signal invalid (29)............. 105 0171-04 Ambient Air Temperature voltage low.... 132
0030-13 PTO Throttle out of calibration (29) ....... 105 0171-11 Ambient Air Temperature Data Lost ...... 132
0041-03 8 Volt Supply voltage high (21).............. 106 0174-00 High Fuel Temperature Warning (65) .... 132
0041-04 8 Volt Supply voltage low (21) ............... 106 0174-03 Fuel Temperature voltage high (13) ...... 133
0043-02 Key Switch Fault (71) ............................ 107 0174-04 Fuel Temperature voltage low (13)........ 133
0052-11 Air Inlet Shutoff Shutdown (00).............. 107 0190-00 Engine Overspeed Warning (35) ........... 133
0054-05 Auxiliary Output #06 current low (66) .... 107 0190-12 Primary Engine Speed loss of signal
0054-06 Auxiliary Output #06 current high (66)... 108 (34) .................................................................... 134
0055-05 Auxiliary Output #07 current low (67) .... 108 0191-07 Transmission Not Responding (68) ....... 134
0055-06 Auxiliary Output #07 current high (67)... 108 0224-11 Theft Deterrent Active (00) .................... 134
0064-12 Secondary Engine Speed loss of signal 0224-14 Theft Deterrent Active with Engine Cranking
(34) .................................................................... 109 (00) .................................................................... 135
0071-00 Idle Shutdown Override (01) ................. 109 0231-02 J1939 Data Incorrect (58)...................... 135
0071-01 Idle Shutdown (47) ................................. 110 0231-11 J1939 Data Link Fault (58) .................... 136
0071-14 PTO Shutdown (47)................................ 110 0231-12 J1939 Device Not Responding.............. 136
0084-00 Vehicle Overspeed Warning (41) ........... 110 0232-03 5 Volt Supply voltage high (21).............. 136
0084-01 Vehicle Speed loss of signal (31) ........... 111 0232-04 5 Volt Supply voltage low (21) ............... 137
0084-02 Vehicle Speed signal invalid (36) ........... 111 0246-11 Brake Pedal Switch #1 Fault ................. 137
0084-08 Vehicle Speed signal out of range (36) .. 112 0247-11 Brake Pedal Switch #2 Fault ................. 137
0084-10 Vehicle Speed signal rate of change 0249-11 J1922 Data Link Fault (58) .................... 138
(36) ..................................................................... 112 0252-11 Engine Software Incorrect (59).............. 138
0084-14 Quick Stop Occurrence .......................... 112 0253-02 Check Customer or System Parameters
0091-08 Throttle Position Invalid (32)................... 113 (56) .................................................................... 139
0091-13 Throttle Position out of calibration (28)... 113 0253-11 Check Transmission Customer Parameters
0100-01 Low Oil Pressure Warning (46) .............. 113 (56) .................................................................... 139
0100-03 Oil Pressure voltage high (24)................ 117 5 Volt Engine Pressure Sensor Supply Circuit -
0100-04 Oil Pressure voltage low (24) ................. 117 Test .................................................................... 140
0100-11 Very Low Oil Pressure (46)..................... 118
0102-00 Excessive Boost Pressure..................... 121
0102-03 Boost Pressure voltage high (25) .......... 121 A
0102-04 Boost Pressure voltage low (25) ........... 122
0105-00 High Intake Manifold Air Temperature Accelerator Pedal (Throttle) Position Sensor Circuit -
Warning (64) ...................................................... 122 Test .................................................................... 145
0105-03 Intake Manifold Air Temperature voltage Air Inlet Shutoff Circuit - Test ............................... 153
high (38)............................................................. 123 ATA (SAE J1587 / J1708) Data Link Circuit -
0105-04 Intake Manifold Air Temperature voltage low Test .................................................................... 159
(38) .................................................................... 123 Auxiliary Brake Circuit - Test................................ 165
0105-11 Very High Intake Manifold Air Temperature
(64) .................................................................... 124
0108-03 Barometric Pressure voltage high (26).. 124 C
0108-04 Barometric Pressure voltage low (26) ... 124
0110-00 High Coolant Temperature Warning Calibration Procedures ........................................ 379
(61) .................................................................... 125 Can Not Reach Top Engine RPM .......................... 73
0110-03 Coolant Temperature voltage high (27).. 125 Probable Causes ............................................... 73
0110-04 Coolant Temperature voltage low (27)... 126 Recommended Actions...................................... 73
0110-11 Very High Coolant Temperature (61) ..... 126
RENR2238-09 387
Index Section
Can Not Reach Vehicle Speed Limit ..................... 74 ECM Memory - Test............................................. 219
Probable Causes ............................................... 74 ECM Snapshot ...................................................... 32
Recommended Actions...................................... 74 Snapshot That is Triggered by a Diagnostic
Check Engine Lamp Circuit - Test ....................... 169 Code................................................................. 32
Check Engine Lamp or Warning Lamp Is Snapshot That is Triggered by a Quick Stop ..... 33
Malfunctioning...................................................... 76 Snapshot That is Triggered by the Operator...... 32
Probable Causes ............................................... 76 Use of Snapshot Data........................................ 33
Recommended Actions...................................... 76 ECM Will Not Accept Factory Passwords.............. 82
Clutch Pedal Position Switch Circuit - Test.......... 173 Probable Causes ............................................... 82
Coolant Level Sensor Circuit - Test ..................... 178 Recommended Actions...................................... 82
Cooling Fan Circuit and A/C High Pressure Switch Electrical Connectors - Inspect............................ 222
Circuit - Test....................................................... 188 Electronic Service Tool Will Not Communicate with
Cooling Fan Is Always ON..................................... 76 ECM..................................................................... 82
Probable Causes ............................................... 76 Probable Causes ............................................... 82
Recommended Actions...................................... 76 Recommended Actions...................................... 82
Cruise Control Switch Circuit - Test ..................... 202 Electronic Service Tools ........................................ 16
Cruise Control, Idle, or PTO Can Not Be Set ........ 78 Optional Service Tools ....................................... 17
Probable Causes ............................................... 78 Required Service Tools ...................................... 16
Recommended Actions...................................... 78 Electronic Troubleshooting ...................................... 5
Customer Passwords ............................................ 31 Engine Cranks but Will Not Start ........................... 83
Customer Specified Parameters............................ 36 Probable Causes ............................................... 83
“Cruise Control Parameters” .............................. 40 Recommended Actions...................................... 84
Customer Parameter Lockout ............................ 36 Engine Misfires, Runs Rough or Is Unstable......... 85
“Dash Display Access Parameters” ................... 54 Probable Causes ............................................... 85
Data Link Parameters ........................................ 61 Recommended Actions...................................... 85
“Dedicated PTO Parameters” ............................ 44 Engine Pressure Sensor Open or Short Circuit -
“Driver Reward”.................................................. 56 Test .................................................................... 226
“ECM Identification Parameters”........................ 38 Engine Retarder (Compression Brake) Will Not Turn
“Engine Monitoring Parameters” ........................ 52 ON ....................................................................... 86
“Engine/Gear Parameters”................................. 47 Probable Causes ............................................... 86
“Idle Parameters” ............................................... 43 Recommended Actions...................................... 86
Injector Codes.................................................... 62 Engine Running Output Circuit - Test .................. 233
“Input Selections” ............................................... 56 Engine Shutdown Output Circuit - Test................ 236
“Maintenance Parameters” ................................ 53 Engine Speed/Timing Sensor - Calibrate ............ 379
“Output Selections” ............................................ 60 Engine Speed/Timing Sensor Circuit - Test......... 239
“Security Access Parameters” ........................... 38 Engine Temperature Sensor Open or Short Circuit -
“Selected Engine Rating” ................................... 37 Test .................................................................... 247
“Timer Parameters” ............................................ 50 Engine Vibration .................................................... 87
“Trip Parameters” ............................................... 54 Probable Causes ............................................... 87
“Vehicle Activity Report”..................................... 56 Recommended Actions...................................... 87
“Vehicle Speed Parameters” .............................. 38 Engine Will Not Crank ........................................... 88
Customer Specified Parameters Table .................. 62 Probable Causes ............................................... 88
Customer Specified Parameters Worksheet ......... 68 Recommended Actions...................................... 88
Injector Codes.................................................... 71 Engine Wiring Harness Diagram ........................... 26
Lifetime Totals Worksheet.................................. 71 Excessive Black Smoke ........................................ 89
Probable Causes ............................................... 89
Recommended Actions...................................... 89
D Excessive Fuel Consumption ................................ 90
Probable Causes ............................................... 90
Diagnostic Codes ................................................ 100 Recommended Actions...................................... 90
Diagnostic Enable Switch Circuit - Test ............... 209 Excessive White Smoke ........................................ 91
Diagnostic Functional Tests................................. 140 Probable Causes ............................................... 91
Driver Questionnaire.............................................. 80 Recommended Actions...................................... 91
Driver Questionnaire Response ............................ 81
F
E
Factory Passwords ................................................ 33
Eaton Top 2 Transmission Circuit - Test .............. 212 Factory Passwords Worksheet.............................. 34
ECM Date/Time Stamped Information................... 31 Fan Override Switch Circuit - Test ....................... 253
Diagnostic Clock ................................................ 32 Flash Programming ............................................... 34
ECM Date/Time Clock ....................................... 31 Programming a Flash File.................................. 34
Total Time .......................................................... 32
I Retarder (Compression Brake) Solenoid Circuit -
Test .................................................................... 324
Idle Shutdown Timer - Test .................................. 256
Ignition Key Switch Circuit and Battery Supply Circuit
- Test .................................................................. 259 S
Ignore Brake/Clutch Switch Circuit - Test ............ 264
Important Safety Information ................................... 2 Sensors and Electrical Connectors ....................... 19
Injector Code - Calibrate...................................... 381 3406E Engine .................................................... 23
Injector Solenoid Circuit - Test............................. 267 C-10 and C-12 Engines ..................................... 21
Intermittent Cruise Control, Idle, or PTO Kickout .. 92 C-15, C-16 and C-18 Engines............................ 25
Probable Causes ............................................... 92 Service Brake Pedal Position (Switch 1) Circuit -
Recommended Actions...................................... 92 Test .................................................................... 334
Intermittent Engine Shutdown ............................... 93 Service Brake Pedal Position (Switch 2) Circuit -
Probable Causes ............................................... 93 Test .................................................................... 339
Recommended Actions...................................... 93 Service Information Report.................................... 35
Intermittent Low Power or Power Cutout............... 94 Recommendations ............................................. 35
Probable Causes ............................................... 94 Starting Aid Output Circuit - Test ......................... 344
Recommended Actions...................................... 94 Starting Aid Switch Circuit - Test ......................... 348
System Configuration Parameters......................... 72
“Engine Serial Number” ..................................... 72
L “Full Load Setting”.............................................. 72
“Full Torque Setting”........................................... 72
Low Power/Poor or No Response to Throttle ........ 96 Interlock Code.................................................... 72
Probable Causes ............................................... 96 “Personality Module Release Date” ................... 72
Recommended Actions...................................... 96 System Overview..................................................... 5
ECM Lifetime Totals ............................................ 11
Effect Of Diagnostic Codes On Engine
M Performance..................................................... 10
Engine Monitoring ................................................ 6
Multi-Torque - Test ............................................... 279 Engine Snapshot Data ....................................... 10
Other ECM Functions Of Performance .............. 10
Passwords ......................................................... 15
N Programmable Parameters................................ 15
Self-Diagnostics ................................................. 10
Neutral Switch Circuit - Test ................................ 280 System Operation ................................................ 5
No Diagnostic Code Detected (55)...................... 101 Trip Data That Is Stored In The ECM ................. 11
P T
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