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SENR9698-09

March 2006

Troubleshooting
C11, C13 and C15 On-highway Engines
KCA1-Up (Engine)
KCB1-Up (Engine)
JAM1-Up (Engine)
BXS1-Up (Engine)

i01658146

Important Safety Information


Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:


Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this


product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.

SENR9698-09

3
Table of Contents

Table of Contents
Troubleshooting Section
Electronic Troubleshooting
System Overview .................................................... 6
Electronic Service Tools ........................................ 13
Replacing the ECM ............................................... 15
Sensors and Electrical Connectors ....................... 17
Programming Parameters
Programming Parameters .....................................
Dyno Mode ...........................................................
Test ECM Mode ....................................................
Customer Passwords ............................................
ECM Date/Time Stamped Information ..................
ECM Snapshot ......................................................
Factory Passwords ...............................................
Factory Passwords Worksheet .............................
Flash Programming ..............................................
Service Information Report ...................................

23
23
23
24
24
25
26
27
27
28

Customer Specified Parameters


Customer Specified Parameters ...........................
Customer Specified Parameters Table .................
Customer Specified Parameters Worksheet .........
Cruise Control Parameters ...................................
Data Link Parameters ...........................................
Dedicated PTO Parameters ..................................
Driver Reward .......................................................
ECM Identification Parameters .............................
Engine/Gear Parameters ......................................
Engine Monitoring Parameters .............................
Idle Parameters ....................................................
Input Selections ....................................................
Maintenance Parameters ......................................
Output Selections .................................................
Security Access Parameters .................................
Selected Engine Rating ........................................
Smart Idle Parameters ..........................................
Timer Parameters .................................................
Trip Parameters ....................................................
Vehicle Activity Report Parameters ......................
Vehicle Speed Parameters ...................................

30
31
37
40
44
44
47
47
48
51
51
52
56
57
58
58
59
59
61
63
63

System Configuration Parameters


System Configuration Parameters ........................ 66
Troubleshooting without a Diagnostic Code
Can Not Reach Top Engine RPM ......................... 67
Can Not Reach Vehicle Speed Limit ..................... 68
Check Engine Lamp or Warning Lamp Is
Malfunctioning ..................................................... 70
Cooling Fan Is Always ON .................................... 70
Cruise Control, Idle, or PTO Can Not Be Set ....... 72
Driver Questionnaire ............................................. 74
Driver Questionnaire Response ............................ 75
ECM Will Not Accept Factory Passwords ............. 76
Electronic Service Tool Will Not Communicate with
ECM .................................................................... 76
Engine Cranks but Will Not Start .......................... 77

Engine Misfires, Runs Rough or Is Unstable ........ 79


Engine Retarder (Compression Brake) Will Not Turn
ON ....................................................................... 80
Engine Vibration ................................................... 81
Engine Will Not Crank ........................................... 82
Excessive Black Smoke ........................................ 83
Excessive Fuel Consumption ............................... 84
Excessive White Smoke ....................................... 85
Intermittent Cruise Control, Idle, or PTO Kickout .. 86
Intermittent Low Power or Power Cutout .............. 87
Low Power/Poor or No Response to Throttle ....... 89
Poor Acceleration or Response ............................ 91
Troubleshooting with a Diagnostic Code
Diagnostic Codes .................................................. 93
No Diagnostic Code Detected (55) ....................... 96
0001-05 Cylinder #1 Injector current low (72) ....... 96
0001-06 Cylinder #1 Injector current high (72) ..... 97
0002-05 Cylinder #2 Injector current low (72) ....... 97
0002-06 Cylinder #2 Injector current high (72) ..... 97
0003-05 Cylinder #3 Injector current low (73) ....... 98
0003-06 Cylinder #3 Injector current high (73) ..... 98
0004-05 Cylinder #4 Injector current low (73) ....... 99
0004-06 Cylinder #4 Injector current high (73) ..... 99
0005-05 Cylinder #5 Injector current low (74) ....... 99
0005-06 Cylinder #5 Injector current high (74) ... 100
0006-05 Cylinder #6 Injector current low (74) ..... 100
0006-06 Cylinder #6 Injector current high (74) ... 100
0022-11 Primary to Secondary Engine Speed Signal
Calibration (42) ................................................. 101
0022-13 Engine Speed Signal Calibration Not
Performed (42) .................................................. 102
0030-08 PTO Throttle signal invalid (29) ............ 103
0030-13 PTO Throttle out of calibration (29) ...... 103
0041-03 8 Volt Supply voltage high (21) ............. 103
0041-04 8 Volt Supply voltage low (21) .............. 104
0043-02 Key Switch Fault (71) ........................... 104
0052-11 Air Inlet Shutoff Shutdown (00) ............. 104
0054-05 Auxiliary Output #06 current low (66) ... 105
0054-06 Auxiliary Output #06 current high (66) .. 105
0055-05 Auxiliary Output #07 current low (67) ... 106
0055-06 Auxiliary Output #07 current high (67) .. 106
0064-08 Secondary Engine Speed loss of signal
(34) .................................................................... 106
0071-00 Idle Shutdown Override (01) ................. 107
0071-01 Idle Shutdown (47) ............................... 107
0071-14 PTO Shutdown (47) .............................. 107
0084-00 Vehicle Overspeed Warning (41) .......... 108
0084-01 Vehicle Speed loss of signal (31) ......... 108
0084-02 Vehicle Speed signal invalid (36) .......... 109
0084-08 Vehicle Speed signal out of range (36) .. 109
0084-10 Vehicle Speed signal rate of change
(36) ..................................................................... 110
0084-14 Quick Stop Occurrence ......................... 110
0091-08 Throttle Position Invalid (32) .................. 110
0091-13 Throttle Position out of calibration (28) .. 111
0100-01 Low Oil Pressure Warning (46) .............. 111
0100-03 Oil Pressure voltage high (24) ............... 114
0100-04 Oil Pressure voltage low (24) ................ 115
0100-11 Very Low Oil Pressure (46) .................... 115
0102-03 Boost Pressure voltage high (25) .......... 119
0102-04 Boost Pressure voltage low (25) ............ 119

4
Table of Contents

0105-00 High Intake Manifold Air Temperature


Warning (64) ..................................................... 120
0105-03 Intake Manifold Air Temperature voltage
high (38) ............................................................ 121
0105-04 Intake Manifold Air Temperature voltage low
(38) .................................................................... 121
0105-11 Very High Intake Manifold Air Temperature
(64) .................................................................... 122
0108-03 Barometric Pressure voltage high (26) .. 122
0108-04 Barometric Pressure voltage low (26) .. 123
0110-00 High Coolant Temperature Warning
(61) .................................................................... 123
0110-03 Coolant Temperature voltage high
(27) .................................................................... 124
0110-04 Coolant Temperature voltage low (27) .. 124
0110-11 Very High Coolant Temperature (61) ..... 124
0111-01 Low Coolant Level Warning (62) ........... 125
0111-02 Coolant Level signal invalid (12) ........... 126
0111-03 Coolant Level voltage high (12) ............ 126
0111-04 Coolant Level voltage low (12) .............. 126
0111-11 Very Low Coolant Level (62) ................. 127
0111-14 Low Coolant Level Warning .................. 128
0121-05 Low/High Retarder current low (14) ...... 129
0121-06 Low/High Retarder current high (14) .... 129
0122-05 Med/High Retarder current low (14) ..... 129
0122-06 Med/High Retarder current high (14) .... 130
0166-14 Rated Engine Power Special
Instructions ........................................................ 130
0168-01 Low ECM Battery Power (17) ............... 130
0171-03 Ambient Air Temperature voltage high .. 131
0171-04 Ambient Air Temperature voltage low ... 131
0171-11 Ambient Air Temperature Data Lost ...... 131
0174-00 High Fuel Temperature Warning (65) ... 132
0174-03 Fuel Temperature voltage high (13) ...... 132
0174-04 Fuel Temperature voltage low (13) ....... 132
0190-00 Engine Overspeed Warning (35) .......... 133
0190-08 Primary Engine Speed Loss of Signal
(34) .................................................................... 133
0191-07 Transmission Not Responding (68) ...... 133
0212-03 5 Volt Sensor Supply #1 voltage high ... 134
0212-04 5 Volt Sensor Supply #1 voltage low .... 134
0224-11 Theft Deterrent Active (00) ................... 135
0224-14 Theft Deterrent Active with Engine Cranking
(00) .................................................................... 135
0231-02 J1939 Data Incorrect (58) ..................... 135
0231-12 J1939 Device Not Responding ............. 136
0246-11 Brake Pedal Switch #1 Fault ................. 136
0247-11 Brake Pedal Switch #2 Fault ................. 136
0252-11 Engine Software Incorrect (59) ............. 137
0253-02 Check Customer or System Parameters
(56) .................................................................... 137
0253-11 Check Transmission Customer Parameters
(56) .................................................................... 138
0283-05 Intake Valve Actuation System Oil Pressure
Solenoid current low (97) .................................. 138
0283-06 Intake Valve Actuation System Oil Pressure
Solenoid current high (97) ................................. 138
0283-07 Intake Valve Actuation Oil Pressure not
responding (91) ................................................. 139
0284-05 Engine Coolant Diverter current low
(98) .................................................................... 139

SENR9698-09

0284-06 Engine Coolant Diverter current high


(98) .................................................................... 139
0285-05 Intake Valve Actuator #1 current low
(92) .................................................................... 140
0285-06 Intake Valve Actuator #1 current high
(92) .................................................................... 140
0285-07 Intake Valve Actuator #1 not responding
(92) .................................................................... 140
0286-05 Intake Valve Actuator #2 current low
(92) .................................................................... 141
0286-06 Intake Valve Actuator #2 current high
(92) .................................................................... 141
0286-07 Intake Valve Actuator #2 not responding
(92) .................................................................... 141
0287-05 Intake Valve Actuator #3 current low
(93) .................................................................... 142
0287-06 Intake Valve Actuator #3 current high
(93) .................................................................... 142
0287-07 Intake Valve Actuator #3 not responding
(93) .................................................................... 143
0288-05 Intake Valve Actuator #4 current low
(93) .................................................................... 143
0288-06 Intake Valve Actuator #4 current high
(93) .................................................................... 143
0288-07 Intake Valve Actuator #4 not responding
(93) .................................................................... 144
0289-05 Intake Valve Actuator #5 current low
(94) .................................................................... 144
0289-06 Intake Valve Actuator #5 current high
(94) .................................................................... 145
0289-07 Intake Valve Actuator #5 not responding
(94) .................................................................... 145
0290-05 Intake Valve Actuator #6 current low
(94) .................................................................... 145
0290-06 Intake Valve Actuator #6 current high
(94) .................................................................... 146
0290-07 Intake Valve Actuator #6 not responding
(94) .................................................................... 146
0385-01 Low Intake Valve Actuation System Oil
Pressure ............................................................ 146
0385-03 Intake Valve Actuation System Oil Pressure
voltage high (95) ............................................... 147
0385-04 Intake Valve Actuation System Oil Pressure
voltage low (95) ................................................. 147
Diagnostic Functional Tests
5 Volt Engine Pressure Sensor Supply Circuit Test ................................................................... 148
Accelerator Pedal (Throttle) Position Sensor Circuit Test ................................................................... 152
Air Inlet Shutoff Circuit - Test .............................. 161
ATA (SAE J1587 / J1708) Data Link Circuit Test ................................................................... 167
Auxiliary Brake Circuit - Test ............................... 175
Check Engine Lamp Circuit - Test ...................... 180
Clutch Pedal Position Switch Circuit - Test ......... 183
Coolant Level Sensor Circuit - Test .................... 188
Cooling Fan Circuit and A/C High Pressure Switch
Circuit - Test ...................................................... 197
Cruise Control Switch Circuit - Test .................... 210
Diagnostic Enable Switch Circuit - Test .............. 217

SENR9698-09

Eaton Top 2 Transmission Circuit - Test ............. 221


ECM Memory - Test ............................................ 228
Electrical Connectors - Inspect ........................... 232
Engine Coolant Diverter Circuit - Test ................. 237
Engine Pressure Sensor Open or Short Circuit Test ................................................................... 242
Engine Running Output Circuit - Test ................. 247
Engine Shutdown Output Circuit - Test ............... 251
Engine Speed/Timing Sensor Circuit - Test ........ 255
Engine Temperature Sensor Open or Short Circuit Test ................................................................... 261
Fan Override Switch Circuit - Test ...................... 265
Idle Shutdown Timer - Test ................................. 269
Ignition Keyswitch Circuit and Battery Supply Circuit Test ................................................................... 272
Ignore Brake/Clutch Switch Circuit - Test ........... 279
Injector Solenoid Circuit - Test ............................ 282
Intake Valve Actuation System Oil Pressure Circuit Test ................................................................... 291
Intake Valve Actuator Circuit - Test ..................... 296
Intake Valve Actuator Response - Test ............... 304
Multi-Torque - Test .............................................. 314
Neutral Switch Circuit - Test ................................ 316
Powertrain Data Link Circuit - Test ..................... 322
PTO Engine RPM Set Speed (Input A and Input B)
Circuit - Test ...................................................... 327
PTO Shutdown Timer - Test ................................ 332
PTO Switch Circuit - Test .................................... 334
PTO Switch ON Lamp Circuit - Test ................... 343
Remote PTO Accelerator Position Sensor Circuit Test ................................................................... 347
Retarder (Compression Brake) Solenoid Circuit Test ................................................................... 354
Service Brake Pedal Position (Switch 1) Circuit Test ................................................................... 364
Service Brake Pedal Position (Switch 2) Circuit Test ................................................................... 369
Starting Aid Output Circuit - Test ........................ 374
Starting Aid Switch Circuit - Test ......................... 378
Tachometer Circuit - Test .................................... 381
Torque Limit Switch Circuit - Test ........................ 386
Two Speed Axle Switch Circuit - Test ................. 389
Vehicle Speed and Speedometer Circuit - Test .. 393
Warning Lamp Circuit - Test ................................ 402
Calibration Procedures
Engine Speed/Timing Sensor - Calibrate ............ 406
Injector Code - Calibrate ..................................... 408
Vehicle Speed Circuit - Calibrate ........................ 410

Index Section
Index ................................................................... 413

5
Table of Contents

6
Troubleshooting Section

SENR9698-09

Troubleshooting Section

The position of the accelerator pedal


The desired vehicle speed in cruise control

Electronic Troubleshooting
i02182977

System Overview
SMCS Code: 1900

System Operation
These truck engines were designed for electronic
control. A solenoid on each injector controls the
amount of fuel that is delivered by the injector. An
Engine Control Module (ECM) sends a signal to each
injector solenoid in order to provide complete control
of the fuel injection.

Electronic Controls

The desired engine rpm in PTO control


Timing Considerations
Once the governor has determined the amount of
fuel that is required, the governor must determine
the timing of the fuel injection. Fuel injection timing is
determined by the ECM after considering input from
the following components:

Coolant temperature sensor


Intake manifold air temperature sensor
Barometric pressure sensor
Boost pressure sensor

RPM

At start-up, the ECM determines the top center


position of the number 1 cylinder from the signal for
the secondary engine speed/timing sensor. After
start-up, the ECM determines the top center position
of the number 1 cylinder from the primary engine
speed/timing sensor. The ECM decides when fuel
injection should occur relative to the top center
position and the ECM provides the signal to the
injector at the desired time. The ECM adjusts timing
for the optimum engine performance, the optimum
fuel economy and the optimum control of white
smoke. Actual timing cannot be viewed with the
Caterpillar Electronic Technician (ET), and desired
timing cannot be viewed on Cat ET.

Other characteristics

Fuel Injection

Engine Governor

The ECM controls the amount of fuel that is


injected by varying the signals to the injectors. The
injectors will pump fuel only if the injector solenoid is
energized. The ECM sends a high voltage signal to
the solenoid. This high voltage signal energizes the
solenoid. By controlling the timing and the duration of
the high voltage signal, the ECM can control injection
timing and the ECM can control the amount of fuel
that is injected.

The electronic system consists of the ECM, the


engine sensors and the vehicle interface. The ECM is
the computer. The personality module is the software
for the computer. The personality module contains
the operating maps. The operating maps define the
following characteristics of the engine:

Horsepower
Torque curves

The ECM serves as the engine governor.


The ECM determines the timing and the amount of
fuel that is delivered to the cylinders. These decisions
are based on the actual conditions and the desired
conditions at any given time.
The governor uses the accelerator pedal position
sensor to determine the desired engine speed. The
governor compares the desired engine speed to the
actual engine speed. The actual engine speed is
determined through the primary engine speed/timing
sensor. If the desired engine speed is greater than
the actual engine speed, the governor injects more
fuel in order to increase engine speed.
The desired engine speed is typically determined by
one of the following conditions:

The personality module inside the ECM sets certain


limits on the amount of fuel that can be injected. The
FRC Fuel Limit is a limit that is based on the boost
pressure. The FRC Fuel Limit is used to control the
air/fuel ratio for control of emissions. When the ECM
senses a higher boost pressure, the ECM increases
the FRC Fuel Limit. A higher boost pressure
indicates that there is more air in the cylinder. When
the ECM increases the FRC Fuel Limit, the ECM
allows more fuel into the cylinder.

SENR9698-09

7
Troubleshooting Section

The Rated Fuel Limit is a limit that is based on


the power rating of the engine and engine rpm.
The Rated Fuel Limit is similar to the rack stops
and the torque spring on a mechanically governed
engine. The Rated Fuel Limit provides the power
curves and the torque curves for a specific engine
family and a specific engine rating. All of these limits
are determined at the factory. These limits are in
the personality module and these limits cannot be
changed.

Some parameters are intended to notify the driver


of potential engine damage (Engine Monitoring
Parameters). Some parameters enhance fuel
economy (Vehicle Speed Limit, Cruise Control
Parameters, Engine/Gear Parameters and Idle
Parameters). Other parameters are used to enhance
the engine installation into the vehicle. Other
parameters are also used to provide engine operating
information to the truck engine owner.

Engine Monitoring
Caterpillar provides a factory installed engine
monitoring system. The Caterpillar engine monitoring
system monitors engine oil pressure, coolant
temperature, intake manifold air temperature, and
coolant level (optional device). Optional devices are
OEM installed.
The oil pressure, intake manifold air temperature,
and coolant temperature sensors are standard on all
engines. The vehicle OEM installs the coolant level
sensor and the associated harness. The coolant level
sensor is the only optional component of Caterpillar
engine monitoring. Coolant level is selected through
a customer programmable parameter.

Illustration 1
(1)
(2)
(3)
(4)

g00628178

TC reference
Speed-timing signal
Electrical current to injector solenoid
Injection pressure curve

Note: The signals and the timing of Illustration 1 are


not to scale.

Customer Parameters And Engine Speed


Governing
A unique feature with electronic engines is customer
specified parameters. These parameters allow the
vehicle owner to fine tune the ECM for engine
operation. Fine tuning the ECM for engine operation
allows the vehicle owner to accommodate the typical
usage of the vehicle and the power train of the
vehicle.
Many of the customer parameters provide additional
restrictions on the actions that will be performed
by the ECM in response to the drivers input. For
example, the PTO Top Engine Limit is an engine
rpm limit that is used by the ECM as a cutoff for the
fuel. The ECM will not fuel the injectors above this
rpm.

Caterpillar engine monitoring can be programmed


to three different modes. These three modes of
programming are the following modes: Warning,
Derate, and Shutdown. The coolant temperature
sensor, the oil pressure sensor and the coolant level
sensor (optional device) will operate in the engine
monitoring mode that is selected.
For example, if Derate mode was selected, the
engine will derate engine power and vehicle speed.
The engine will derate engine power and vehicle
speed if the coolant temperature sensor, the oil
pressure sensor or the coolant level sensor detects
conditions that exceed acceptable limits.
An excessive intake manifold air temperature will not
derate the engine. Also, an excessive intake manifold
air temperature will not shut down the engine.

Caterpillar Engine Monitoring


Warning
If the system is programmed to Warning, the ECM
causes the warning lamp to turn on. This will also
cause the check engine lamp to flash because of the
active diagnostic code. The flashing check engine
lamp indicates that a problem has been detected by
the engine monitoring system. No further action by
the ECM or action by the engine occurs if the ECM is
programmed to Warning.

8
Troubleshooting Section

If the problem is due to one of the following


conditions, the ECM will cause the warning lamp to
turn ON and the ECM will cause the check engine
lamp to flash:

Low coolant level


High coolant temperature
High intake manifold air temperature
Low oil pressure
Derate
If the system is programmed to Derate, the ECM
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.
This response is identical to the response when the
system is in the Warning mode.
The Derate mode alters the engine performance
when any of the following conditions exist:

Oil pressure becomes very low oil pressure.


Coolant level becomes very low coolant level.
Coolant temperature becomes high coolant
temperature.

Coolant temperature becomes very high coolant


temperature.

Whenever the warning lamp is flashing, the ECM is


limiting or derating the engine.
The ECM limits the maximum vehicle speed and the
ECM reduces the available power when any of the
following conditions exist:

High coolant temperature


Very high coolant temperature
Very low coolant level
If the ECM detects very low oil pressure, the ECM
limits the following parameters:

Maximum vehicle speed


Available power
Engine rpm

SENR9698-09

This derating of engine performance is provided in


order to get the drivers attention so the driver can
take action in order to avoid engine damage.
Shutdown
If the system is programmed to Shutdown, the ECM
takes all the action that is indicated for the Derate
mode and the ECM will eventually shut down the
engine under some conditions.
The Shutdown mode will shut down the engine
when any of the following conditions exist:

Oil pressure becomes very low oil pressure.


Coolant level becomes very low coolant level.
Coolant temperature becomes very high coolant
temperature.

Monitoring Fuel Temperature


The fuel temperature sensor monitors the fuel
temperature. The fuel rate that is calculated by
the ECM is adjusted in order to compensate for
changes in fuel temperature. The fuel rate is also
adjusted for constant power. The sensor is also used
to warn the operator of excessive fuel temperature
with a diagnostic event code because excessive
fuel temperatures can adversely affect engine
performance. Cat ET can be used to temporarily
disable the adjustment of fuel temperature. This could
be necessary for testing a vehicle on a dynamometer
with fuel temperature compensation.

Other ECM Functions of


Performance
The ECM also provides enhanced control of the
engine for vehicle functions such as retarding
the engine and controlling the cooling fan. Refer
to Troubleshooting, Component Diagram for
supplemental information about the systems that
can be monitored by the ECM in order to provide
enhanced vehicle performance, fuel economy and
convenience for the driver.

Self-Diagnostics
The electronic system has the ability to diagnose
problems. When a problem is detected, a diagnostic
code is generated and the check engine/diagnostic
lamp may be turned ON. In most cases, the code is
also stored in permanent memory or logged in the
ECM.

SENR9698-09

9
Troubleshooting Section

When diagnostic codes occur, the diagnostic codes


are called active diagnostic codes. Active diagnostic
codes indicate that a problem of some kind currently
exists. Always service active diagnostic codes before
any other work is performed. If a truck is brought in
with an active code, find the code in this manual and
proceed to diagnose the cause.

Diagnostic Fault Codes

Diagnostic codes that are stored in memory are


called logged diagnostic codes. Logged diagnostic
codes do not necessarily indicate that something
needs to be repaired. The problem may have been
temporary, or the problem may have been repaired
since the problem was logged. Logged diagnostic
codes are instead meant to be an indication of
probable causes for intermittent problems.

If the check engine lamp is flashing and the driver


indicates that a performance problem occurs, the
diagnostic code may indicate the cause of the
problem. Correct the problem as soon as possible.

Diagnostic codes that identify operating conditions


outside the normal operating range are called events.
Event codes are not typically an indication of an
electronic system problem.

Diagnostic fault codes are provided in order to


indicate that a system problem has been detected by
the ECM. In some cases, the engine performance
can be affected when the condition that is causing
the code exists.

If the driver does not indicate a problem with the


engine performance and a diagnostic code is logged
by the ECM, the situation indicates that the ECM
detected an abnormal condition, but the abnormal
condition did not affect engine performance.
In this situation, the system has no faults except
when either of the following conditions exist:

Some of the diagnostic codes require passwords to


be cleared from memory. Diagnostic codes that do
not require passwords to be cleared from memory
are automatically deleted after 100 hours of engine
operation.

There are several occurrences of the diagnostic

Engine Snapshot Data

Diagnostic Event Codes

Whenever most diagnostic codes occur, the ECM


records the time in engine hours of the occurrence.
Also, the ECM records the operating parameters of
the engine for 9.6 seconds before the diagnostic
code and 3.4 seconds after the diagnostic code. The
operating parameters of the engine that are recorded
are similar to the operating parameters of the engine
that are displayed in the status screens of Cat ET.
Not all of the status screens or parameters are
recorded. The engine snapshot can also be triggered
from the cruise control Set/Resume switch. In order
to trigger the engine snapshot from the cruise control
Set/Resume switch, quickly toggle the switch to the
Set position. Then, quickly toggle the switch to the
Resume position. You can also toggle the cruise
control Set/Resume switch from the Resume position
to the Set position. The engine snapshot can also
be triggered from Cat ET.

Diagnostic event codes are used to indicate that


some operational problem has been detected in the
engine or in the truck by the ECM. Usually, this does
not indicate an electronic malfunction.

Effect Of Diagnostic Codes On


Engine Performance

111-11 Very Low Coolant Level

The discussion on engine monitoring mentions that


the check engine lamp flashes when a specific
condition exists. When the ECM detects the engine
problem, the ECM generates an active diagnostic
code. Also, the ECM logs the diagnostic code in order
to indicate the time of the problems occurrence. The
ECM also logs the number of occurrences of the
problem. There are two types of diagnostic codes.
There are fault codes and event codes.

Refer to Troubleshooting, Diagnostic Codes for a


listing of all of the diagnostic codes.

code in a very short period of time.

The ECM is indicating an active code at the


present time.

The ECM also provides an ECM date/time clock that


is used to time stamp the following diagnostic event
codes:

84-00 Vehicle Overspeed Warning


84-14 Quick Stop Occurrence
100-11 Very Low Oil Pressure
105-11 Very High Intake Manifold Air Temperature
110-11 Very High Coolant Temperature

190-00 Engine Overspeed Warning

ECM Lifetime Totals


The ECM maintains total data of the engine for the
following parameters:

Total Time (Engine Hours)

10
Troubleshooting Section

SENR9698-09

Total Distance

Trip Data

PTO Time and PTO Fuel

The trip data allows the tracking of engine operation


by the vehicle owner over intervals that are defined
by the vehicle owner. Two types of trip data are
stored in the ECM, Driver Trip Data and Fleet Trip
Data. All of the trip data is stored in memory and the
trip data is maintained through the unswitched battery
lines when the key switch is OFF. An internal battery
will maintain this information while the unswitched
battery lines are disconnected.

Idle Time and Idle Fuel


Average Load Factor (Engine)
Total Fuel
Total Max Fuel
The Total Time is the engines operating hours. The
engine hours do not include operating time when the
ECM is powered ON but the engine is not running.
Total Distance data requires a vehicle speed
sensor or an electronic vehicle speed source to be
connected to the ECM. The same sensor is used for
ECM vehicle speed. Distance can be displayed in
miles or in kilometers.

Driver Trip Data


Driver trip data is known as the driver trip segment.
The driver trip segment includes data for the following
parameters:

Total Time
Driving Time

PTO Time and PTO Fuel are logged if the engine


RPM is set with the cruise switch and when the
engine is operating under a load. Also, the PTO
Time and the PTO Fuel are logged when the PTO
On/Off switch is in the ON position and vehicle speed
is within the range of the PTO Vehicle Speed Limit
parameter.

Distance

Idle Time and Idle Fuel can include operating time


when all of the following conditions are met:

Idle Time

When engine speed is set by using the cruise

switches and the vehicle speed is within the range


of the Idle Vehicle Speed Limit parameter.

The engine is not operating under a load.


Fuel information can be displayed in US gallons or
in liters.
Total Fuel is the total amount of fuel that is
consumed by the engine during operation.
Total Max Fuel is the maximum amount of fuel that
could have been consumed by the engine during
operation.
Average Load Factor provides relative engine
operating information. Average Load Factor
compares actual engine operation information to
the maximum engine operation that is available.
Average Load Factor is determined by using Total
Max Fuel, Idle Fuel, and Total Fuel. All of these
parameters are available by using Cat ET. These
parameters are available within the menu for Current
Totals.

Fuel
Overall Fuel Economy
Driving Fuel Economy

Idle Fuel
Percent Idle Time
PTO Time
PTO Fuel
Percent PTO Time
Average Load Factor
Average Vehicle Speed
Average Driving Speed
Maximum Vehicle Speed
Maximum Engine Speed
Start Time
End Time
Start Odometer
End Odometer

SENR9698-09

11
Troubleshooting Section

A driver trip segment can be reset by using Cat ET or


a Caterpillar Messenger Driver Information Display.
When the data is reset, the ECM stores the current
totals at the time of the reset. This data is used as
the starting point for the driver trip data. Cat ET or
the Messenger accesses this starting point and the
current totals from the ECM in order to calculate the
data for the driver trip segment. Resetting the driver
trip segment does not require passwords.

Fleet Trip Data


Fleet trip data includes a fleet trip segment,
histograms, and custom data. The fleet trip segment
records the same parameters as the driver trip
segment except that the fleet trip segment can be
reset independently of the driver trip segment.
Three histograms are available. One histogram
records engine hours versus the engine speed.
The second histogram records engine hours versus
vehicle speed. The third histogram records engine
hours versus engine speed and vehicle speed.
Cat ET calculates the percentage of time that is spent
in each of the engine rpm or vehicle speed ranges.
Custom data is available. Custom data allows the
recording of engine parameters that are specified by
the vehicle owner. The ECM records the custom data.
A reset of the fleet trip data which includes the fleet
trip segment, the histograms, and the custom data
can be done in several ways. The following tools can
be used in order to access and in order to reset the
fleet trip data:

Caterpillar Electronic Technician (Cat ET)


Caterpillar Fleet Information Software (FIS)
Caterpillar Messenger Driver Information Display
When the data is reset, the ECM records the current
totals at the time of the reset. These totals are used
as the starting point for the fleet trip.
The tool then subtracts the recorded starting point
from the current totals in the ECM in order to
calculate the fleet trip data. Resetting the fleet trip
data requires customer passwords if the passwords
are programmed.

Illustration 2

g00628194

Basic Program

The following list defines the options for variable 1 of


the basic program:

Engine Hours
Distance Traveled
Fuel Burned
Occurrences
Refer to the following list for information regarding
the options that are available for variable 2 and
variable 5.
Variables 3, 4, 6, and 7 define the minimum range
and the maximum range of variables 2 and 5.

Engine Speed
Vehicle Speed
Fuel Rate
Load Factor
Coolant Temperature
Oil Pressure
Fuel Temperature
Intake Manifold Air Temperature
Cruise

Fleet Trip Custom Data

PTO

Fleet trip custom data is part of the fleet trip segment.


Fleet trip custom data allows the owner of the vehicle
to set five customized methods of recording data
for the vehicle. Refer to Illustration 2 for the basic
program.

Engine Retarder
Throttle Position
Brake

12
Troubleshooting Section

Refer to the example of a custom data program, as


shown below.
Fuel Burned when Fuel Temperature is between
7 and 67 C (45 and 120 F) and Vehicle Speed is
between 87 and 137 km/h (55 and 85 mph)
The custom data programs are protected by customer
passwords. The programs are stored in permanent
memory. The programs are not reset when the fleet
trip segment is reset, but the data that is recorded
for the trip is reset.

Fuel Correction Factor


A Fuel Correction Factor is available for fine
tuning the calculations for fuel consumption. The
Fuel Correction Factor is protected by customer
passwords. The Fuel Correction Factor enhances
the accuracy of the calculation for fuel consumption.
Altering the Fuel Correction Factor does not affect
data that is already stored in the ECM. Altering the
Fuel Correction Factor only affects data that is
stored in the ECM after the Fuel Correction Factor
is entered.
Note: The Fuel Correction Factor should be
adjusted from data that has been recorded for a long
time, data from the fuel tank and recorded data in
the ECM.

Quick Stop Rate


A customer parameter is available in order to
record the quick stop occurrences. The parameter
determines the rate of change in vehicle speed that
is used by the ECM in order to record a quick stop
event code and a quick stop snapshot. Refer to
Troubleshooting, ECM Snapshot.

Maintenance Indicator Data


The ECM records the current totals when a reset
occurs for the following three levels of maintenance:

PM1
PM2
Cooling system clean/flush
The ECM uses the previous point of maintenance in
order to calculate the timing of the next scheduled
maintenance work.
The maintenance indicator mode is programmable
to hours or distance. The PM 1 Interval parameter
is programmable to the Off, Automatic Distance,
Automatic Hours, Manual Distance, or Manual
Hours setting.

SENR9698-09

If the PM 1 Interval is programmed to the


automatic mode, the ECM calculates the next point
of maintenance by considering the history of the
vehicles operation from the previous maintenance
interval. If the vehicle has a history of poor fuel
economy the maintenance indicator parameter will
occur sooner than a vehicle with better fuel economy.
The ECM also uses the engine oil capacity. A larger
engine oil capacity provides a longer maintenance
interval. The engine oil capacity is programmed into
the ECM in liters or quarts. If the PM 1 Interval
is programmed to the manual mode, the owner
can program the ECM in the owners specific
maintenance interval. The maintenance interval can
be programmed to the owners specific interval that is
based on mileage or on time. The interval for the PM2
and the interval for the cooling system clean/flush are
established by the factory.

Messenger
The Caterpillar Messenger Driver Information Display
is available to provide engine operating information
to the driver. The driver trip segment, the fleet trip
segment, and the maintenance indicator data can be
viewed. However, the fleet trip histograms and the
custom data cannot be viewed from the display.
Messenger provides the ability to enter an ID code
for a driver in order to divide the fleet trip segment
for two drivers. If the driver enters the information
regarding the state of travel, the fleet trip segment
can be tagged by the state of travel.
Messenger can be used in order to tag portions of
the fleet trip segment into two ID codes. Messenger
can also be used in order to tag portions of the fleet
trip segment into the state of travel. The ID code and
the information regarding the state of travel cannot
be viewed from the display. Only the Caterpillar Fleet
Information Software (FIS) can view this information.
The ability to reset any of these parameters is
dependent on customer parameters in the ECM.
Messenger will also display engine operating
parameters such as engine rpm, coolant
temperature, boost pressure and many other
parameters.
Messenger will also display engine diagnostic codes.
Messenger will also display a brief text description
of the diagnostic codes.
An available feature on Messenger is the theft
deterrent. The theft deterrent allows the driver to input
a password prior to shutdown. The theft deterrent will
prevent the engine from restarting until the password
is successfully entered. Messenger must have the
version of software that is capable of supporting this
feature.

SENR9698-09

An Auto-Enable option is available as a theft


deterrent. If this option is selected, the theft deterrent
will automatically be activated when the engine
is shut down. The driver must input the correct
password in order to start the engine.
Secure Idle is another theft deterrent. This allows
the driver to bring the engine to an idle condition.
The driver then enters the password. The engine will
remain at low idle until the password is re-entered. If
the engine is shutdown, a password will be required
to go above low idle after start-up.

13
Troubleshooting Section

Wireless Communication Enable


The Wireless Communication Enable parameter in
the ECM allows the ECM to communicate through
the SAE J1587 Data Link with certain systems
of communication. Programming this parameter
requires factory passwords.
With this system, the customer can remotely change
the following parameters with the Caterpillar FIS:

Fuel correction factor

Fleet Information Software (FIS)

Custom data

The FIS is another method that can be used to review


the trip information. The entire fleet trip segment,
which includes the following elements of data can
be accessed with the FIS:

Maintenance indicator data

Histograms

Current totals

Custom data

Reports on custom data

Information that is tagged by the ID code

Fleet trip data

Information that is tagged by the state of travel

Economy model

Maintenance Indicator information can be retrieved


with the FIS.

Maintenance information

When the FIS downloads the information, the FIS


also resets the ECM in order to prepare the ECM for
the next trip. The information can be downloaded to
a computer with the FIS or the information can be
downloaded to an Argo Mobile Data Tool (MDT). The
MDT is then connected to a computer in order to
download the information.

Driver Reward Feature


The driver reward feature automatically adjusts the
vehicle speed limit (VSL) as a reward to the driver for
operating a truck in a manner that meets the truck
engine owners specifications. Several parameters
are monitored in order to evaluate a drivers operating
technique. Weighting factors are applied to the
parameters that reflect the operating techniques
that are desired and the operating techniques that
are expected. If the operating techniques meet the
owners specifications or the operating techniques
exceed the owners specifications, the VSL is
automatically increased as a reward. The VSL will
decrease when the operating techniques do not meet
the owners specifications.
Messenger can be used to monitor parameters that
affect the driver reward, which allows the driver to
adjust the operating techniques, as required.

With this system, the customer can remotely extract


the following information from the ECM:

Settings for customer parameters


The reports are processed for the owner of the fleet
with the FIS. The frequency and the timing of the
downloading of the information can be at set intervals
or the downloading of the information can be done
manually.
i02182997

Electronic Service Tools


SMCS Code: 0785
Caterpillar electronic service tools are designed to
help the service technician with the diagnosis and
with the repair of electronic engines. Several tools
are available to assist the service technician.

14
Troubleshooting Section

SENR9698-09

Required Service Tools

Copy the configuration for ECM replacement.

Table 1

Data logging

Part Number
N/A

Description
4 mm Allen Wrench

Snapshot recorder
The following components are required to use Cat
ET to service the engine.

6V-2197

Transducer

7X-1171

Transducer Adapter

7X-1695

Cable As

1U-5804

Crimp Tool(12 to 18 AWG)

1U-5805

Wire Removal Tool

151-6320

Wire Removal Tool

167-9225

Harness(Service Tool Adapter)

140-2266

Cable(70-Pin Breakout)

JERD2124

Electronic Technician Program (Cat ET)

9U-7330
or
146-4080

Digital Multimeter

JERD2125

Electronic Technician Truck Engine Data


Subscription

190-8900

Connector Repair Kit

Table 2

Required Electronic Service Tools for


the Use of Cat ET
Part
Number

Caterpillar Electronic Technician

Digital Multimeter(RS-232)

Two short jumper wires are needed to check the


continuity of some wiring harness circuits. A long
extension wire may also be needed to check the
continuity of some wiring harness circuits.

or
JERD2129

Cat ET can display the following information:

Parameters
Diagnostic codes
Engine rating history
Driver and fleet trip segments
Histograms
Custom data
ECM date/time clock
Maintenance intervals
Cat ET can also be used to perform the following
functions:

Diagnostic tests
Sensor calibrations
Flash programming
Set parameters

Electronic Technician Engine/Machine


Data Subscription

171-4400(1)

Communication Adapter II Gp

237-7547(2)

Adapter Cable As

(1)
(2)

Caterpillar Electronic Technician (ET)

Description

The 7X-1700 Communication Adapter Gp may also be used.


The 237-7547 Adapter Cable As is required to connect to the
USB port on computers that are not equipped with a RS232
serial port.

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
software.

SENR9698-09

15
Troubleshooting Section

Connecting Cat ET and the Communication


Adapter II

Optional Service Tools


Table 3

Part Number

Illustration 3
(1)
(2)
(3)
(4)

g00647144

Personal computer (PC)


196-0055 Adapter Cable As
171-4401 Communication Adapter As
207-6845 Adapter Cable As

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

Description

7X-6370

Adapter Cable As(3-Pin Breakout)

8T-8726

Adapter Cable As(3-Pin Breakout)

5P-7277

Voltage Tester

9U-5103

Socket(Slotted)

7X-1710

Multimeter Probe

1U-5718

Vacuum Pump

1U-8757

Tube(Fluid Sampling)

169-7372

Fluid Sampling Bottle

9S-9082

Engine Turning Tool

198-4240
or
1U-5470

Digital Pressure Indicator

6V-9130

Temperature Adapter

124-5643

Cable As(Service Tool Breakout)

125-3662

Cable As(Sensor Bypass)

157-4829

Cable Adapter

7X-1403

Adapter Cable As

7X-1686

Cable Adapter

139-4166

Data Link Cable As(18 FT)

208-0059

Cable As(70-PIN BREAKOUT)

Engine Pressure Group

i02126668

Replacing the ECM

Use the following procedure to connect Cat ET and


the Communication Adapter II.

SMCS Code: 1901-510

1. Turn the keyswitch to the OFF/RESET position. If


the keyswitch is not placed in the OFF/RESET
position, the engine may start.

Replacing the Engine Control


Module (ECM) with the Use of the
ECM Replacement Feature from the
Electronic Service Tools

2. Connect cable (2) between the COMPUTER


end of communication adapter (3) and the RS232
serial port of PC (1).
3. Connect cable (4) between the DATA LINK end
of communication adapter (3) and the service tool
connector.
4. Turn the keyswitch to the ON position. If Cat
ET and the communication adapter do not
communicate with the Engine Control Module
(ECM), refer to Troubleshooting, Electronic
Service Tool Will Not Communicate With ECM.

1. Ensure that the ECM is the problem by first


connecting a test ECM. This is a temporary
connection. Hang the test ECM on the side of
the engine. Refer to Troubleshooting, Test ECM
Mode.
2. If the test ECM repairs the problem, reconnect
the suspect ECM. Verify that the problem returns
when the suspect ECM is reconnected.
3. Select the ECM Replacement Feature under the
Service/Copy Configuration menu and load the
parameters from the failed ECM.

16
Troubleshooting Section

4. Temporarily connect the new ECM by connecting


both ECM connectors. Do not mount the ECM on
the engine yet.
5. Flash program the personality module into the
new ECM if the personality module is not already
installed. The new ECM is shipped with a blank
personality module.
6. Use the ECM replacement feature in Caterpillar
Electronic Technician (ET) in order to program the
new ECM.
7. Enter the value for the Rating Number parameter
into the new ECM.
8. Check for active codes. Program any required
parameters that have not been programmed.
Note: On initial powerup of a new ECM, the
parameter Rating Number must be programmed to
avoid activating a 253-02 diagnostic code.
9. If the 22-13 diagnostic code is not active, install
the new ECM on the engine. Otherwise, perform a
timing calibration first.

Replacing the ECM without the Use


of the ECM Replacement Feature
from the Electronic Service Tool
1. Ensure that the ECM is the problem by first
connecting a test ECM. This is a temporary
connection. Hang the test ECM on the side of the
engine. Flash program the identical Personality
Module that was used in the suspect ECM into
the test ECM. Program any parameters that
are necessary to use the ECM for the test. For
example, Vehicle speed parameters need to be
programmed to check the vehicle speed circuit.
Program the parameters in the test ECM to be
equal to the parameters in the suspect ECM.
2. If the test ECM repairs the problem, reconnect
the suspect ECM. Verify that the problem returns
when the suspect ECM is reconnected.
3. Obtain customer parameters from the failed ECM.
a. Obtain the customer passwords and record the
customer passwords. If the customer (owner)
has lost the passwords or if the customer
(owner) has forgotten the passwords, proceed
to Troubleshooting, Customer Passwords for
more details.

SENR9698-09

b. Use Cat ET to access customer specified


parameters from the ECM that is being
replaced. If the ECM does not communicate
with the electronic service tool, obtain the
required parameter list from the OEM.
c. Use the Troubleshooting, Customer Specified
Parameters Worksheet to record the customer
parameters.
d. Record the serial number for the unit injectors.
The serial numbers for the unit injectors can
be found on the Injector Trim Calibration in
Calibrations under the Service menu on Cat
ET. Refer to Troubleshooting, Injector Code Calibrate for more information.
4. Record ECM lifetime totals.
a. Use the Troubleshooting, Customer Specified
Parameters Worksheet (Current Totals
Worksheet) in order to record the old ECM
Current Totals.
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.
6. Flash program the personality module into the
new ECM if the personality module is not already
installed. The new ECM is shipped with a blank
personality module.
7. Obtain the factory passwords when the passwords
are required.
Note: The following parameters can be programmed
on a new ECM without factory passwords: Full
Load Setting (FLS), Full Torque Setting (FTS),
and Engine Serial Number. System configuration
parameters must be entered before the customer
specified parameters are entered. If customer
parameters are entered before the system
configuration parameters, the total tattletale will
change. It will then be necessary to obtain another
set of factory passwords in order to access system
configuration parameters.
8. Perform the following operations.
a. Use the Troubleshooting, Factory Passwords
Worksheet to record the following information
from the engine information plate: Full Load
Setting (FLS), Full Torque Setting (FTS), and
Engine Serial Number.

SENR9698-09

17
Troubleshooting Section

b. Record the mileage from the vehicle odometer.


Use Cat ET to access system configuration
parameters. When the screen for the Factory
Specified Passwords appears, record the
following information: ECM Serial Number,
Engine Serial Number, ET Serial Number,
Total Tattletale, and Reason Code.
c. Leave Cat ET on the screen for the Factory
Specified Passwords and obtain the factory
passwords. Complete the Troubleshooting,
Factory Passwords Worksheet.
9. Program the new ECM.
Note: On initial powerup of a new ECM, the following
parameters must be programmed to avoid activating
the 253-02 diagnostic code: Full Load Setting
(FLS), Full Torque Setting (FTS), Vehicle Speed
Calibration (ppm), Rating Number, Engine Serial
Number, and Injector Codes Calibration.
a. Use Cat ET to access system configuration
parameters. Enter the following parameters
that are recorded on the worksheet: Full Load
Setting (FLS), Full Torque Setting (FTS), and
Engine Serial Number.
b. Use Cat ET to access customer specified
parameters. Enter the customer specified
parameters and the original customer
passwords that are recorded on the worksheet.
c. Use Cat ET to access current totals from the
Read/Change Current Totals main menu.
Record the information on the Troubleshooting,
Factory Passwords Worksheet in order to
obtain the factory passwords. Enter the totals
from the original ECM that are recorded on the
worksheet.
d. Use Cat ET to program the injector codes.
Select the following screens in order: Service,
Calibrations, Injector Codes Calibration.
Refer to Troubleshooting, Injector Code Calibrate for more information.
e. Select the following screens in order to calibrate
the engine timing: Service, Calibrations, and
Timing Calibration. Calibrate the timing. Refer
to Troubleshooting, Engine Speed/Timing
Circuit - Test.
10. Install the new ECM on the engine.
i02167267

Sensors and Electrical


Connectors
SMCS Code: 1900-NS; 7553-WW

18
Troubleshooting Section

Illustration 4
Diagram of components

SENR9698-09

g01051473

SENR9698-09

19
Troubleshooting Section

C11 and C13 Engines

Illustration 5
Sensor locations (left side view)

g01098502

20
Troubleshooting Section

Illustration 6

SENR9698-09

g01004205

Sensor locations (top view)

Illustration 7
Sensor locations (right side view)

g01004206

SENR9698-09

21
Troubleshooting Section

C15 Engine

Illustration 8
Sensor locations (left side view)

g01098568

22
Troubleshooting Section

Illustration 9
Sensor locations (right side view)

SENR9698-09

g01014707

SENR9698-09

23
Troubleshooting Section

Programming Parameters

The key switch is cycled.


The ECM loses communication with Cat ET.

i02305999

Programming Parameters

i02345343

Test ECM Mode

SMCS Code: 1901


Programmable parameters affect the operation of the
engine. The parameters are stored in the Engine
Control Module (ECM).
The parameters are divided into two different types:
Customer Specified Parameters Customer
specified parameters allow the vehicle owner to
influence the operating technique of the driver.
Customer passwords may be required to change the
values of customer specified parameters. Refer to
Troubleshooting, Customer Specified Parameters
for additional information.
System Configuration Parameters System
configuration parameters affect the emissions of the
engine or the power of the engine. Factory passwords
may be required to change the values of system
configuration parameters. Refer to Troubleshooting,
System Configuration Parameters for additional
information.
i02306073

Dyno Mode
SMCS Code: 1901
Dyno mode is a feature in the software that helps
ensure that a dyno run is accurate. Dyno mode
should be used whenever a dyno run is performed on
the engine. Dyno mode disables certain strategies
that could cause the dyno run to be invalid. For
example, the cooling fan may be disabled. The
following features are disabled by dyno mode:

Idle shutdown
Control of the cooling fan
Fuel temperature power correction

SMCS Code: 1901


Test ECM Mode is a feature that can be used to
help troubleshoot an engine that may have a problem
with the Engine Control Module (ECM). This feature
allows a standard ECM to be used as a test ECM.
This feature eliminates the need to stock a test ECM.
1. Obtain the latest available flash file for the engine.
Note: If a newer software version is available for the
engine, install the newest software on the suspect
ECM. If the new software does not fix the problem
continue with this procedure.
2. Use the Copy Configuration feature on the
Caterpillar Electronic Technician (ET) to copy the
parameters from the suspect ECM.
Note: If the ECM Replacement feature cannot
be used, record the programmed values into the
Customer Specified Parameters Worksheet. Also
record the system configuration parameters.
3. Disconnect the suspect ECM. Temporarily connect
the test ECM to the engine. Do not mount the test
ECM on the engine.
4. Flash program the test ECM with the latest
available flash file.
5. Start the Test ECM Mode on Cat ET. Access the
feature through the Service menu. Cat ET will
display the status of the test ECM and the hours
that are remaining for the Test ECM Mode.
Note: Test ECM Mode can only be activated if
the engine serial number has not already been
programmed during normal operation of the ECM.
If the engine serial number is programmed and the
ECM is not in Test ECM Mode, the ECM can never
be used as a test ECM.

Instructions from the anti-lock brake system (ABS)

6. Use the Copy Configuration feature on Cat ET to


program the test ECM.

Certain derates

Note: If the ECM Replacement feature can not be


used, program the test ECM with the values from the
Customer Specified Parameters Worksheet and the
values from the System Configuration Parameters.

and traction control system

Dyno mode is enabled with the Caterpillar Electronic


Technician (ET) prior to a dyno run. The Engine
Control Module (ECM) contains an internal timer
that allows Dyno Mode to be active for 30 minutes.
After 30 minutes, Dyno Mode must be restarted. The
following events cause Dyno Mode to exit:

7. Program the engine serial number into the test


ECM.

24
Troubleshooting Section

SENR9698-09

Note: The Test ECM Mode must be activated


before the engine serial number is programmed into
the ECM.
8. Verify that the test ECM fixes the problem.
When the Test ECM Mode is activated, an internal
timer sets a 24 hour clock. This clock will count down
only while the ECM is powered and the key switch is
in the ON position. After the ECM has counted down
the 24 hour period, the ECM will exit the Test ECM
Mode. The parameters, the accumulated mileage,
and the engine serial number will be set.
If the test ECM fixes the problem, the vehicle can be
released while the Test ECM Mode is still active.
Once an ECM has been activated in the Test ECM
Mode, the ECM will stay in the Test ECM Mode
until the timer times out. If the ECM is used as a test
ECM for more than one engine, the Test ECM Mode
must be reactivated. Anytime prior to the Test ECM
Mode timing out, the ECM can be reset to 24 hours
by starting the Test ECM Mode on Cat ET.
i02419716

Customer Passwords
SMCS Code: 0785
Customer passwords may be used to protect
customer parameters from being changed. The
passwords are programmed into the Electronic
Control Module (ECM) with the Caterpillar Electronic
Technician (ET). One password may be programmed
or both passwords may be programmed. If
customer passwords are not programmed, customer
parameters may be changed by anyone.
To obtain customer passwords, contact the owner of
the engine. If the owner has forgotten the customer
passwords, customer passwords may be read by
using Cat ET. Factory passwords are required in
order to read customer passwords.
Use the following procedure in order to read customer
passwords with Cat ET:
1. Select the Information menu. Then select
Passwords.
2. When the Factory Password screen appears,
record the information that is listed on the Factory
Passwords Worksheet. Refer to programming
parameters Troubleshooting, Factory Passwords
Worksheet for additional information.

3. Obtain the factory passwords. The information


that is recorded on the Factory Passwords
Worksheet must be provided. When you obtain
the factory passwords, a permanent record of your
access is generated at Caterpillar.
4. From the Factory Password screen, enter the
factory passwords.
5. When the Read Customer Passwords screen
appears, record the customer passwords. The
customer passwords may then be used to change
parameters that are customer programmable.
i02306136

ECM Date/Time Stamped


Information
SMCS Code: 0785

ECM Date/Time Clock


The Electronic Control Module (ECM) contains a
Date/Time Clock. Typically, the Date/Time Clock
indicates the time of day and the date. The clock is
used to time stamp the following diagnostic event
codes:

84-00 Vehicle Overspeed Warning


84-14 Quick Stop Occurrence
94-01 Low Fuel Pressure
100-11 Very Low Oil Pressure
110-11 Very High Coolant Temperature
111-11 Very Low Coolant Level
190-00 Engine Overspeed Warning
The ECM also attaches a time stamp to each
snapshot.

Adjustment of the ECM Date/Time Clock


Do not replace an ECM because of an incorrect
time of day. Do not change the ECM Date/Time
Clock just because the date or the time is incorrect.
Remember that the vehicle may be based in a
different time zone.

SENR9698-09

Before adjusting the ECM Date/Time Clock, ask


the owner/operator if the time stamped information
should be recorded. After the time stamped
information is recorded, clear the information before
adjusting the ECM Date/Time Clock. This is a very
important step if the adjustment of the clock is a big
adjustment. This will prevent unnecessary confusion
if someone else views the information at a later date.
Compare the current time of day on the ECM to the
time stamped information in the ECM in order to
determine the amount of time that has passed since
the occurrence of the time stamped event. Refer to
the following example:
The Caterpillar Electronic Technician (ET) indicates
that a diagnostic code occurred. The 190-00 Engine
Overspeed Warning occurred on 19 November 1998
at 10:30:46. Cat ET also indicates that the current
time of day in the ECM is 24 November 1998 at
11:20:58. This indicates that the problem occurred in
the past (approximately one week and 50 minutes).
The engine control modules time of day may
differ significantly from the current time of day. For
example, the month may be incorrect. In this case,
ensure that any important time stamped information
is recorded before the clock is adjusted. After
recording the information, clear the code or the
snapshot. Then adjust the clock.

Diagnostic Clock
Do not confuse the ECM Date/Time Clock with the
diagnostic clock. The diagnostic clock starts at zero
when battery power and the key switch input are first
applied to the ECM. Then, the diagnostic clock will
increment while the key switch and battery power are
applied to the ECM. The diagnostic clock is used to
time stamp diagnostic codes and event codes.
Logged diagnostic codes and logged event codes
display the diagnostic clock hour of the first
occurrence and the last occurrence and the total
number of occurrences.

Total Time
The Total Time is the total cumulative time of engine
operation. The Total Time can be obtained from the
Current Totals menu of Cat ET.

25
Troubleshooting Section

i02305595

ECM Snapshot
SMCS Code: 0785
The Engine Control Module (ECM) can record a
snapshot of certain engine parameters and certain
vehicle parameters. The snapshot records the
parameters for a period of 13 seconds that surround
an event. The following events trigger snapshots:

Certain diagnostic codes


Operator request
Quick Stop event
The ECM can store a maximum of two snapshots that
are triggered by a diagnostic code, two snapshots
that are triggered manually, and one Quick Stop
snapshot. The snapshots are stored in a circular
buffer. The newest snapshot will replace the oldest
snapshot.
The ECM stores the snapshots in memory. Snapshots
are maintained by the internal battery in the ECM until
the snapshots are cleared. The following conditions
will clear a snapshot:

Operator request via the Caterpillar Electronic


Technician (ET)

The snapshot has been stored for 100 hours.

Snapshot That is Triggered by a


Diagnostic Code
When certain diagnostic codes occur the ECM
records many of the status parameters that
are available on Cat ET. The ECM records this
information for approximately nine seconds before
the code occurs and approximately four seconds
after the code occurs.

Snapshot That is Triggered by the


Operator
A snapshot can be triggered by the operator by
using the Cruise Control Set/Resume Switch, or
by using Cat ET. Use the following procedure in
order to trigger the snapshot with the Cruise Control
Set/Resume Switch:

26
Troubleshooting Section

SENR9698-09

Clutch Switch
Vehicle Speed
Cruise Status
Brake Switch

Use of Snapshot Data

Illustration 10

g00627693

(1) OFF position


(2) SET position
(3) RESUME position

1. Toggle the switch quickly from the OFF position


(1) to the SET position (2).
2. Toggle the switch quickly from the SET position
(2) to the RESUME position (3).
3. Toggle the switch quickly from the RESUME
position (3) back to the OFF position (1).
Note: All three steps must occur within a one second
time period in order to take a snapshot. Performing
the steps in the reverse order also triggers a
snapshot.
On Cat ET, the snapshot can be triggered from the
Snapshot Recorder Tool. Refer to the instructions on
the screen or the systems documentation for help.

Snapshot That is Triggered by a


Quick Stop
A snapshot can also be recorded for a Quick Stop
event if the customer parameter is programmed. The
ECM stores the number of occurrences of the Quick
Stop event and a snapshot of the latest occurrence.
One data record is kept for the most recent Quick
Stop event. The previous record is replaced by the
most recent record.
Each Quick Stop record contains 60 frames of
information. Frame 45 is the Quick Stop event. The
record contains 44 frames before the Quick Stop
event and 15 frames after the Quick Stop event.
Each frame is separated by one second. Each frame
of the Quick Stop record stores the following data:

Engine RPM
Throttle Position

Use snapshot data only to help determine


engine/vehicle operating conditions when an
intermittent problem occurs. If an intermittent
diagnostic code is causing problems, use the
snapshot data. Snapshot data can be used to
determine whether the problem occurs under specific
circumstances. The following list contains examples
of specific circumstances:

Engine rpm
Range of vehicle speeds
Range of coolant temperatures
Use the snapshot data in order to determine the
operating conditions that were present during the
event. Attempt to duplicate the conditions in order
to get the code to recur.
Replacement of electronic components should
not be based on snapshot data alone. If too much
emphasis is put on snapshot data, the result could
be a misdiagnosed root cause. Also when snapshot
data that is triggered by a diagnostic code is being
viewed, the ECM sets a sensor value with an active
diagnostic code to a default value when the code
is active. This is the reason that the sensor value
suddenly jumps to a specific value at the trigger point
and the sensor value remains at the specific value for
the rest of the snapshot frames.
i02306413

Factory Passwords
SMCS Code: 0785
Factory passwords are required in order to perform
the following functions in the Caterpillar Electronic
Technician (ET):
Change the system configuration parameters.
When the Engine Control Module (ECM) is replaced,
the system configuration parameters must be
programmed into the new ECM. A new ECM will allow
these parameters to be programmed once without
factory passwords. After the initial programming,
factory passwords are required to program the
parameters.

SENR9698-09

27
Troubleshooting Section

Rerating the engine to another engine family


This includes flash programming an ECM from a
non-multitorque flash file to a multitorque flash file.
Read customer passwords. Factory passwords
are required in order to read the customer passwords.

Table 4

Factory Passwords Worksheet


Dealer Code
Customers Name
Address

Clear certain diagnostic event codes. Certain


diagnostic event codes require a factory password in
order to clear the code. A 252-11 Engine Software
Incorrect code is one example.
Unlock a customer specified parameter that is
locked. If a customer specified parameter has
been locked out, factory passwords are required
to unlock the parameter. Refer to Troubleshooting,
Customer Specified Parameters for additional
information.
Change certain customer specified parameters.
Refer to Troubleshooting, Customer Specified
Parameters for additional information.
If you must perform one of these functions, proceed
as if you already have the factory passwords. At
some point, the electronic service tool will request
the factory passwords and the electronic service tool
will display the information that is required to obtain
the passwords.
i02170328

Factory Passwords Worksheet

Telephone Number
Information From the Engine Information Plate
Engine Serial Number
Full Load Setting
Full Torque Setting
Information From the Vehicle Odometer
Engines Miles (km)
Information From the Factory Password Entry
Screen on the Caterpillar Electronic Technician (ET)
Electronic Service Tool
Serial Number
Engine Serial Number
ECM Serial Number
Total Tattletale
Reason Code
From Interlock(1)
To Interlock(1)

SMCS Code: 0785


Note: A mistake in recording these parameters will
result in incorrect passwords.

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

This parameter is required when the engine is being rerated.


This parameter is displayed only when the engine is being
rerated.

i02419726

Flash Programming
SMCS Code: 1901-591
Flash Programming This is a method of
programming or updating the flash file in an engines
Electronic Control Module (ECM).
Caterpillar Electronic Technician (ET) is used to flash
program a file into the memory of the engines ECM.

28
Troubleshooting Section

If you do not have the flash file, use the Flash File
Search tool on the Service Technician Workbench
(STW) to obtain the flash file for your engine.
Alternatively, use the Service Software Files feature
on SIS Web to obtain the flash file for your engine.
You must have the engine serial number in order to
search for the flash file. After locating the correct
flash file, download the flash file to your PC. Write
down the name of the flash file for future reference.

Programming a Flash File


1. Establish communication between Cat ET and the
engines ECM.
2. Select WinFlash from the Utilities menu on Cat
ET.
Note: If WinFlash will not communicate with the
ECM, refer to troubleshooting without a diagnostic
code Troubleshooting, Electronic Service Tool Will
Not Communicate with ECM.
3. Program the flash file into the ECM.
a. Select the engine ECM under the Detected
ECMs.
b. Press the Browse button in order to select the
name of the flash file that will be programmed
into the ECM.
c. When the correct flash file is selected, press
the Open button.
d. Verify that the File Values match the
application. If the File Values do not match
the application, obtain the correct flash file.
e. When the correct flash file is selected, press
the Begin Flash button.
f. Cat ET will indicate when flash programming
has been successfully completed.
4. Start the engine and check for proper operation.
Repair any active diagnostic or event codes.

WinFlash Error Messages


If you receive any error messages during flash
programming, click on the Cancel button in order
to stop the process. Access the information about
the ECM Summary under the Information menu.
Make sure that you are flashing the correct file for
your engine.

SENR9698-09

i02278907

Service Information Report


SMCS Code: 0336
After verifying the correct repair has been performed
on the engine, it is critical to provide brief, detailed
information. This information helps Caterpillar better
serve you and the customer.

Recommendations
Customers 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:

Indicate if the diagnostic lamp was flashing.


Indicate if the warning lamp was flashing, or if the
lamp was on continuously.

Indicate the symptoms of engine operation that are


present.

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:

A specific procedure in the manual was followed.


A visual inspection indicated that wire abrasion on
the engine harness existed.

An engine dynamometer test indicated that the

power was below the specification at 1700 rpm


due to the loss of the no. 4 injector and an engine
dynamometer test indicated that the power was
below the specification at all engine speeds above
1700 rpm due to the loss of the no. 4 injector.

Be as specific as possible.

Repair Procedure
Comments on the repair procedure should include
the following types of information:

SENR9698-09

The wiring harness was repaired.


The Full Load Setting (FLS) was changed per the
factorys instructions.

Be as specific as possible.

29
Troubleshooting Section

30
Troubleshooting Section

SENR9698-09

Customer Specified
Parameters

A locked out parameter also provides an audit trail.


The audit trail can be used to determine the following
information:
i02504214

Customer Specified
Parameters
SMCS Code: 1901
Customer specified parameters allow the vehicle
owner to influence the operating technique of a driver.
Some parameters may affect engine operation in a
way that would not be expected by an inadequately
trained driver. These parameters may lead to power
or performance complaints even though the engines
performance is within the engines specification.
Customer parameters may be changed repeatedly
as a customers operation changes or as new drivers
are assigned to a truck. Customer passwords are
required to change these parameters. The customer
password must be programmed into the Engine
Control Module (ECM).

Time of change
Operator during change
The following customer parameters are available for
lockout:

Multi-Torque Ratio
Vehicle Speed Calibration
Vehicle Speed Cal (J1939 - Trans)
Vehicle Speed Cal (J1939 - ABS)
Vehicle Speed Limit
VSL Protection
Soft Vehicle Speed Limit
Two Speed Axle - Low Speed Range Axle Ratio

The following information is a brief description of


the customer specified parameters. The following
parameter values are included with the descriptions:

Nominal Axle Ratio - High Speed Range Axle Ratio

Minimum

High Cruise Control Set Speed Limit

Maximum

Adaptive Cruise Control Enable

Default

Transmission Style

The tables show values in an approximate range for


metric units that is followed by the metric conversion
to English units. The exact range of the parameter in
metric units depends on the service tool that is being
used. Each tool may use slightly different conversion
factors.

Top Gear Ratio

Customer Parameter Lockout


The customer parameter lockout is available in order
to restrict access to changing some of the available
parameters. Locking out a parameter requires
customer passwords (if used). Once a parameter is
locked out, the parameter can not be changed until
the parameter is unlocked.
If a lockable parameter is not locked out, factory
passwords are not required. A locked out parameter
restricts the parameter from being changed directly
by the operator. This helps vehicle owners that
are encountering problems with operators that are
obtaining customer passwords and altering some of
these parameters.

Low Cruise Control Set Speed Limit

Top Gear Minus One Ratio


Top Gear Minus Two Ratio
A/C Switch Fan On-Time
Engine Retarder Delay
Engine Monitoring Lamps
Engine Coolant Temperature Derate Enable Status
Prior to DEC 03

Vehicle Overspeed Threshold


Driver Reward Enable
Fan Control Type

SENR9698-09

31
Troubleshooting Section

When an attempt to change a locked out parameter


occurs, the factory password screen will come up.
If changing the parameter is required, follow the
instructions on the Caterpillar Electronic Technician
(ET).
Factory passwords are also required to change a
parameter from a locked parameter to an unlocked
parameter. If more than one parameter is locked out,
and each one needs to be unlocked, one factory
password is required.
i02048211

Customer Specified
Parameters Table
SMCS Code: 1901
Table 5

Table for Customer Specified Parameters


Parameter

Available Range or Options

Default

Selected Engine Rating


Rating Number
Multitorque Ratio

Dependent on engine power


Unavailable (Standard Ratings)
MT-A
MT-B
MT-C

Unavailable (Standard Ratings)


MT-A (Multitorque Ratings)

17 Digits
Available characters are dependent
on the service tools.

all zeroes

No
Yes

No

2485 to 93226 PPKM


(4000 to 150000 PPM)

Not Programmed

Vehicle Speed Cal (J1939 - Trans)

0 to 43000 revolutions per km (0 to


65000 revolutions per mile)

Not Programmed

Vehicle Speed Cal (J1939 - ABS)

0 to 6.550

Not Programmed

48 to 204 km/h (30 to 127 mph)

204 km/h (127 mph)

1000 to TEL rpm

TEL rpm

12.0 to 500.0 pulses per revolution

113.0 pulses per revolution

No
Yes

No

1.00 to 19.99

1.00

1.0 to 9.99

1.00

ECM Identification Parameters


Vehicle ID

Security Access Parameters


ECM Wireless Communication Enable
Vehicle Speed Parameters
Vehicle Speed Calibration

Vehicle Speed Limit


VSL Protection
Tachometer Calibration
Soft Vehicle Speed Limit
Two Speed Axle - Low Speed Range
Axle Ratio
Nominal Axle Ratio - High Speed
Range Axle Ratio
Cruise Control Parameters

(continued)

32
Troubleshooting Section

SENR9698-09

(Table 5, contd)

Table for Customer Specified Parameters


Parameter

Available Range or Options

Default

Low Cruise Control Speed Set Limit

24 to 204 km/h (15 to 127 mph)

204 km/h (127 mph)

High Cruise Control Speed Set Limit

48 to 204 km/h (30 to 127 mph)

204 km/h (127 mph)

Coast
Latch
Manual

Manual

Hard Limit
Soft Limit

Hard Limit

Engine Retarder Minimum Vehicle


Speed

0 to 204 km/h (0 to 127 mph)

0 km/h (0 mph)

Auto Retarder in Cruise (0 = Off)

0 to 16 km/h (0 to 10 mph)

0 km/h (0 mph)

0 to 8 km/h (0 to 5 mph)

3 km/h (2 mph)

Set/Accel-Res/Decel
Set/Decel-Res/Accel

Set/Accel-Res/Decel

No
Yes

Yes

Disabled
Enabled

Disabled

2 to 24 km/h (1 to 15 mph)

2 km/h (1 mph)

Low Idle to 2120 rpm

2120 rpm

5 to 1000 rpm/sec

50 rpm/sec

5 to 500 rpm

20 rpm

Cab Switches
Off
Remote Switches
Remote Throttle

Off

Low Idle to 2120 rpm

2120 rpm

PTO Engine RPM Set Speed (0 = Off)

Low Idle to PTO TEL rpm

PTO Engine RPM Set Speed A

Low Idle to PTO TEL rpm

PTO Engine RPM Set Speed B

Low Idle to PTO TEL rpm

No
Yes

No

Maximum PTO Enable Speed

Low Idle to PTO TEL rpm

PTO TEL rpm

PTO Cab Controls RPM Limit

Low Idle
TEL
PTO TEL

TEL

2 to 204 km/h (1 to 127 mph)

2 km/h (1 mph)

24 to 204 km/h (15 to 127 mph)

204 km/h (127 mph)

270 Nm (200 lb ft) to Rated Torque

3400 Nm (2500 lb ft)

3 to 1440 minutes

600 to PTO TEL rpm

PTO TEL rpm

Engine Retarder Mode

Engine Retarder Minimum VSL Type

Auto Retarder in Cruise Increment


Cruise/Idle/PTO Switch Configuration
Soft Cruise Control
Adaptive Cruise Control Enable
Idle Parameters
Idle Vehicle Speed Limit
Idle RPM Limit
Idle/PTO RPM Ramp Rate
Idle/PTO Bump RPM
Dedicated PTO Parameters
PTO Configuration

PTO Top Engine Limit

PTO to Set Speed

PTO Kickout Vehicle Speed Limit


Max PTO Vehicle Speed
Torque Limit
PTO Shutdown Time (0 = Off)
PTO Shutdown Timer Maximum RPM

(continued)

SENR9698-09

33
Troubleshooting Section

(Table 5, contd)

Table for Customer Specified Parameters


Parameter

Available Range or Options

Default

Continuous
Normal

Normal

1100 to TEL rpm

TEL rpm

5 to 48 km/h (3 to 30 mph)

5 km/h (3 mph)

1100 to TEL rpm

TEL rpm

8 to 80 km/h (5 to 50 mph)

8 km/h (5 mph)

1300 to TEL rpm

TEL rpm

48 to 204 km/h (30 to 127 mph)

204 km/h (127 mph)

600 to 750 rpm

600 rpm

Automatic Option 1
Automatic Option 2
Automatic Option 3
Automatic Option 4
Eaton Top 2
Manual Option 1

Manual Option 1

No
Yes

No

Top Gear Ratio

0.000 to 3.750

0.000

Top Gear Minus One Ratio

0.000 to 3.750

0.000

Top Gear Minus Two Ratio

0.000 to 3.750

0.000

Full Range
Min/Max
Min/Max with Speed Control

Full Range

3 to 1440 minutes

0 minutes

Low Idle to 2120 rpm

2120 rpm

J1587 Outside Temp Based


No
Outside Temperature Based
Yes

Yes

Minimum Idle Shutdown Outside Temp

40 to 49C (40 to 120F)

49 C (120 F)

Maximum Idle Shutdown Outside


Temp

40 to 49C (40 to 120F)

49 C (120 F)

A/C Switch Fan On-Time (0 = Off)

1 to 600 seconds

0 seconds

Fan with Engine Retarder in High


Mode

No
Yes

No

0.0 to 3.0 seconds

0.0 seconds

0 to 25.5 volts

0.0 volts

Derate
Shutdown
Warning

Warning

PTO Activates Cooling Fan


Engine/Gear Parameters
Lower Gears Engine RPM Limit
Lower Gears Turn Off Speed
Intermediate Gears Engine RPM Limit
Intermediate Gears Turn Off Speed
Gear Down Protection RPM Limit
Gear Down Protection Turn On Speed
Low Idle Engine RPM
Transmission Style

Eaton Top 2 Override with Cruise


Switch

Governor Type

Timer Parameters
Idle Shutdown Time (0 = Off)
Idle Shutdown Timer Maximum RPM
Allow Idle Shutdown Override

Engine Retarder Delay


Smart Idle Parameters
Battery Monitor and Engine Control
Voltage
Engine Monitoring Parameters
Engine Monitoring Mode

(continued)

34
Troubleshooting Section

SENR9698-09

(Table 5, contd)

Table for Customer Specified Parameters


Parameter

Available Range or Options

Default

Option 1
Warning Lamp

Warning Lamp

2-wire Float Sensor


4-pin
No

No

Disabled
Enabled

Disabled

Automatic Distance
Automatic Hours
Manual Distance
Manual Hours
Off

Off

8050 to 56325 km (5000 to 35000 miles)


100 to 750 hours

24140 km (15000 miles)


250 hours

19 to 57 L (20 to 60 qt)

C11, C13: 34 L (36 qt)


C15: 38 L (40 qt)

63.5 to 63.5 %

0 %

No
Yes

No

Dash-PM 1 Reset

No
Yes

No

Dash-Fleet Trip Reset

No
Yes

No

Dash-State Selection

No
Yes

Yes

Auto-Enable
No
Yes

No

Four Characters

0000

Quick Stop Rate

5 to 24 km/h per sec (3 to 15


mph per sec)

0 km/h per sec (0 mph per sec)

Vehicle Overspeed Threshold

48 to 204 km/h (30 to 127 mph)

204 km/h (127 mph)

0 to 1440 minutes

0 minutes

Disabled
Enabled

Enabled

Engine Monitoring Lamps


Coolant Level Sensor

Engine Coolant Temperature Derate


Enable Status
This parameter is not supported in DEC
03 and newer software.
Maintenance Parameters
Maintenance Indicator Mode

PM 1 Interval (Manual Maintenance


Indicator Mode)
Engine Oil Capacity
Trip Parameters
Fuel Correction Factor
Dash-Change Fuel Correction Factor

Theft Deterrent System Control

Theft Deterrent Password

Vehicle Activity Report Parameters


Minimum Idle Time (0 = Off)
Driver Reward
Driver Reward Enable
Input Selections
(continued)

SENR9698-09

35
Troubleshooting Section

(Table 5, contd)

Table for Customer Specified Parameters


Parameter

Available Range or Options

Default

J1/P1:46
J1/P1:47
J1/P1:6
J1/P1:7
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None

None

None
J1939
J1/P1:62

None

Ignore Brake/Clutch Switch

J1/P1:47
None

None

Torque Limit Switch

J1/P1:7
None

None

J1/P1:46
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None

None

J1/P1:56
J1939 - Cab Controller
J1939 - Body Controller
J1939 - Instrument Cluster

J1/P1:56

J1/P1:58
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None

J1/P1:58

J1/P1:60
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None

J1/P1:60

J1/P1:46
J1/P1:58
J1/P1:6
J1/P1:60
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None

None

J1/P1:46
J1/P1:58
J1/P1:6
J1/P1:60
None

None

J1/P1:46
J1/P1:47
J1/P1:6
J1/P1:7
None

None

Fan Override Switch

Transmission Neutral Switch

Diagnostic Enable

PTO On/Off Switch

Remote PTO Set Switch

Remote PTO Resume Switch

PTO Engine RPM Set Speed Input A

PTO Engine RPM Set Speed Input B

Starting Aid On/Off Switch

(continued)

36
Troubleshooting Section

SENR9698-09

(Table 5, contd)

Table for Customer Specified Parameters


Parameter

Available Range or Options

Default

J1/P1:6
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None

None

J1/P1:59
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster

J1/P1:59

Cruise Control Set/Resume/Accel/


Decel Switch

J1/P1:35 & 44
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster

J1/P1:35 & 44

Cruise Control Pause Switch

J1939 - Body Controller


J1939 - Cab Controller
J1939 - Instrument Cluster
None

None

J1/P1:22
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster

J1/P1:22

J1/P1:23 & 40
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster

J1/P1:23 & 40

J1/P1:45
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster

J1/P1:45

J1/P1:66

J1/P1:66

J1/P1:32 & 33
J1939 ABS
J1939 Trans

J1/P1:32 & 33

J1/P1:10
J1/P1:12
J1/P1:13
None

None

J1/P1:10
J1/P1:12
J1/P1:13
None

None

Auxiliary Brake

J1/P1:12
None

None

Starting Aid Output

J1/P1:10
J1/P1:12
J1/P1:13
None

None

J2/P2:13
None

None

Two-Speed Axle Switch

Cruise Control On/Off Switch

Clutch Pedal Position Switch

Retarder Off/Low/Medium/High Switch

Service Brake Pedal Position Switch


#1

Accelerator Pedal Position


Vehicle Speed Input

Output Selections
Engine Running Output

Engine Shutdown Output

Air Inlet Shutoff Relay Control

(continued)

SENR9698-09

37
Troubleshooting Section

(Table 5, contd)

Table for Customer Specified Parameters


Parameter

Available Range or Options

Default

None
On/Off PWM
On/Off DC
Three-Speed Fan PWM
Three-Speed Fan DC
Variable Speed Fan Option S

None

J1/P1:19
None

None

8 Digits
Available characters are dependent
on the service tools.

Not Programmed

J1939
None

J1939

Fan Control Type

PTO Active Output


Customer Passwords
Customer Password #1
Customer Password #2
Data Link Parameters
Power Train Data Link

i02504411

Customer Specified
Parameters Worksheet
SMCS Code: 1901
Table 6

Selected Engine Rating


Rating Number
Rating Type
Multitorque Ratio
Advertised Power
Governed Speed
Rated Peak Torque
Top Engine Speed Range
Test Spec
Test Spec with BrakeSaver
Table 7

ECM Identification Parameters


Vehicle ID
Engine Serial Number
ECM Serial Number
Personality Module Part
Number
Personality Module
Release Date

Table 8

Security Access Parameters


Total Tattletale
Last Tool to change
Customer Parameters
Last Tool to change System
Parameters
ECM Wireless
Communication Enable

38
Troubleshooting Section

Table 9

SENR9698-09

Table 12

Vehicle Speed Parameters

Dedicated PTO Parameters

Vehicle Speed Calibration

PTO Configuration

Vehicle Speed Cal (J1939


- Trans)

PTO Top Engine Limit

Vehicle Speed Cal (J1939


- ABS)
Vehicle Speed Limit (VSL)
VSL Protection
Tachometer Calibration

PTO Engine RPM Set


Speed (0 = Off)
PTO Engine RPM Set
Speed
PTO Engine RPM Set
Speed A

Soft Vehicle Speed Limit

PTO Engine RPM Set


Speed B

Two Speed Axle - Low


Speed Range Axle Ratio

PTO to Set Speed

Nominal Axle Ratio - High


Speed Range Axle Ratio

Maximum PTO Enable


Speed
PTO Cab Controls RPM
Limit

Table 10

Cruise Control Parameters


Low Cruise Control Speed
Set Limit
High Cruise Control Speed
Set Limit
Cruise/Idle/PTO Switch
Configuration
Soft Cruise Control
Adaptive Cruise Control
Enable
Table 11

Idle Parameters
Idle Vehicle Speed Limit
Idle RPM Limit
Idle/PTO RPM Ramp Rate
Idle/PTO Bump RPM

PTO Kickout Vehicle


Speed Limit
Max PTO Vehicle Speed
Torque Limit
PTO Shutdown Time (0 =
Off)
PTO Shutdown Timer
Maximum RPM
PTO Activates Cooling Fan

SENR9698-09

39
Troubleshooting Section

Table 13

Table 16

Engine Monitoring Parameters

Engine/Gear Parameters
Lower Gears Engine rpm
Limit

Engine Monitoring Mode


Engine Monitoring Lamps

Lower Gears Turn Off


Speed

Coolant Level Sensor

Intermediate Gears Engine


RPM Limit

Engine Coolant
Temperature Derate
Enable Status

Intermediate Gears Turn


Off Speed

Table 17

Gear Down Protection


RPM Limit
Gear Down Protection
Turn On Speed
Low Idle Engine RPM
Transmission Style
Eaton Top 2 Override with
Cruise Switch
Top Gear Ratio
Top Gear Minus One Ratio

Maintenance Parameters
Maintenance Indicator
Mode
PM 1 Interval
Engine Oil Capacity
Table 18

Trip Parameters
Fuel Correction Factor

Top Gear Minus Two Ratio

Dash - Change Fuel


Correction Factor

Governor Type

Dash - PM 1 Reset
Dash - Fleet Trip Reset

Table 14

Timer Parameters
Idle Shutdown Time (0 =
Off)
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
(0 = Off)

Dash - State Selection


Theft Deterrent System
Control
Theft Deterrent Password
Quick Stop Rate
Vehicle Overspeed
Threshold
Table 19

Vehicle Activity Report Parameters


Minimum Idle Time (0 =
Off)
Table 20

Table 15

Driver Reward
Smart Idle Parameters

Battery Monitor and Engine


Control Voltage

Driver Reward Enable

40
Troubleshooting Section

Table 21

SENR9698-09

Table 23

Input Selections

Customer Passwords

Fan Override Switch

Customer Password #1

Transmission Neutral
Switch

Customer Password #2

Ignore Brake/Clutch Switch

Table 24

Data Link Parameters

Torque Limit Switch

Power train Data Link

Diagnostic Enable
PTO On/Off Switch
Remote PTO Set Switch
Remote PTO Resume
Switch
PTO Engine RPM Set
Speed Input A
PTO Engine RPM Set
Speed Input B

Lifetime Totals Worksheet


Table 25

Lifetime Totals Worksheet


Total Time
Total PTO Time
Total Idle Time

Starting Aid On/Off Switch

Total Distance

Two Speed Axle Switch

Total Fuel

Cruise Control On/Off


Switch

Total PTO Fuel

Cruise Control
Set/Resume/Accel/Decel
Switch

Total Maximum Fuel

Total Idle Fuel

Average Load Factor

Cruise Control Pause


Switch
Clutch Pedal Position
Switch
Service Brake Pedal
Position Switch #1
Accelerator Pedal Position
Vehicle Speed Input
Table 22

Output Selections
Engine Running Output
Engine Shutdown Output
Auxiliary Brake
Starting Aid Output
Air Inlet Shutoff Relay
Control
Fan Control Type
PTO Active Output

i02183201

Cruise Control Parameters


SMCS Code: 1901

Low Cruise Control Speed Set


Limit
The Low Cruise Control Speed Set Limit sets
the lowest vehicle speed that will allow the cruise
control to be set. Programming this parameter to the
maximum value disables cruise control.
Table 26

Minimum

Maximum

Default

24 km/h (15 mph)

204 km/h
(127 mph)

204 km/h
(127 mph)

SENR9698-09

41
Troubleshooting Section

High Cruise Control Speed Set


Limit
The High Cruise Control Speed Set Limit sets the
highest vehicle speed that will allow the cruise control
to be set. If a driver attempts to set a vehicle speed
higher than this limit, the High Cruise Control Speed
Set Limit will be the cruise set speed. If the High
Cruise Control Speed Set Limit is programmed to a
value that is greater than the vehicle speed limit, the
cruise control switches can be used to exceed the
programmed vehicle speed limit.

Table 28

Alternative

Default

Coast
Latch

Manual

Table 27

Minimum

Maximum

Default

48 km/h (30 mph)

204 km/h
(127 mph)

204 km/h
(127 mph)

Engine Retarder Mode


Engine Retarder Mode determines the operation of
the auxiliary retarder output and the exhaust retarder
output while the cruise control On/Off switch is in the
ON position but the engine is not in cruise control.
This does not determine engine retarder operation
while the engine is in cruise control. Also, this does
not allow engine retarder operation while the engine
is in cruise control.
The following modes are allowable options:

Coast
Latch
Manual
When the Engine Retarder Mode is programmed to
the coast mode, the engine retarder is enabled only
while the service brakes are being applied. When the
Engine Control Module (ECM) is programmed to the
latch mode, the engine retarder stays enabled after
the service brakes are released. A direct, immediate
pressure on the brake pedal latches the engine
retarder in the ON position and the engine retarder
will remain in the ON position until the accelerator
pedal is depressed.
When the ECM is programmed to the manual mode,
the cruise control switch is not required to be in the
ON position. When the ECM is programmed to the
manual mode, the engine retarder will activate when
all of the following conditions are met:

The engine retarder switch is in the ON position.


The engine rpm is greater than 800 rpm.
The engine is not being fueled.

Illustration 11

g00631045

Coast and latch of engine retarder mode

Engine Retarder Minimum VSL


Type
The Engine Retarder Minimum VSL Type defines
the use of the Engine Retarder Minimum Vehicle
Speed parameter. The Engine Retarder Minimum
VSL Type provides the following two options:

Hard limit
Soft limit
If the Engine Retarder Minimum VSL Type is
programmed to the hard limit, the engine retarder will
turn off when the value that is programmed into the
engine retarder minimum vehicle speed is reached.
If the Engine Retarder Minimum VSL Type is
programmed to the soft limit, the engine retarder
will remain on and the retarder will have a value
that is below the value that is programmed in the
engine retarder minimum vehicle speed. The engine
retarder will remain on until the parameters that
would normally turn off the engine retarder are met.
In both cases, the engine retarder will remain off until
vehicle speed is higher than the programmed value
of the engine retarder minimum vehicle speed and
the engine retarder has been engaged again.

42
Troubleshooting Section

SENR9698-09

The following diagram illustrates the engine retarder


operation for both options of the Engine Retarder
Minimum VSL Type. The engine retarder parameter
is programmed to the manual option and the
parameter for the engine retarder minimum vehicle
speed is programmed to 48 km/h (30 mph).

Engine Retarder Minimum Vehicle


Speed
Engine retarder minimum vehicle speed determines
the minimum vehicle speed limit for the engine
retarders to turn ON. Below this vehicle speed, the
ECM will not turn on the engine retarder unless
the vehicle is stationary. If the vehicle is stationary,
the vehicle speed is 0 km/h (0 mph). If the vehicle
speed signal was not being read by the ECM, the
vehicle could be moving but the vehicle speed signal
would be 0 km/h (0 mph). If engine retarder minimum
vehicle speed is programmed to 0 km/h (0 mph) the
engine retarder will operate at all vehicle speeds.
This parameter affects both the engine retarder and
any auxiliary retarder such as a BrakeSaver.
Table 30

Minimum

Maximum

Default

0 km/h (0 mph)

204 km/h
(127 mph)

0 km/h (0 mph)

Auto Retarder in Cruise


g00631048

Illustration 12

Note: When the vehicle speed drops below the


engine retarder minimum vehicle speed and the
parameter is programmed to the hard limit, the
engine retarder turns off. When the vehicle speed
drops below the engine retarder minimum vehicle
speed and the parameter is programmed to the soft
limit, the engine retarder remains on.
If the engine retarder minimum vehicle speed
has been programmed to 0 km/h (0 mph), the
programming of the parameter for the Engine
Retarder Minimum VSL Type does not affect the
operation of the engine retarder.
Table 29

Alternative

Default

Soft Limit

Hard Limit

The Auto Retarder in Cruise determines the vehicle


speed in kilometers per hour (km/h) or miles per hour
(mph) above the cruise set speed when the engine
retarder will be activated. The engine retarder switch
must be in the ON position and the cruise control
must be set for this feature to operate. Programming
the Auto Retarder in Cruise parameter to zero
disables this feature. This parameter affects the
engine while the cruise control is activated.
Note: This parameter only affects the factory
installed engine retarder (compression brake). This
parameter does not affect an auxiliary braking device
or Brakesaver.
The actual level of braking is limited by the settings
of the retarder switch. For example, the retarder will
not come on if the retarder is switched off.
If soft cruise control is programmed to yes, the
retarder will not come on until the vehicle speed is
5 km/h (3 mph) above the cruise set speed. The
Caterpillar Electronic Technician (ET) will change an
attempt to 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 31

Minimum

Maximum

Default

0 km/h (0 mph)

16 km/h (10 mph)

0 km/h (0 mph)

SENR9698-09

43
Troubleshooting Section

Auto Retarder in Cruise


Increment
Auto Retarder in Cruise Increment requires
the Auto Retarder in Cruise parameter to be
programmed above zero. Auto Retarder in Cruise
Increment determines the increment in kilometers
per hour (km/h) or miles per hour (mph) when the
medium level of engine retarder will activate. Auto
Retarder in Cruise Increment also determines the
increment in kilometers per hour (km/h) or miles per
hour (mph) when the High level of engine retarder
will activate. Programming the parameter to zero will
allow the retarder to come on in the high mode when
the programmed Auto Retarder in Cruise speed is
reached. The Auto Retarder in Cruise speed must
be set above the cruise set speed. This parameter
affects the engine while the cruise control is activated.
The actual level of braking is limited by the settings
of the retarder switch. For example, the retarder will
not come on if the retarder is switched off.
Table 32

Minimum

Maximum

Default

0 km/h (0 mph)

8 km/h (5 mph)

3 km/h (2 mph)

Cruise/Idle/PTO Switch
Configuration
Cruise/Idle/PTO Switch Configuration defines the
function of the Set/Resume switch for Accel mode
and Decel mode. This parameter affects cruise
control mode, idle mode and PTO mode.
Table 33

Alternative

Default

Set/Decel-Res/Accel

Set/Accel-Res/Decel

Soft Cruise Control


Soft Cruise Control provides a 8 km/h (5 mph)
operating range around the cruise control set speed
in order to provide a smoother cruise control. Soft
Cruise Control controls the cruise speed within the
following range:

4 km/h (2.5 mph) below the set vehicle speed at


full load

4 km/h (2.5 mph) above the set vehicle speed at


no load

g00670797

Illustration 13
Table 34

Alternative

Default

No

Yes

Adaptive Cruise Control Enable


Adaptive cruise control reduces the need to manually
cancel cruise control when you approach a slower
vehicle. The system responds by decreasing the
cruise control set speed until a following distance
is obtained. If the slower vehicle speeds up, the
cruise control set speed will be adjusted in order
to maintain the following distance. Adaptive cruise
control will restore the original set speed when there
are no vehicles within the range of control. Adaptive
cruise control will not increase the cruise control set
speed above the original setting. If the vehicle is
approaching the target too rapidly, the ECM will turn
off the cruise control.
Table 35

Alternative

Default

Enabled

Disabled

44
Troubleshooting Section

SENR9698-09

i02183219

Data Link Parameters


SMCS Code: 1901

Power Train Data Link

Brake switch

This parameter (Power Train Data Link) determines


if the Engine Control Module (ECM) will communicate
to the power train over the J1939 data link. If the
vehicle is not using the data link for communication
to the power train systems, this parameter must be
programmed to None. The following systems are
examples of power train systems:

Traction control systems


Anti-lock brake systems
Electronically controlled transmissions

Table 36

Default

None

J1939

Dedicated PTO Parameters


SMCS Code: 1901

PTO Configuration
The PTO Configuration determines the features
that are available for dedicated PTO applications
and the input signals that are used for dedicated
PTO applications. When the PTO Configuration is
turned off, the application does not use the PTO.
The remaining PTO programmable options require a
PTO On/Off circuit that is connected to Input 1. A
PTO switch on lamp can also be connected to output
1 (J1/P1:30).
If the ECM is programmed to the cab switches, the
Engine Control Module (ECM) will use the signals
from the following two switches for PTO control and
for cruise control:

Resume switch (J1/P1:44)

Accelerator
Cruise control switches
If the ECM is programmed to Remote Throttle, the
ECM will monitor J1/P1:68 for the remote accelerator
pedal. The ECM will monitor programmed signals
and the ECM will ignore all cab controls when the
PTO On/Off circuit is ON.

Alternative

Default

Cab Switches
Remote Switches
Remote Throttle

Off

PTO Top Engine Limit


i02183226

Set switch (J1/P1:35)

Clutch switch

Table 37

Note: In addition, the J1939 data link can be used


for switch inputs to the ECM. This includes the PTO
switches, cruise control switches, and other switches.

Alternative

If the ECM is programmed to Remote Switches,


the ECM will monitor programmed signals such
as the remote set switch and the remote resume
switch. Signals from the cab controls will be ignored
when the PTO On/Off circuit is on. The following
components are cab controls:

The PTO Top Engine Limit is the top engine limit


that is available by using a PTO On/Off circuit that
is connected to Input 1 of ECM connector J1/P1.
Note: The PTO Configuration must be programmed
to Cab Switches, to Remote Switches, or to
Remote Throttle before this parameter can be
programmed.
Table 38

Minimum

Maximum

Default

Low Idle rpm

2120 rpm

2120 rpm

PTO Engine RPM Set Speed (0 =


Off)
This parameter allows automatic ramping to the
preset rpm when the PTO is engaged. PTO to
Set Speed must be programmed to Yes for this
parameter to function. When the PTO is engaged
the rpm will change according to the programmed
PTO Ramp Rate. This parameter is only available
when the PTO Configuration is programmed to
Cab Switches, to Remote Switches, or to Remote
Throttle.

SENR9698-09

45
Troubleshooting Section

Table 39

Minimum

Maximum

Default

Low Idle rpm

PTO TEL rpm

0 rpm

PTO Engine RPM Set Speed Input


A
The ECM controls this engine rpm. This control
occurs when the PTO ON/OFF circuit is on and the
PTO Engine RPM Set speed Input A switch is on.
The rpm can be programmed to operate from low idle
up to the PTO Top Engine Limit. While the engine is
operating at this set speed, all other inputs for speed
control are ignored. The inputs for speed control
that are ignored include the cab throttle switch, the
remote throttle switch, the set/accel switch, and the
resume/decel switch. This feature can also be used
in conjunction with the PTO to Set speed feature
and with the PTO Engine RPM Set Speed B feature
for multiple speed PTO operation. This feature can
also override the PTO to Set speed feature and the
PTO Engine RPM Set Speed B feature for multiple
speed PTO operation.
The engine will only operate at this programmed
speed when the PTO ON/OFF circuit is on and the
PTO Engine RPM Set Speed Input A switch is on.
The engine will operate at the programmed speed
unless a condition that causes PTO operation kickout
occurs. The conditions that will cause PTO operation
kickout include the depression of the brake pedal, the
depression of the clutch pedal, and the PTO Vehicle
Speed Limit that is exceeded. The engine will return
to low idle if the PTO operation is kicked out.
Note: The PTO Configuration parameter must
be programmed to Cab Switches, to Remote
Switches, or to Remote Throttle and the PTO
Engine RPM Set Speed Input A parameter must be
programmed to a dedicated switch input (J1/P1:6,
J1/P1:46, J1/P1:58, or J1/P1:60) for this feature to
function.
Table 40

Minimum

Maximum

Default

Low Idle rpm

PTO TEL rpm

0 rpm

PTO Engine RPM Set Speed Input


B
The ECM controls this engine rpm. This control
occurs when the PTO ON/OFF circuit and the PTO
Engine RPM Set Speed Input B switch is on and
the PTO Engine RPM Set Speed A switch is off.
The rpm can be programmed to operate from low idle
up to the PTO Top Engine Limit. While the engine
is operating at this set speed, all other inputs for
speed control are ignored except for the PTO Engine
RPM Set Speed A. The inputs for speed control
that are ignored include the cab throttle switch, the
remote throttle switch, the set/accel switch, and the
resume/decel switch. This feature can also be used
in conjunction with the PTO to Set speed feature for
multiple speed PTO operation. This feature can also
override the PTO to Set speed feature for multiple
speed PTO operation.
The engine will only operate at this programmed
speed when the PTO ON/OFF circuit and the PTO
Engine RPM Set Speed Input B switch is on and
the PTO Engine RPM Set Speed A switch is off.
The engine will operate at the programmed speed
unless a condition that causes PTO operation kickout
occurs. The conditions that will cause PTO operation
kickout include the depression of the brake pedal, the
depression of the clutch pedal, and the PTO Vehicle
Speed Limit that is exceeded. The engine will return
to low idle if the PTO operation is kicked out.
Note: The PTO Configuration parameter must
be programmed to Cab Switches, to Remote
Switches, or to 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, or J1/P1:60) for this feature to
function.
Table 41

Minimum

Maximum

Default

Low Idle rpm

PTO TEL rpm

0 rpm

PTO to Set Speed


This parameter causes the ECM to proceed to the
programmed PTO Engine RPM Set Speed when
the PTO ON/OFF switch is on. PTO Configuration
must be programmed to Cab Switches or to
Remote Switches before this parameter can be
programmed.
Note: This parameter is not available for PTO
Configuration Remote Throttle.
Table 42

Alternative

Default

Yes

No

46
Troubleshooting Section

SENR9698-09

Maximum PTO Enable Speed


This parameter specifies the maximum engine speed
for the engagement of the PTO mode. The PTO
mode will engage when the engine rpm is equal to
the programmed limit or less than the programmed
limit. This parameter is only available when the PTO
Configuration is programmed to Cab Switches, to
Remote Switches, or to Remote Throttle.
Table 43

Minimum

Maximum

Default

700 rpm

PTO TEL rpm

PTO TEL rpm

PTO Cab Controls RPM Limit


This determines the engine rpm limit of the cab
mounted accelerator pedal position sensor when
PTO Configuration is programmed to Cab
Switches and the PTO On/Off circuit is on. This
parameter is intended to prevent engine overspeed
when dedicated PTO is used.

Table 45

Minimum

Maximum

Default

2 km/h (1 mph)

204 km/h
(127 mph)

2 km/h (1 mph)

Max PTO Vehicle Speed


This parameter sets the maximum allowable vehicle
speed while the vehicle is in PTO mode.
Table 46

Minimum

Maximum

Default

24 km/h (15 mph)

204 km/h
(127 mph)

204 km/h
(127 mph)

Torque Limit

If the parameter is programmed to low idle, the cab


controls are ignored.

If the parameter is programmed to Top Engine


Limit (TEL), the engine will operate to the
programmed Top Engine Limit.

If the parameter is programmed to PTO TEL, the


engine will operate to the programmed PTO Top
Engine Limit.

Note: PTO Configuration must be programmed


to Cab Switches for this parameter to take effect.
If PTO Configuration is programmed to Remote
Switches or to Remote Throttle, the ECM will
always ignore the cab throttle when the PTO On/Off
circuit is on.
Table 44

Alternative

Default

Low Idle
TEL
PTO TEL

TEL

PTO Kickout Vehicle Speed Limit


(VSL)
This is the maximum vehicle speed for setting or
maintaining a set engine rpm in PTO mode. PTO
mode is entered if the PTO On/Off Switch is on.
(This uses input 1.) If the vehicle speed signal
exceeds this value, the engine will not maintain the
set engine rpm.

g00628600

Illustration 14
Operation of Torque limit
(1) Programmed torque limit

The parameter for the Torque Limit defines the


maximum torque output of the engine during
dedicated PTO operation. This parameter provides
temporary protection of equipment. The torque
limit of the engine is active when the circuit for the
torque limit switch is on. The maximum value is the
rated torque of the engine. The Torque Limit is
programmable to Nm (lb ft) of torque. Programming
a value higher than the rated torque is limited by the
ECM to rated torque. The torque limit is indicated by
the dashed line in Illustration 14.
Table 47

Minimum

Maximum

Default

270 Nm
(200 lb ft)

3400 Nm
(2500 lb ft)

3400 Nm
(2500 lb ft)

SENR9698-09

47
Troubleshooting Section

PTO Shutdown Time

PTO Activates Cooling Fan

The PTO Shutdown Time sets the amount of idle


time before the PTO shuts down. The time begins
when the PTO On/Off circuit is on and there is
no vehicle speed. The PTO Shutdown Timer will
not begin counting if the engine is in cold mode.
This parameter requires the PTO Configuration
to be programmed to Cab Switches, to Remote
Switches, or to Remote Throttle for the timer to
function.

This parameter requires the use of the ECM cooling


fan circuit. When this parameter is programmed to
continuous mode, the ECM will signal the cooling
fan to run continuously when the PTO On/Off
circuit is on. The cooling fan runs continuously
in order to reduce changes in the load while the
engine is being used for dedicated PTO applications.
When this parameter is programmed to the normal
mode, the operation of the fan is based on coolant
temperature, on intake manifold air temperature
or on air conditioning high head pressure. The
PTO Configuration must be programmed to Cab
Switches, to Remote Switches, or to Remote
Throttle before this parameter can be programmed.
The Fan Control Type must be programmed to the
On/Off setting or to the Three-Speed Fan Setting.

Note: This feature does not shut down the vehicles


power. The ECM and the vehicle remain powered.
Table 48

Minimum

Maximum

Default

3 minutes

1440 minutes

0 minutes

Table 50

PTO Shutdown Timer Maximum


RPM
This parameter can be used to reset the PTO
shutdown timer if engine speed goes above the
programmed PTO Shutdown Timer Maximum RPM.
Programming this parameter to 2120 rpm disables
this feature. If this parameter is programmed to a
value below 2120 rpm and the PTO shutdown timer
is used, the timer will be reset when the engine rpm
exceeds the programmed value.

Alternative

Default

Continuous

Normal

i02374194

Driver Reward
SMCS Code: 1901

Driver Reward Enable


Driver Reward is used in order to promote good
habits by operators. If the vehicle is operated in a
manner that satisfies the owner, the vehicle speed
limit (VSL) is automatically increased as a reward to
the driver. If the vehicle is operated in a manner that
does not satisfy the owner, the vehicle speed limit
(VSL) is automatically decreased.
Table 51

Alternatives

Default

Disabled

Enabled

i02183252

ECM Identification Parameters


SMCS Code: 1901
g00671143

Illustration 15
PTO Shutdown Timer Maximum RPM Graph
Table 49

Minimum

Maximum

Default

600 rpm

2120 rpm

2120 rpm

Vehicle ID
Vehicle ID is the identification of the vehicle that
is assigned by the customer. Vehicle ID is used
only for the customers reference. Vehicle ID is not
required by the Engine Control Module (ECM).

48
Troubleshooting Section

SENR9698-09

i02183257

Engine/Gear Parameters
SMCS Code: 1901

Lower Gears Engine RPM Limit


The engine will accelerate at a slower rate when this
limit is exceeded under normal driving conditions.
This parameter is used to encourage the driver to
shift to the next highest gear.

Gear Down Protection RPM Limit


This parameter is the engine rpm limit when the
vehicle speed is above the Gear Down Protection
Turn On Speed. This is a hard limit. The Engine
Control Module (ECM) will not allow fuel to the engine
above this limit. This parameter is used to encourage
the driver to shift into overdrive or top gear.
Table 56

Minimum

Maximum

Default

1300 rpm

TEL rpm

TEL rpm

Table 52

Minimum

Maximum

Default

1100 rpm

TEL rpm

TEL rpm

Lower Gears Turn Off Speed


The Lower Gears Turn Off Speed parameter is
the vehicle speed which turns off the Lower Gears
Engine RPM Limit. This must be matched with the
Lower Gears Engine RPM Limit to the specific drive
train for best performance.
Table 53

Minimum

Maximum

Default

5 km/h (3 mph)

48 km/h (30 mph)

5 km/h (3 mph)

Intermediate Gears Engine RPM


Limit
This parameter is similar to the Lower Gears Engine
RPM Limit. The engine will accelerate at a slower
rate when this limit is exceeded under normal driving
conditions. This parameter is typically programmed
to a slightly higher rpm than the Lower Gears Engine
RPM Limit.

Gear Down Protection Turn On


Speed
This parameter is the vehicle speed when the
Gear Down Protection RPM Limit is turned on.
This must be matched to the specific drive train for
best performance. Above this vehicle speed limit,
the engine rpm will be limited by the Gear Down
Protection RPM Limit.
Table 57

Minimum

Maximum

Default

48 km/h (30 mph)

204 km/h
(127 mph)

204 km/h
(127 mph)

Low Idle Engine RPM


The Low Idle Engine RPM is the minimum engine
rpm.
Table 58

Minimum

Maximum

Default

600 rpm

750 rpm

600 rpm

Transmission Style

Table 54

Minimum

Maximum

Default

1100 rpm

TEL rpm

TEL rpm

Intermediate Gears Turn Off


Speed
This parameter is similar to the Lower Gears Turn
Off Speed. This parameter is typically programmed
to a slightly higher vehicle speed than the Lower
Gears Turn Off Speed.
Table 55

Minimum

Maximum

Default

8 km/h (5 mph)

80 km/h (50 mph)

8 km/h (5 mph)

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:

Brake switch (No. 2)


Clutch switch
Neutral switch
If an automatic transmission is installed, program this
parameter to one of the following options:

Automatic option 1

SENR9698-09

49
Troubleshooting Section

Automatic option 2
Automatic option 3
Automatic option 4
The manual selection requires a clutch pedal position
switch to be connected to the ECM connector
J1/P1:24. The transmission selections with a neutral
switch require a transmission neutral switch to be
connected to the ECM connector J1/P1:62. J1/P1:62
is the input 12. The transmission selections with two
brake switches require a second brake switch to be
connected to the ECM connector J1/P1:64. J1/P1:64
is the input 13.
The Eaton Top 2 transmission is a manual
transmission and the Eaton Top 2 transmission
requires a clutch switch. The ECM operates two
outputs in order to control shifting between the top
two gears of an Eaton Top 2 transmission. A total of
four parameters must be programmed for the system
to operate correctly.
Table 59

Transmission Style
Parameter Setting

Use of Switch
Service Brake No. 1

Service Brake No. 2

Clutch

Neutral

Optional

Manual Option 1

Automatic Option 1

Automatic Option 2

Optional

Automatic Option 3

Automatic Option 4

Eaton Top 2

Optional

X
X

Table 60

Alternative
Automatic Option
Automatic Option
Automatic Option
Automatic Option
Eaton Top 2

Default
1
2
3
4

Manual Option 1

Optional

Eaton Top 2 Override with Cruise


Switch
If this parameter is programmed to Yes the cruise
control On/Off switch can be used to disable Top 2
mode. If the cruise control On/Off switch is turned to
the OFF position and the transmission is not in Top 2
mode, the Top 2 mode will be disabled. This condition
is applicable to the manual mode of operation only. If
the cruise control On/Off switch is turned to the ON
position, the Top 2 mode will be enabled and the
transmission will be allowed to shift automatically
in the Top 2 gears. When the vehicle is operating
in one of the Top 2 gears and the Top 2 mode is
enabled, switching the cruise control On/Off switch to
the OFF position will place the transmission in hold
mode. When the transmission is in the hold mode,
the transmission will not shift out of the currently
selected gear. When the cruise control On/Off switch
is returned to the ON position, the transmission will
return to Top 2 mode. When the clutch is depressed
and the transmission is in the hold mode, the manual
mode will be enabled and the Top 2 will be disabled.

50
Troubleshooting Section

SENR9698-09

Table 61

Alternative

Default

Yes

No

Note: This parameter must be precisely programmed


to three decimal places to ensure the proper
operation of the Eaton Top 2 and Caterpillar engine
drive train in the top two gears.
Table 64

Top Gear Ratio


The Top Gear Ratio identifies the highest gear
ratio for an Eaton Top 2 transmission. For example,
tenth gear for an Eaton Super 10 Top 2 transmission
is the top gear. The programmable range is 0.000
to 3.750 in 0.001 increments. The default is 0.000.
Refer to Gear Ratios for Eaton Top 2 Transmission
for programmable values for each Eaton Top 2
transmission.

Minimum

Maximum

Default

0.000

3.750

0.000

Gear Ratios for Eaton Top 2


Transmission
Table 65

Note: This parameter must be precisely programmed


to three decimal places to ensure the proper
operation of the Eaton Top 2 and Caterpillar engine
drive train in the top two gears.

Transmission
Model

Top
Gear
Minus
Two
Ratio

Top
Gear
Minus
One
Ratio

Top
Gear
Ratio

RTLO-XX610B-T2

1.352

1.000

0.741

Table 62

RTLO-XX710B-T2

1.825

1.351

1.000

Minimum

Maximum

Default

RTLO-XX713A-T2

1.000

0.856

0.730

0.000

3.750

0.000

RTLO-XX718B-T2

1.000

0.856

0.730

Top Gear Minus One Ratio


The Top Gear Minus One Ratio identifies the
second highest gear ratio for an Eaton Top 2
transmission. For example, ninth gear for an Eaton
Super 10 Top 2 transmission is top gear minus
one. The programmable range is 0.000 to 3.750
in 0.001 increments. The default is 0.000. Refer
to Gear Ratios for Eaton Top 2 Transmission
for programmable values for each Eaton Top 2
transmission.
Note: This parameter must be precisely programmed
to three decimal places to ensure the proper
operation of the Eaton Top 2 and Caterpillar engine
drive train in the top two gears.
Table 63

Minimum

Maximum

Default

0.000

3.750

0.000

Top Gear Minus Two Ratio


The Top Gear Minus Two Ratio identifies the third
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.
The programmable range is 0.000 to 3.750 in
0.001 increments. The default is 0.000. Refer
to Gear Ratios for Eaton Top 2 Transmission
for programmable values for each Eaton Top 2
transmission.

Note: The XX that appears in the model number


of the transmission refers to the nominal torque
capacity. XX times 100 equals the nominal torque
capacity. For example, RTLO-14613A has a nominal
torque capacity of 14 times 100 or 1900 Nm
(1400 lb ft).
The model designation of the transmission and
other information are stamped on a tag on the
transmission. The tag is located on the lower left side
near the front of the transmission.

Governor Type
This parameter determines the type of governor that
controls the engine. Select Full Range for manual
transmissions and for electronically shifted manual
transmissions. Select Min/Max for automatic
transmissions.
The Min/Max with Speed Control option allows
the use of a full range governor when the vehicle is
not moving and the transmission is in neutral. The
Min/Max with Speed Control option is preferred
for applications that currently use the Min/Max
governor.

SENR9698-09

51
Troubleshooting Section

Coolant Level Sensor

Table 66

Alternative

Default

Min/Max
Min/Max with Speed Control

Full Range

i02103626

This parameter determines if the ECM monitors


the input signal of the coolant level sensor. This
parameter also determines the type of sensor that
is installed.
Table 69

Engine Monitoring Parameters


SMCS Code: 1901

Engine Monitoring Mode


This parameter determines the level of action that
will be taken by the Engine Control Module (ECM)
in response to a condition that has the capability to
damage the engine. The ECM reads the coolant
temperature, oil pressure and intake manifold air
temperature. If the ECM has been programmed to
monitor the OEM installed coolant level sensor, the
ECM will read that sensor.
Table 67

Alternative

Default

Derate
Shutdown

Warning

Engine Monitoring Lamps


This parameter determines the lamp requirements
for the engine monitoring system. If this parameter is
programmed to the Warning Lamp option, J1/P1:29
is available for the connection of a red warning lamp.
The warning lamp is used to alert the operator that
an engine problem is occurring. The warning lamp
also indicates when the engine is being derated or
the lamp will indicate that shutdown will take place.
If this parameter is programmed to Option 1,
there will be up to three discrete lamp outputs that
are available for use to indicate specific engine
problems. Option 1 configures J1/P1:29 for the
connection of a low oil pressure lamp and Option
1 also configures J1/P1:31 for the connection of a
high coolant temperature lamp. If a coolant level
sensor is used, then J1/P1:30 will also be available
for the connection of a low coolant level warning
lamp. If the parameter for the Coolant Level Sensor
is programmed to No, then J1/P1:30 can be used to
connect a PTO switch on lamp.
Table 68

Alternative

Default

Option 1

Warning Lamp

Alternative

Default

4 pin
2 wire Float Sensor

No

Engine Coolant Temperature


Derate Enable Status
Note: This parameter is not supported on DEC 03
and newer software. This parameter may be turned
OFF. This parameter may also be locked out.
This parameter allows the coolant temperature
derate to be enabled or disabled. When the coolant
temperature reaches 103 C (217 F) the engine
power is derated by three percent. When the coolant
temperature reaches 104 C (219 F) the engine
power is derated by six percent. 166-14 Rated
Engine Power Special Instructions becomes active
when the ECM derates power to the engine.
Note: This parameter will not disable the engine
monitoring of the engine coolant temperature. If
110-00 High Coolant Temperature Warning or 110-11
Very High Coolant Temperature is active, the ECM
will take action relative to the programming of the
Engine Monitoring Mode parameter.
Table 70

Alternative

Default

Enabled

Disabled

i01938915

Idle Parameters
SMCS Code: 1901

Idle Vehicle Speed Limit


The Idle Vehicle Speed Limit is the maximum
vehicle speed for setting or for maintaining a set
engine rpm in the idle mode. In order to enter the idle
mode, the engine rpm must be set by the Set/Resume
switch while the cruise control On/Off switch is in the
ON position. If the vehicle speed signal exceeds this
value, the engine will not maintain the set engine rpm.
Table 71

Minimum

Maximum

Default

2 km/h (1 mph)

24 km/h (15 mph)

2 km/h (1 mph)

52
Troubleshooting Section

SENR9698-09

Idle RPM Limit

Table 74

The Idle RPM Limit is the maximum engine rpm


in idle mode. The idle mode occurs if the engine
rpm is set by using the cruise control On/Off switch
and the Set/Resume switch. The actual high limit of
this parameter is determined by the programmed
top engine limit. The lower limit is determined by the
programmed Low Idle Engine rpm.

Minimum

Maximum

Default

5 rpm

500 rpm

20 rpm

i02183267

Input Selections

Programming this parameter to 600 rpm will prevent


the engine from idling at a constant rpm above the
programmed low idle rpm.

SMCS Code: 1901

Table 72

Four input connections can be used in order to


connect the Fan Override Switch. The Fan
Override Switch can be programmed to the following
connections:

Minimum

Maximum

Default

600 rpm

2120 rpm

2120 rpm

Idle/PTO RPM Ramp Rate


The Idle/PTO RPM Ramp Rate determines the rate
of the increase or of the decrease in engine rpm for
the following functions:

Fan Override Switch

J1/P1:7(Input 4)
J1/P1:47(Input 5)
J1/P1:6(Input 6)
J1/P1:46(Input 7)

Idle rpm

The J1939 data link can also be used to control the


Fan Override Switch.

PTO rpm
The parameter can be set to a value between 5 rpm
and 1000 rpm in one rpm increments.
Note: The parameter affects both idle control and
PTO control. The idle mode occurs if the engine rpm
is set by using the cruise control On/Off switch and
the Set/Resume switch. The PTO mode occurs if the
engine rpm is set by using the PTO On/Off switch
and the Set/Resume switch.
Table 73

Minimum

Maximum

Default

5 rpm/sec

1000 rpm/sec

50 rpm/sec

Idle/PTO Bump RPM


The Idle/PTO Bump RPM determines the increment
or the decrement in engine rpm when the accel
switch or the decel switch is briefly toggled. The
Idle/PTO Bump RPM also pertains to the dedicated
PTO and idle. If a PTO Engine RPM Set Speed
has been programmed, the Idle/PTO Bump RPM
pertains only to the control of the engine rpm that is
initiated by using the cruise control On/Off switch. If a
PTO engine rpm set speed has been programmed,
the Idle/PTO Bump RPM also pertains to the control
of the engine rpm that is initiated by using the PTO
On/Off switch.

This switch will allow the operator to turn on the


cooling fan at any time for improved retarding and
for braking of the engine. This will also allow better
engine cooling.
Table 75

Alternative

Default

J1/P1:7
J1/P1:47
J1/P1:6
J1/P1:46
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster

None

Transmission Neutral Switch


The Engine Control Module (ECM) receives a signal
from the transmission when the transmission is in
neutral. The signal from the transmission can be
broadcast over the J1939 data link or the signal
can be sent directly to the ECM at pin J1/P1:62. If
a transmission neutral switch is not utilized in the
configuration, this parameter must be programmed
to None.

SENR9698-09

53
Troubleshooting Section

PTO On/Off Switch

Table 76

Alternative

Default

J1939
J1/P1:62

None

Ignore Brake/Clutch Switch


The Input 5 to the ECM can be used to connect
an Ignore Brake/Clutch Switch. The Ignore
Brake/Clutch Switch is used for applications that
require the mobile use of the vehicle with a set PTO
engine set rpm that does not require the brake or the
clutch to disengage the engines PTO operation. This
parameter (Ignore Brake/Clutch Switch) must be
programmed to J1/P1:47 to enable this feature.
Table 77

Alternative

Default

J1/P1:47

None

Torque Limit Switch


The Input 4 to the ECM can be used to connect the
Torque Limit Switch in order to limit the engine
torque to a programmable value. Only use this switch
for temporary protection of equipment. The Torque
Limit Switch parameter cannot be programmed if the
PTO Configuration is programmed to Off. If the
PTO Configuration is programmed to Off, the ECM
will ignore the Torque Limit Switch. This parameter
(Torque Limit Switch) must be programmed to
J1/P1:7 to enable this feature.
Table 78

Alternative

Default

J1/P1:7

None

Diagnostic Enable
The J1939 data link and input 7 can be used
to connect the Diagnostic Enable. Diagnostic
flash codes can be prompted by using the
Diagnostic Enable. To initiate the flash codes,
depress the momentary Diagnostic Enable until
the check engine lamp begins to flash. Refer to
Troubleshooting, Diagnostic Codes for additional
information regarding flash codes.
Table 79

Alternative

Default

J1/P1:46
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster

None

This parameter allows the connection of a PTO


On/Off Switch using either the J1939 data link or
J1/P1:56.
Table 80

Alternative

Default

J1939 - Body Controller


J1939 - Cab Controller
J1939 - Instrument Cluster

J1/P1:56

Remote PTO Set Switch


The J1939 data link and input 2 can be used
to connect the Remote PTO Set Switch. The
Remote PTO Set Switch is used when the PTO
Configuration is programmed to Remote Switches
and the PTO On/Off switch is in the ON position.
Table 81

Alternative

Default

J1939 - Body Controller


J1939 - Cab Controller
J1939 - Instrument Cluster
None

J1/P1:58

Remote PTO Resume Switch


The J1939 data link and input 3 can be used to
connect the Remote PTO Resume Switch. The
Remote PTO Resume Switch is used when the
PTO Configuration is programmed to Remote
Switches and the PTO On/Off switch is in the ON
position.
Table 82

Alternative

Default

J1939 - Body Controller


J1939 - Cab Controller
J1939 - Instrument Cluster
None

J1/P1:60

PTO Engine RPM Set Speed Input


A
The PTO Engine RPM Set Speed Input A switch can
be connected to any one of the following locations:
J1/P1:6, J1/P1:46, J1/P1:58, J1/P1:60, and J1939
data link. If the PTO Engine RPM Set Speed Input
A parameter is programmed to the corresponding
switch input option, the switch is used to control
engine speed during PTO operation. The PTO
Configuration parameter must be programmed to
Cab Switches, to Remote Switches or to Remote
Throttle and the PTO Engine RPM Speed Input A
parameter must be programmed to a valid speed.

54
Troubleshooting Section

SENR9698-09

Two-Speed Axle Switch

Table 83

Alternatives

Default

J1/P1:6
J1/P1:46
J1/P1:58
J1/P1:60
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster

None

PTO Engine RPM Speed Input B


The PTO Engine RPM Set Speed Input B switch can
be connected to any one of the following locations:
J1/P1:6, J1/P1:46, J1/P1:58, J1/P1:60, and J1939
data link. If the PTO Engine RPM Set Speed Input
B parameter is programmed to the corresponding
switch input option, the switch is used to control
engine speed during PTO operation. The PTO
Configuration parameter must be programmed to
Cab Switches, to Remote Switches or to Remote
Throttle and the PTO Engine RPM Speed Input B
parameter must be programmed to a valid speed.

The J1939 data link and input 6 to the ECM is used to


connect the Two-Speed Axle On/Off Switch. When
a two-speed axle is used, the change in gear ratios
from the high speed range to the low speed range
alters the calibration of the vehicle speed signal.
When this parameter is programmed to J1/P1:6 or
J1939 and the switch is in the ON position the ECM
automatically adjusts the vehicle speed calibration.
This will ensure that the ECM driven speedometer
and the information that is stored in the ECM correctly
reflect the actual vehicle speed. The High Speed
Range Axle Ratio and Low Speed Range Axle
Ratio must also be programmed for this feature to
function correctly.
Table 86

Alternative

Default

J1/P1:6
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster

None

Cruise Control On/Off Switch

Table 84

Alternatives

Default

J1/P1:6
J1/P1:46
J1/P1:58
J1/P1:60

None

Starting Aid On/Off Switch


The Starting Aid On/Off Switch can be connected
to either of the following locations: J1/P1:6, J1/P1:7,
J1/P1:46, and J1/P1:47. The starting aid system
does not require a switch for automatic operation. A
switch can be installed in order to allow the operator
to disable the automatic starting aid. If a switch
is installed and the Starting Aid On/Off Switch
parameter is programmed to the corresponding
switch input, the switch will control the starting aid
system. When the switch is in the ON position, the
starting aid system will automatically enable the
starting aid output when conditions require the use of
a starting aid. When the switch is in the OFF position,
the starting aid system will not function.
Table 85

Alternatives

Default

J1/P1:6
J1/P1:7
J1/P1:46
J1/P1:47

None

The Cruise Control On/Off input circuit is available


for the connection of a Cruise Control On/Off Switch
to ECM connector J1/P1:59 or the J1939 data link.
This switch is used to enable cruise control when the
vehicle is moving. Also, this switch is used to control
the engine idle rpm when the vehicle is stationary.
Table 87

Alternative

Default

J1939 - Body Controller


J1939 - Cab Controller
J1939 - Instrument Cluster

J1/P1:59

Cruise Control Set/Resume/Accel/


Decel Switch
The Cruise Control Set/Resume input circuits
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 must
be connected to J1/P1:35 and the Resume input
must be connected to J1/P1:44. This switch is used
in conjunction with the cruise control On/Off Switch
to perform the following functions:

Control the operation of the cruise control while the


vehicle is moving.

Adjust the engine idle rpm while the vehicle is


stationary.

SENR9698-09

55
Troubleshooting Section

Enable the diagnostic flash codes on the check

Table 91

engine lamp.

When the PTO Configuration is programmed to


Cab Switches, the cruise control Set/Resume
switch is also used with the PTO On/Off switch to
control the engine rpm in PTO mode.
Table 88

Alternative

Default

J1939 - Body Controller


J1939 - Cab Controller
J1939 - Instrument Cluster

J1/P1:35 & 44

Cruise Control Pause Switch


This parameter configures an input for use as a
cruise control pause switch. This functionality is only
available for use over a J1939 data link.
Table 89

Alternative

Default

J1939 - Body Controller


J1939 - Cab Controller
J1939 - Instrument Cluster

None

Clutch Pedal Position Switch


The input for the Clutch Pedal Position Switch is
available for the connection of a clutch pedal position
switch to ECM connector J1/P1:22 or the J1939
data link. This input is used when the Transmission
Style is programmed to the manual mode. When the
Transmission Style is programmed to the manual
mode, an input that is used to determine the position
of the clutch pedal is required.
Table 90

Alternative

Default

J1939 - Body Controller


J1939 - Cab Controller
J1939 - Instrument Cluster

J1/P1:22

Alternative

Default

J1939 - Body Controller


J1939 - Cab Controller
J1939 - Instrument Cluster

J1/P1:23 & 40

Service Brake Pedal Position


Switch #1
The Input for Service Brake Pedal Position Switch
1 is available for the connection of a service brake
pedal position switch. The Service Brake Pedal
Position Switch 1 can be connected by using the
J1939 data link or by using ECM connector J1/P1:45.
The input is used to determine the position of the
service brake pedal. The position of the service brake
pedal can affect the following functions:

Cruise
Idle
PTO
Idle shutdown
Table 92

Alternative

Default

J1939 - Body Controller


J1939 - Cab Controller
J1939 - Instrument Cluster

J1/P1:45

Accelerator Pedal Position


The Input for the Accelerator Pedal Position is
available for the connection of an accelerator pedal
position sensor. The Sensors signal line should
be connected to ECM connector J1/P1:66. This
parameter (Accelerator Pedal Position) must be
programmed to J1/P1:66. The input is used to
determine the position of the accelerator pedal.
Table 93

Alternative

Retarder Off/Low/Med/High
Switch
The input for the Retarder Solenoid Low/Hi Switch
and the input for the Retarder Solenoid Med/Hi
Switch are available for the connection of a selector
switch for engine retarder solenoid. The retarder
switch can be connecting using the J1939 data link
or using J1/P1:23 & 40. If J1/P1:23 & 40 is used, the
low/hi input must be connected to ECM connector
J1/P1:23 and the med/hi Input must be connected to
ECM connector J1/P1:40. This switch controls the
operation of the engine retarder solenoids.

Default
J1/P1:66

Vehicle Speed Input


The ECM has an input circuit that can be used to
receive vehicle speed information. The ECM input
can receive the vehicle speed information in either of
the following ways:

A vehicle speed sensor can be connected to the


input.

A signal wire from an electronic control can be


connected to the input.

56
Troubleshooting Section

SENR9698-09

The Vehicle Speed Input parameter must be


programmed to J1/P1:32 & 33 to use this option.
The ECM can also be configured to receive vehicle
speed information from an electronic transmission
control unit via the J1939 data link. The transmission
must be capable of supporting the J1939 ETC1
Broadcast Message. The Vehicle Speed Input
must be programmed to J1939-Trans.
The ECM can also be configured to receive vehicle
speed information from the ABS via the J1939 data
link. The ABS must be capable of supporting the
J1939 High Resolution Wheel Speed Broadcast
Message. The Vehicle Speed Input must be
programmed to J1939-ABS.
Table 94

Alternative

Default

J1939 - ABS
J1939 - Trans

J1/P1:32 & 33

Table 96

Manual Distance
Minimum

Maximum

Default

8050 km
(5000 miles)

56325 km
(35000 miles)

24140 km
(15000 miles)

Table 97

Manual Hours
Minimum

Maximum

Default

100

750

300

Engine Oil Capacity


The PM 1 Interval can be determined by the
ECM. The ECM bases the PM 1 Interval on fuel
usage. This parameter (Engine Oil Capacity)
can be programmed only when the Maintenance
Indicator Mode is programmed to an automatic
mode (distance or hours). Capacity of the sump
influences the maintenance interval.

i01945507

Maintenance Parameters

Table 98

SMCS Code: 1901

Minimum

Maximum

Default

19 L (20 qt)

57 L (60 qt)

Refer to Table
99.

Maintenance Indicator Mode


Table 99

The Engine Control Module (ECM) records data that


is related to the vehicles maintenance. If distance
is selected, all maintenance indications on the
service tool will be displayed in distance. Typical
maintenance indications are PM 1, PM 2 and the
cooling system clean/flush.
If hour is selected, all maintenance indications on
the service tool will be displayed in hours. Typical
maintenance indications are PM 1, PM 2 and the
cooling system clean/flush. The ECM provides
PM 1 maintenance interval and last maintenance
information.
Table 95

Alternative

Default

Manual Distance
Manual Hours
Automatic Distance
Automatic Hours

Off

PM 1 Interval
The PM 1 Interval allows a maintenance interval
(PM 1) to be specified by the user. This parameter
(PM 1 Interval) can be programmed only when the
Maintenance Indicator Mode is programmed to a
manual mode (distance or hours).

(1)

Engine Model

Default

C11 and C13

34 L (36 qt)

C15

38 L (40 qt)(1)

The C15 Engine with a Front Sump BrakeSaver should be


programmed to 49 L (52 qt).

SENR9698-09

57
Troubleshooting Section

i02183296

Output Selections
SMCS Code: 1901

Engine Running Output


Output 2, output 3, or output 4 is available for the
connection of an engine running output relay that
is used to prevent engagement of the starter while
the engine is running. The Engine Running Output
can be programmed to J1/P1:10, to J1/P1:12 or to
J1/P1:13. The Engine Running Output comes on
when the engine is running. The Engine Running
Output turns off when the engine rpm is 0. The relay
is normally closed so cranking can be achieved
immediately at powerup. During cranking, the
Engine Control Module (ECM) energizes the Engine
Running Output once engine low idle rpm has been
achieved. The relay is de-energized when the engine
speed falls by 100 rpm below the programmed low
idle. The programmed low idle range is 600 rpm to
750 rpm.
Table 100

Alternative

Default

J1/P1:10
J1/P1:12
J1/P1:13

None

Auxiliary Brake
The auxiliary brake output is for use with a
BrakeSaver or other aftermarket braking devices.
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.
Table 102

Table 101

Alternative

Default

J1/P1:10
J1/P1:12
J1/P1:13

None

Default

J1/P1:12

None

Starting Aid Output


Output 2, output 3 or output 4 is available for the
connection of the starting aid relay or the starting
aid solenoid. If a starting aid switch is not used, the
starting aid output will turn on automatically when
operating conditions require the use of a starting
aid. If the Starting Aid On/Off Switch parameter
is programmed and a switch connected to the
corresponding switch input, the starting aid output will
not function when the switch is in the OFF position.
Table 103

Engine Shutdown Output


Output 2, output 3 or output 4 is available for the
connection of an engine shutdown output relay that is
used to shut down the vehicle electrical system after
the idle timer has expired. The Engine Shutdown
Output can be programmed to J1/P1:10, to J1/P1:12
or to J1/P1:13. The Engine Shutdown Output
comes on after the engine runs for more than three
seconds. The Engine Shutdown Output turns off
when the engine rpm is at least 100 rpm below the
low idle rpm for more than three seconds.

Alternative

Alternatives

Default

J1/P1:10
J1/P1:12
J1/P1:13

None

Air Inlet Shutoff Relay Control


The air inlet shutoff is available for certain engine
ratings that operate in areas with large amounts of
combustible gases. The air inlet shutoff will protect
the engine from an engine overspeed when these
gases are present. If this option is installed, the Air
Inlet Shutoff Relay Control cannot be turned off.
J1/P1:62 must be connected to the +Battery in order
for the air inlet shutoff to operate. If a neutral switch
is installed in the vehicle, the neutral switch must be
connected to J1/P1:62. The air inlet shutoff will only
operate when the transmission is in neutral.
Table 104

Alternatives

Default

J2/P2:13

None

58
Troubleshooting Section

SENR9698-09

Fan Control Type

i02048633

If the ECM is used to operate the cooling fan, this


parameter must be programmed to On/Off, to
Three-Speed Fan, or to Variable Speed Fan Option
S. This parameter must be programmed to None
if the ECM is not operating the cooling fan relay or
the cooling fan solenoid.

Default

On/Off PWM
On/Off DC
Three-Speed Fan PWM
Three-Speed Fan DC
Variable Speed Fan
Option S

None

SMCS Code: 1901

Rating Number
The rating number is the selected rating within a
power rating family. The personality module defines
the power rating family (242 kW (325 hp)) and the
personality module may contain only one or several
ratings. The rating number defines the power rating
that is used within the power rating family. The
following list illustrates examples of the power rating:

Table 105

Alternative

Selected Engine Rating

324 kW (435 hp) at a governed engine speed of


1800 rpm

PTO Active Output

324 kW (435 hp) at a governed engine speed of


2100 rpm

The PTO Active Output parameter allows the use


of an output when the engine is in PTO mode. The
PTO switch must be on in order for the PTO Active
Output to function. The PTO Active Output will stay
active until there is a kickout of PTO mode or the
PTO switch is turned to the OFF position.
Table 106

Alternative

Default

J1/P1:19

None

i02183321

Security Access Parameters


SMCS Code: 1901

ECM Wireless Communication


Enable
The ECM Wireless Communication Enable
determines if the Engine Control Module (ECM) will
transfer information over the data link through remote
communications systems for customers.
The parameter will default out of Caterpillar to no
access. The parameter can only be enabled by
getting factory passwords. This feature can only
be enabled after the truck has been delivered to
the customer. Refer to Troubleshooting, System
Overview for additional information.
Table 107

Alternative

Default

Yes

No

Both ratings will be displayed for multitorque


applications.

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 multitorque 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 108

Programmable Option

Turn On Ratio (RPM


to MPH)

MT-A

27.9

MT-B

33.0

MT-C

38.0

Note: This feature is not used with standard engine


ratings. This feature is only available for multitorque
ratings.

SENR9698-09

59
Troubleshooting Section

Table 109

Type of Engine
Rating

Alternatives

Standard
Ratings

Unavailable

Unavailable

Multitorque
Ratings

MT-B
MT-C

MT-A

Default

Note: This feature does not shut down the vehicles


power. The ECM and the vehicle remain powered.
Table 111

i02183325

Smart Idle Parameters


SMCS Code: 1901

Battery Monitor & Engine Control


Voltage
This parameter is used to determine the voltage trip
point. Below this trip point, the Engine Control Module
(ECM) will automatically elevate engine idle in order
to maintain ideal battery voltage. This feature is used
to promote additional battery life. The engine idle will
only be increased if the vehicle is stopped and the
transmission is out of gear. If these conditions are
not met, the engine idle will not be adjusted. This
feature will not function when the engine is operating
in dedicated PTO mode (PTO On/Off switch in the
ON position).
The recommended setting is 12.2 Volts for a 12 Volt
system, and 24.5 Volts for a 24 Volt system.
Note: This feature requires the installation of a
Neutral Switch on J1/P1. This is terminal 62 (Input
12). Engine speed will only be elevated when the
transmission is in Neutral.

Minimum

Maximum

Default

3 minutes

1440 minutes

0 minutes

Idle Shutdown Timer Maximum


RPM
This parameter can be used to reset the Idle
Shutdown Timer if engine speed goes above the
programmed Idle Shutdown Timer Maximum RPM.
Programming this parameter to 2120 rpm disables
this feature. By disabling this feature, the Idle
Shutdown Timer cannot be overridden by increasing
the engine rpm. If this parameter is programmed to
a value below 2120 rpm and the PTO Shutdown
Timer is used, the timer will be reset when the
engine rpm exceeds the programmed value.
Table 112

Minimum

Maximum

Default

600 rpm

2120 rpm

2120 rpm

Allow Idle Shutdown Override


This parameter determines if the clutch or the service
brake can be used to override the idle shutdown
timer during the driver alert. The driver alert is
the last 90 seconds when the check engine lamp
begins flashing. This parameter requires the Idle
Shutdown Time to be programmed to three or more
minutes for the parameter to be enabled. When the
Idle Shutdown Time is programmed to zero, the
parameter is turned off.

Table 110

Minimum

Maximum

Default

0 Volts

25.5 Volts

0 Volts

i02183329

Timer Parameters
SMCS Code: 1901

Idle Shutdown Time


The Idle Shutdown Time is the time (minutes) of
engine idle before shutting down. The engine will
only shut down if the Engine Control Module (ECM)
senses low engine load and no vehicle speed.
The idle shutdown timer will not begin counting
if the engine is in cold mode. If this parameter is
programmed to zero, this feature is disabled and the
engine will idle until the key switch is in the OFF
position.

In order to override the timer under the following


conditions, depress the clutch or the service
brake if the parameter is programmed to Outside
Temperature Based or J1587 Outside Temperature
Based and the driver alert is activated. Depression of
the clutch or the service brake will override the timer:

The outside temperature is below the programmed


Minimum Idle Shutdown Outside Temperature.

The outside temperature is above the Maximum


Idle Shutdown Outside Temperature.

Note: When the timer is overridden, the engine will


not shut down.

60
Troubleshooting Section

SENR9698-09

If the outside temperature is between the Minimum


Idle Shutdown Outside Temperature and the
Maximum Idle Shutdown Outside Temperature,
the timer is not overridden and the engine will shut
down. If the Outside Temperature Based option
is programmed, an air temperature sensor must be
installed in order to measure the outside temperature.
If the sensor is not installed, 171-03 Ambient Air
Temperature voltage high will be active for the sensor.
If the J1587 Outside Temperature Based option is
programmed and 171-11 Ambient Air Temperature
Data Lost is active, the idle shutdown timer will be
disabled.
Table 113

Alternative

Default

No
Outside Temperature Based
(J1587) Outside Temperature
Based

Yes

Maximum Idle Shutdown Outside


Temperature
This parameter determines the upper outside
temperature limit when the Allow Idle Shutdown
Override is programmed to one option of the options
that follow:

Outside Temperature Based


J1587 Outside Temperature Based
Illustration 16 indicates that the Allow Idle Shutdown
Override is allowed in the final 90 seconds of the
timers countdown. During the final 90 seconds, one
of the following conditions must exist in order for the
engine to be shut down:

The outside temperature is below the programmed


Minimum Idle Shutdown Outside Temperature.

Minimum Idle Shutdown Outside


Temperature
This parameter determines the lower outside
temperature limit when the Allow Idle Shutdown
Override is programmed to one option of the options
that follow:

Outside Temperature Based


J1587 Outside Temperature Based
Table 114

Minimum

Maximum

Default

40 C (40 F)

49 C (120 F)

49 C (120 F)

The outside temperature is above the Maximum


Idle Shutdown Outside Temperature.

Table 115

Minimum

Maximum

Default

40 C (40 F)

49 C (120 F)

49 C (120 F)

A/C Switch Fan-On Time


The input 11 to the ECM can be used for the
connection of a normally closed high pressure A/C
switch. The ECM has a built-in timer. The timer is
used to prevent excessive cycling of the cooling
fan clutch due to successive cycling of the A/C
switch. Programming this parameter to 0 disables the
function. Programming depends on the refrigerant,
and the design of the air conditioning system as well
as the use of the signal input. Program the timer to
one second for the connection of this input to another
system. Programming the timer to one second also
provides a time delay. This feature requires the Fan
Control Type to be programmed to the On/Off or the
Three-Speed Fan.
Table 116

Illustration 16

g00631057

The Allow Idle Shutdown Override is programmed to the Outside


Temperature Based option or to the Outside Temperature Based
(J1587) option.

Minimum

Maximum

Default

1 second

600 seconds

0 seconds

SENR9698-09

61
Troubleshooting Section

Fan with Engine Retarder in High


Mode
This parameter determines whether the cooling fan
will turn on when the engine brake has been active
for at least two seconds. This feature requires the
Fan Control Type to be programmed to On/Off or
to Three-Speed Fan. An ECM controlled fan must
be installed in order for this parameter to function.

g00629908

Illustration 17

OLD FCF Fuel correction factor in ECM

Table 117

Alternatives

Default

Yes

No

TANK Actual fuel economy


ECM Fuel economy in ECM stored trip data

Engine Retarder Delay


This parameter provides a programmable delay
after provisions to turn on the engine retarder or the
engine brake are met.

Refer to Illustration 18 as an example. The actual


tank fuel economy is 7.1 mpg. The fuel economy in
the ECM stored trip data is 7.0 mpg over the same
distance with an old FCF of 2.5.

Table 118

Minimum

Maximum

Default

0 seconds

3 seconds

0 seconds

i02183335

Trip Parameters
SMCS Code: 1901

Fuel Correction Factor

g00629939

Illustration 18

The Fuel Correction Factor is available to fine tune


all fuel data that will be stored in the future by the
ECM. Caterpillar recommends changing this factor
only after a significant operating interval that includes
a comparison of actual tank fuel economy to the
fuel economy that is recorded in the Engine Control
Module (ECM). The operating interval should also
reflect a typical route. The fuel correction factor (FCF)
is a percentage that is programmable in 0.5 percent
increments.

Dash - Change Fuel Correction


Factor
This parameter allows the driver to adjust the Fuel
Correction Factor. An owner/operator would want
the driver to be able to change this information, but a
fleet operation might not want the driver to be able to
change this information.
Table 120

Table 119

Minimum

Maximum

Default

Alternative

Default

63.5

+63.5

Yes

No

Calculating Fuel Correction Factor

Dash - PM 1 Reset

The following formula should be used to determine


the new FCF.

This parameter determines the drivers access for


resetting the PM 1 (maintenance) after the PM 1 has
been performed. The maintenance indicator mode
cannot be programmed to Off for the PM 1 Reset
parameter to take effect.

62
Troubleshooting Section

SENR9698-09

Theft Deterrent Password

Table 121

Alternative

Default

Yes

No

Dash - Fleet Trip Reset


This parameter determines the drivers access for
resetting the fleet trip segment.

The Theft Deterrent Password is the password


that is required by the ECM before the feature of
theft deterrent is enabled. After the theft deterrent
is enabled, the Theft Deterrent Password is the
password that is required to restart the engine. All of
the characters must be in the upper case.
Table 125

Alternative

Default

Four Characters
A through Z
0 through 9

0000

Table 122

Alternative

Default

Yes

No

Dash - State Selection

Quick Stop Rate

Program this parameter to NO to disable this function


of Messenger. Messenger will not show State
Selection as an option to the driver. If this parameter
is programmed to YES (default), Messenger will
provide the feature of State Selection.

This parameter determines the rate of vehicle speed


change that is used by the ECM to record a quick stop
event code and a quick stop snapshot. Programming
this parameter to zero will disable this feature and
no quick stop events will be logged. Each quick stop
snapshot contains 60 frames of information. The no.
45 frame is the quick stop event. The quick stop
snapshot also contains 44 frames before the quick
stop event and 15 frames after the quick stop event.
Each frame is separated by 1.0 second.

Programming this parameter to NO eliminates


State Selection. Therefore, the storage of the trip
data (State Selection) is eliminated.
Table 123

Alternative

Default

No

Yes

Theft Deterrent System Control


When this parameter is used with a Theft Deterrent
Password, this parameter prevents the engine from
starting unless the password has been entered via
the dash display of Messenger. Before the operator
can use the feature of theft deterrent of Messenger,
the system must be turned on. In order to turn on the
theft deterrent, the Caterpillar Electronic Technician
(ET) must be used to program the parameter for the
theft deterrent to Yes. The operator must first enter
the password before the engine is shut off. This will
enable the system. Enabling the system prevents the
engine from starting without re-entering the password
on the next attempted start.
Note: After the Theft Deterrent System Control
parameter is set to Auto-Enabled, the Theft
Deterrent Password is the password that is required
to restart the engine.
Table 124

Alternative

Default

Yes
Auto-Enable

No

Table 126

ECM Snapshot Frame Data


Engine rpm
Throttle Position
Clutch Switch

Vehicle Speed
Cruise Status
Brake Switch

The most recent quick stop snapshot is stored in


the ECM memory. When a quick stop event occurs
the ECM replaces the old quick stop snapshot with
the new quick stop snapshot. The ECM also logs a
diagnostic event code for each quick stop event. The
ECM stores a maximum of 255 occurrences.
Table 127

Alternative

Default

5 km/h per second (3


mph per second) to 24 km
per hour per second (15
mph per second)

0 kilometers per hour


per second (0 miles per
hour per second)

Note: Programming the Quick Stop Rate too low


will cause an excessive number of quick stop event
codes. A vehicle without a load or a trailer will be
able to stop much more quickly than a vehicle with
a heavy load. If too many quick stop event codes
are being logged, the Quick Stop Rate should be
increased. This will improve the detection of the
exceptions when the exceptions occur.

SENR9698-09

63
Troubleshooting Section

Vehicle Overspeed Threshold


This parameter determines the trip point for the 84-00
Vehicle Overspeed Warning. If the vehicle speed
exceeds the programmed value, the event will be
recorded in the ECM.
Table 128

Minimum

Maximum

Default

48 km/h (30 mph)

204 km/h
(127 mph)

204 km/h
(127 mph)

i01762713

Vehicle Activity Report


Parameters
SMCS Code: 1901

Minimum Idle Time

i02183346

Vehicle Speed Parameters


SMCS Code: 1901

Vehicle Speed Calibration


The Vehicle Speed Calibration is the value that is
used by the Engine Control Module (ECM) in order to
translate the vehicle speed signal into kilometers per
hour (miles per hour). This parameter is programmed
in pulses per kilometer (PPKM) or pulses per mile
(PPM). This parameter must be programmed. If
the Vehicle Speed Calibration parameter is not
programmed, 253-02 Check Customer or System
Parameters will be active. This parameter affects
the cruise control and the ECM speedometer signal.
Also, this parameter can affect the PTO operation,
extended idle and trip totals.
Table 130

The Vehicle Activity Report provides a log of


engine operation in chronological order. This report
records the following items: vehicle starts, vehicle
stops, idle time, driving time, and PTO time.
The Minimum Idle Time parameter can be used to
adjust the recorded idle time. This is done in order
to remove the time for the following occurrences:
stopped in traffic, switching into PTO mode and
switching out of PTO mode, and idling for other
brief periods of time. If the Minimum Idle Time is
programmed to a value above 0 minutes (default),
the previous mode of operation will be logged until
the idle time exceeds the programmed limit.
Table 129

Minimum

Maximum

Default

0 Minutes

1440 Minutes

0 Minutes

Minimum

Maximum

Default

2485 PPKM
(4000 PPM)

93226 PPKM
(150000 PPM)

8696 PPKM
(14000 PPM)

Vehicle Speed Cal (J1939-Trans)


The Vehicle Speed Cal (J1939-Trans) is used
when the ECM is configured to use the speed of
the transmission output shaft in order to calculate
vehicle speed. The Vehicle Speed Input parameter
must be programmed to Vehicle Speed Cal
J1939-Trans. This value represents the revolution
of the transmission output shaft as revolutions per
kilometer (revolutions per mile). This parameter must
be programmed. If this parameter is not programmed,
253-02 Check Customer or System Parameters
will be active. This parameter affects the cruise
control and the ECM speedometer signal. Also, this
parameter can affect the PTO operation, extended
idle and trip totals.
Table 131

Minimum

Maximum

Default

43000
revolutions per
km
65000
revolutions per
mile

64
Troubleshooting Section

SENR9698-09

Vehicle Speed Cal (J1939 ABS)

VSL Protection

The Vehicle Speed Cal (J1939-ABS) is used to


calculate vehicle speed by using the input from the
wheel speed. The data from the wheel speed is
transmitted via the J1939 data link. The Vehicle
Speed Input parameter must be programmed to
Vehicle Speed Cal J1939-ABS. The manufacturer
of the ABS must transmit tire revolutions per mile that
is based on the tire size. If the tire size is changed
from the tire size that is programmed in the ABS the
Vehicle Speed Cal (J1939-ABS) must be changed.
The value that is contained in the Vehicle Speed
Cal (J1939-ABS) parameter is a ratio. If the actual
tire size is equal to the tire size that is programmed
in the ABS, the Vehicle Speed Cal (J1939-ABS)
parameter will be 1. The ratio can be found by
dividing the tire revolutions per mile that is transmitted
by the ABS by the actual tire revolutions per mile.
Contact the manufacturer of the ABS in order to
verify that this message is supported.

The VSL Protection is the maximum engine rpm


when there is a problem with the vehicle speed signal
that is detected by the ECM. The ECM limits the
engine to this engine rpm when the ECM senses
no vehicle speed signal, and a load on the engine.
This is a feature that is used to prevent tampering by
running without a vehicle speed input to the ECM.

If the Vehicle Speed Input parameter is programmed


to Vehicle Speed Cal J1939-ABS, this parameter
must be programmed. If this parameter is not
programmed, 253-02 Check Customer or System
Parameters will be active. This parameter affects
the cruise control and the ECM speedometer signal.
Also, this parameter can affect the PTO operation,
extended idle and trip totals.

Tachometer Calibration

Table 132

Minimum

Maximum

Default

6.550

Vehicle Speed Limit (VSL)


The Vehicle Speed Limit (VSL) is the maximum
vehicle speed that is allowed by the ECM. The ECM
will shut off fuel above this speed. An inexperienced
driver may think that something is wrong with the
engine because the ECM will not fuel the engine
above this vehicle speed limit. Vehicle speed limiting
allows the implementation of a gear fast/run slow
specification for the truck. The gear fast/run slow
specification for the truck improves fuel economy
while the parameter for the vehicle speed limit limits
the maximum vehicle speed of the truck.
Note: The driver reward can be used to automatically
adjust the VSL according to the drivers operating
techniques.
Table 133

Minimum

Maximum

Default

48 km/h (30 mph)

204 km/h
(127 mph)

204 km/h
(127 mph)

Note: When this parameter is programmed to the


programmed TEL rpm, the ECM disables 84-01
Vehicle Speed loss of signal and 84-10 Vehicle
Speed signal rate of change and the VSL Protection
may be exceeded by disconnecting the vehicle speed
sensor.
Table 134

Minimum

Maximum

Default

1000 rpm

TEL rpm

TEL rpm

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.
Table 135

Minimum

Maximum

Default

12.0 PPR

500.0 PPR

113.0 PPR

Soft Vehicle Speed Limit


The Soft Vehicle Speed Limit operates in
conjunction with the Vehicle Speed Limit. The Soft
Vehicle Speed Limit limits the vehicle speed within
the following range:

The minimum value is 4 km/h (2.5 mph) below the


programmed Vehicle Speed Limit at full load.

The maximum value is 4 km/h (2.5 mph) above the


selected Vehicle Speed Limit at no load.

Table 136

Alternative

Default

Yes

No

SENR9698-09

65
Troubleshooting Section

Two Speed Axle - Low Speed


Range Axle Ratio
The Two Speed Axle - Low Speed Range Axle
Ratio must be programmed when a Two-Speed
Axle On/Off Switch is used by the ECM to adjust
the Vehicle Speed Calibration. When a two-speed
axle is used, the change in gear ratios from the
high speed range to the low speed range alters the
calibration of the vehicle speed signal. Since the
vehicle speed signal has been altered, a calibration
adjustment is required to ensure that the ECM driven
speedometer and the information that is stored in
the ECM correctly reflect the actual vehicle speed.
This parameter must be programmed to the actual
value of the axle ratio for the low speed range. This
parameter only requires programming when the
Two-Speed Axle Switch parameter is enabled.
Table 137

Minimum

Maximum

Default

1.00

19.99

1.00

Nominal Axle Ration - High Speed


Range Axle Ratio
The Nominal Axle Ration - High Speed Range Axle
Ratio must be programmed when a Two-Speed
Axle On/Off Switch is used by the ECM to adjust
the Vehicle Speed Calibration. When a two-speed
axle is used, the change in gear ratios from the
high speed range to the low speed range alters the
calibration of the vehicle speed signal. Since the
vehicle speed signal has been altered, a calibration
adjustment is required to ensure that the ECM driven
speedometer and the information that is stored in the
ECM correctly reflect the actual vehicle speed. This
parameter must be programmed to the actual value
of axle ratio for the high speed range. This parameter
only requires programming when the Two-Speed
Axle Switch parameter is enabled.
Table 138

Minimum

Maximum

Default

1.00

9.99

1.00

66
Troubleshooting Section

SENR9698-09

System Configuration
Parameters
i02306927

When a flash file is loaded into a new ECM, the ECM


stores the personality module code into memory.
When a different flash file is loaded into an ECM, the
ECM compares the new personality module code
with the personality module code that is stored in
memory. The ECM causes the following conditions to
occur if the personality module codes do not match:

System Configuration
Parameters

The engine speed is limited to low idle.

SMCS Code: 1901

A 253-02 diagnostic code is activated. Personality

System configuration parameters affect the emissions


of the engine or the power of the engine. The
parameters are stored in the Engine Control Module
(ECM). Use the Caterpillar Electronic Technician (ET)
to view the values of the parameters and change the
values of the parameters. The following information
describes the parameters:

Full Load Setting


The Full Load Setting (FLS) represents an
adjustment to the fuel system that was made at the
factory in order to fine tune the fuel system. The
correct value for this parameter is stamped on the
engine information plate.
A new ECM requires this parameter to be
programmed. FLS will be displayed beneath the
253-02 diagnostic code until the FLS is programmed.
Factory passwords are not required in order to
program the FLS into a new ECM.
Factory passwords are required to change the FLS
after an FLS has been programmed.

Full Torque Setting


Full Torque Setting (FTS) is similar to Full Load
Setting.
A new ECM requires this parameter to be
programmed. FTS will be displayed beneath the
253-02 diagnostic code until the FTS is programmed.
Factory passwords are not required in order to
program the FTS into a new ECM.
Factory passwords are required to change the FTS
after an FTS has been programmed.

Personality Module Code


Every flash file contains a personality module
code. The personality module code indicates the
horsepower family and the emission certification of
the flash file.

Module Code is displayed beneath the code.

Perform one of the following actions in order to


correct the condition:

Obtain factory passwords. Factory passwords will


allow you to change the personality module code.

Load the correct flash file into the ECM.

SENR9698-09

67
Troubleshooting Section

Troubleshooting without a
Diagnostic Code
i02183349

Can Not Reach Top Engine


RPM
SMCS Code: 1915-035

Probable Causes
Note: If this problem occurs under load, refer to
Troubleshooting, Low Power/Poor or No Response
to Throttle.
The probable root causes are listed in order below:

Lower Gears Engine RPM Limit


Intermediate Gears Engine RPM Limit
Gear Down Protection Engine RPM Limit
Top Engine Limit Engines with software
prior to DEC 02

VSL Protection
PTO Top Engine Limit with the PTO On/Off
Switch turned ON.

PTO Vehicle Speed Limit with the PTO


On/Off Switch turned ON.

d. Set each parameter to the parameters


maximum value one at a time and determine
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
Accelerator pedal position sensor
Vehicle speed signal
Fuel supply
Power train data link
Air intake and exhaust system

Recommended Actions
1. Check for diagnostic codes.
a. Connect the Caterpillar Electronic Technician
(ET) to the data link connector.
b. Check for active diagnostic codes and/or
logged diagnostic codes.
Certain diagnostic codes will limit the engine
speed.
c. Troubleshoot all active diagnostic codes before
continuing with this procedure.
2. Check customer specified parameters.
a. Verify that the complaint is not normal operation
(programmed parameter).
b. Access the Configuration screen on Cat ET.
c. Check the following parameters:

Vehicle Speed Limit

a. Monitor Cat ET in order to verify that the engine


has progressed from Cold Mode.
Cold Mode is indicated in the upper corner
of any status screen.
4. Check the accelerator pedal position sensor.
a. Use the Cruise/Idle On/Off Switch to put the
engine in idle mode.
b. Vary the engine rpm with the Set/Resume
switches.
If both of the following conditions are met,
monitor the status of the accelerator pedal
position sensor.

The engine is stable by using idle mode to


control the engine rpm.

The engine is unstable by using the


accelerator pedal position sensor.

If the status of the accelerator pedal position


sensor is unstable, refer to Troubleshooting,
Accelerator Pedal (Throttle) Position Sensor
Circuit - Test.
5. Monitor the vehicle speed signal. Ensure the
accuracy of the vehicle speed signal by comparing
the vehicle speed signal to the actual vehicle
speed.

68
Troubleshooting Section

If the vehicle speed is greater than the VSL,


the engine rpm is limited to the programmed
VSL Protection. If a problem is discovered,
refer to Troubleshooting, Vehicle Speed and
Speedometer Circuit - Test.
6. Check the fuel supply.
a. Monitor the exhaust for smoke while the engine
is being cranked.
If no smoke is present, there may be a problem
with the fuel quality or there may be a problem
with the fuel supply.
b. Check the fuel quality.
c. Check the fuel pressure.
d. Ensure that the fuel system has been primed.
e. Check for air in the fuel system.
f. Check for fuel supply lines that are restricted.
g. Check the fuel filters . Refer to Testing and
Adjusting for more information on the fuel
system. Also refer to Truck Application and
Installation Guide, LEBT5109.
h. If the temperature is below 0 C (32 F), check
for solidified fuel (wax).
7. Check the Powertrain Data Link. Ensure that the
power train data link is not limiting the power.
a. Monitor the Powertrain Data Link status
screen while the vehicle is experiencing
problems.
If the Powertrain Data Link status screen
indicates that the Powertrain Data Link is
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.
8. Air intake and exhaust system
a. Clean plugged air filters or replace plugged air
filters. Refer to the Operation and Maintenance
Manual.
b. Check the air intake and the exhaust system
for restrictions and/or leaks. Refer to Testing
and Adjusting for more information.

SENR9698-09

i02183361

Can Not Reach Vehicle Speed


Limit
SMCS Code: 7463-035

Probable Causes
The probable root causes are listed in order below:

Diagnostic codes
Customer specified parameters (normal operation)
Cold mode
Electronic system problem
Fuel supply
Air intake system or exhaust system
Leakage in air-to-air aftercooler core

Recommended Actions
1. Check for diagnostic codes.
a. Connect the Caterpillar Electronic Technician
(ET) to the data link connector.
b. Turn the key switch to the ON position.
c. Check for active diagnostic codes and logged
diagnostic codes.
Certain diagnostic codes will limit the vehicle
speed to 45 mph.
d. Troubleshoot all diagnostic codes before
continuing with this procedure.
2. Check customer specified parameters.
a. Verify that the complaint is not due to normal
operation (programmed parameter).
b. Access the Configuration screen on Cat ET.
c. Check the following parameters:

Vehicle Speed Limit


Soft Vehicle Speed Limit
Lower Gears Engine RPM Limit
Intermediate Gears Engine RPM Limit

SENR9698-09

Gear Down Protection Engine RPM Limit


VSL Protection
Top Engine Limit
Incorrect programming of the Vehicle Speed
calibration (ppm).

PTO Top Engine Limit with the PTO On/Off


Switch turned ON.

Maximum PTO Vehicle Speed with the


PTO On/Off Switch turned ON.

d. Set each parameter to the parameters


maximum value one at a time and determine
whether the problem is corrected.
Note: The Soft Vehicle Speed Limit will not allow
the vehicle to achieve the programmed VSL under
all engine load conditions. Programming the Soft
Vehicle Speed Limit to NO may be required to
eliminate the complaint.
3. Check cold mode operation.
Note: This is normal operation if the problem occurs
only after start-up in cold weather.
a. Check the status screen on Cat ET.
Cold Mode is indicated in the upper corner of
any status screen when cold mode is active.
4. Check for an electronic system problem.
a. Monitor the fuel position, the Rated Fuel Limit,
and the FRC Fuel Limit.
While the vehicle is operating under full load,
the parameters should meet the following
conditions:

The fuel position is equal to the Rated Fuel


Limit.

The fuel position is less than the FRC Fuel


Limit.

If the fuel position is equal to the Rated Fuel


Limit and the fuel position is less than the
FRC fuel Limit, the electronics are operating
correctly. Go to Step 6.
5. If the fuel position is not equal to the Rated Fuel
Limit and/or the fuel position is not less than the
FRC Fuel Limit, perform the following tests in
order:
a. When the engine is OFF, turn the key switch
to the ON position. Check the boost pressure
on Cat ET.

69
Troubleshooting Section

When the engine is OFF, the boost pressure


should be 0 kPa (0 psi).
b. Monitor the status of the accelerator pedal
position sensor. Operate the engine at high idle
with the vehicle in Neutral.
If the engine can not reach the programmed
Top Engine Limit, check the duty cycle for the
accelerator pedal position sensor in order to
ensure that the duty cycle is within calibration
(75 to 90 Percent at high idle).
If the accelerator pedal position is unstable,
check the duty cycle of the accelerator pedal
position sensor. Check the duty cycle by slowly
operating the accelerator pedal in order to
verify that the duty cycle is within calibration.
The accelerator pedal position sensor is
within calibration when both of the following
conditions are met:

10 to 22 percent at low idle


75 to 90 percent at high idle
Also, ensure that the duty cycle changes as the
pedal position changes.
If a problem with the accelerator pedal position
sensor is suspected, refer to Troubleshooting,
Accelerator Pedal (Throttle) Position Sensor
Circuit - Test.
Note: If the engine exceeds the Top Engine Limit,
the Top Engine Limit with Droop is programmed to
YES.
6. Monitor the vehicle speed signal. Ensure the
accuracy of the vehicle speed signal by comparing
the vehicle speed signal to the actual vehicle
speed.
If the vehicle speed is greater than the VSL,
the Power is limited. If a problem is discovered,
refer to Troubleshooting, Vehicle Speed and
Speedometer Circuit - Test.
7. Check the Powertrain Data Link. Ensure that the
SAE J1939 Powertrain Data Link is not limiting
the power.
a. Monitor the Powertrain Data Link status
screen while the vehicle is experiencing
problems.
If the Powertrain Data Link status screen
indicates that the Powertrain Data Link is
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.
8. Check the fuel supply.

70
Troubleshooting Section

SENR9698-09

a. Monitor the exhaust for smoke while the engine


is being cranked.
If no smoke is present, there may be a problem
with the fuel quality or there may be a problem
with the fuel supply.
b. Check the fuel quality.
c. Check the fuel pressure.
d. Ensure that the fuel system has been primed.
e. Check for fuel supply lines that are restricted.
f. Check the fuel filters.
g. Check for air in the fuel system. Refer to
Testing and Adjusting for more information on
the fuel system. Also refer to Truck Application
and Installation Guide, LEBT5109.

Check the Circuit for the Warning Lamp


Refer to Troubleshooting, Warning Lamp Circuit Test.

Check the Systems on the Power Train


Data Link
A system that is connected to the power train data link
may be illuminating the lamp. These systems include
the brakes, the transmission, and/or the cab control.
Note: You may need a special service tool in order to
monitor the other modules on the J1939 data link.
Obtain the necessary equipment, when possible.
Monitor the appropriate parameters while the vehicle
is experiencing problems. Determine if the condition
is normal operation. Refer to the vehicles Original
Equipment Manufacturer (OEM) if the condition is
not normal operation.

h. If the temperature is below 0 C (32 F), check


for solidified fuel (wax).
9. Check the air intake system for restrictions or
leakage. Check the exhaust system for restrictions
or leakage. Refer to Testing and Adjusting, Air
Inlet and Exhaust System - Inspect.
10. Check for leakage in the Air-to-Air Aftercooler
Core . Refer to Testing and Adjusting, Aftercooler
- Test.

i02183417

Cooling Fan Is Always ON


SMCS Code: 1350-035

Probable Causes
The probable root causes are listed in order below:

OEM vehicle component failure


i02318684

Check Engine Lamp


or Warning Lamp Is
Malfunctioning

PTO mode
A/C high pressure switch circuit
Manual fan override switch

SMCS Code: 7431-035

Dyno mode

Probable Causes

Recommended Actions

Burned out bulb

Perform the following diagnostic procedures in order:

Problem with the lamp circuit

1. Check for OEM vehicle component failure.

A system on the power train data link

Note: A failure in the circuit for the cooling fan


solenoid will cause the cooling fan to stay on all the
time.

Recommended Actions
Check the Circuit for the Check Engine
Lamp
Refer to Troubleshooting, Check Engine Lamp
Circuit - Test.

a. Inspect the J1/P1 connector. Check for a wire


that goes into terminal 13 (Output 4) and/or
terminal 11 (Output 5).

SENR9698-09

71
Troubleshooting Section

If a wire is not connected to terminal 13 (Output


4) and/or terminal 11 (Output 5), the ECM is
not connected to the cooling fan system. The
problem is in the OEM vehicle system.

a. Connect Cat ET to the data link connector.

If a wire is connected to the J1/P1 ECM


connector, proceed to Step 4.b.

c. Check the PTO Activates Cooling Fan


parameter.

b. Turn the keyswitch to the ON position while


the engine is OFF.
c. Connect the Caterpillar Electronic Technician
(ET) to the data link connector.
d. Access the parameter for the Fan Control
Type.
Ensure that the parameter for the Fan Control
Type is programmed to On/Off control for
an On/Off fan or ensure that the parameter
for the Fan Control Type is programmed to
Three-Speed Fan control for a three-speed fan.
If the fan is an On/Off fan, proceed to Step 1.e.
If the fan is a three-speed fan, proceed to Step
1.h.
e. Access the On/Off Cooling Fan test.
f. Ensure that any fan override switches on the
dash are in the OFF position.
g. Listen for the solenoid and/or the relay to click
as the test is activated and deactivated.
If the solenoid and/or the relay is clicking, the
Engine Control Module (ECM) and the circuit
to the solenoid and/or the relay are operating
correctly.
If the solenoid and/or the relay are not clicking,
refer to Troubleshooting, Cooling Fan Circuit
and A/C High Pressure Switch Circuit - Test.
h. Access the Three-Speed Fan Slip Output test.
i. Listen for the Slip Solenoid to click as the test
is activated and deactivated.
If the Slip Solenoid is clicking, the ECM and
the circuit to the Slip Solenoid are operating
correctly.
If the Slip Solenoid is not clicking, refer to
Troubleshooting, Cooling Fan Circuit and A/C
High Pressure Switch Circuit - Test.
2. Check the PTO Activates Cooling Fan parameter.
Note: If the problem occurs in PTO mode, continue
with this step. If the problem does not occur in PTO
mode, skip this step.

b. Access the configuration parameters on Cat


ET.

d. If the parameter is programmed to Continuous


the cooling fan will run continuously while the
engine is in PTO mode.
3. Check the A/C high pressure switch circuit.
a. Connect Cat ET to the data link connector.
b. Access the status screen for the A/C Fan
Input.
If the status screen for the A/C Fan Input
indicates that the A/C Fan Input is disabled,
the ECM is not programmed to use the signal
input for the A/C high pressure switch. The
ECM will not turn the fan ON because of a
high A/C pressure. The problem is in the OEM
vehicle system.
If the status screen for the A/C Fan Input
indicates that the A/C Fan Input is OFF, ON
or COUNTING, the ECM is programmed to
turn the fan ON because the A/C high pressure
switch circuit is open. If the status screen for
the A/C Fan Input indicates OFF, ON or
COUNTING, proceed to Step 3.c.
c. Start the engine. Allow the engine to idle.
Watch the status screen on Cat ET that
indicates the status of the A/C Fan Input.
If the status screen indicates OFF at any
time and the fan is still ON, the A/C high
pressure switch circuit is operating correctly.
The problem is in the OEM vehicle system.
If the status screen indicates ON and/or
COUNTING, the ECM is turning the fan ON
because the A/C high pressure switch circuit is
open. Refer to Troubleshooting, Cooling Fan
Circuit and A/C High Pressure Switch Circuit
- Test.
4. Check the manual fan override switch.
a. Connect Cat ET to the data link connector.
b. Access the parameter for the Fan Override
Switch.
c. Check the parameter for the Fan Override
Switch. Ensure that the fan override switch
is programmed to one of the options for Input
Selections.

72
Troubleshooting Section

SENR9698-09

If the parameter is programmed to one of the


four available outputs, check the input for
the fan override switch. The four available
options for Input Selections are the following
connections:

J1/P1:6

J1/P1:47
d. Access the status screen for the Fan Override
Switch.
If the status is ON, either the manual fan
override switch is ON or there is a short in the
circuit for the Fan Override Switch. Refer to
Troubleshooting, Cooling Fan Circuit and A/C
High Pressure Switch Circuit - Test.
5. Dyno Mode will cause the cooling fan to run
continuously. During a dyno run, the ECM should
be in Dyno Mode.
Dyno Mode will only be active for 30 minutes. After
30 minutes, the ECM will exit Dyno Mode. Dyno
Mode can only be enabled with the electronic
service tool.
i02183433

Cruise Control, Idle, or PTO


Can Not Be Set
SMCS Code: 1915-035

Probable Causes
The probable root causes are listed below:

Customer specified parameters (normal operation)


Cruise control pause switch
On/Off switch for cruise control and idle control

Circuit for service brake switch


Transmission neutral switch circuit
Clutch switch circuit

Recommended Actions
1. When the cruise control or the idle control is
set with the cruise control on/off switch, use the
Caterpillar Electronic Technician (ET) in order
to check the Configuration. Check the following
parameters:

J1/P1:46

Set/resume switch

Adaptive cruise control

Perform the following diagnostic procedures in order:

J1/P1:7

PTO on/off switch

Vehicle speed circuit

Low Cruise Control Set Speed Limit


High Cruise Control Set Speed Limit
Idle Vehicle Speed Limit
Idle rpm Limit
Note: If the vehicle speed exceeds the High Cruise
Control Set Speed Limit and the driver attempts to
set a cruise control speed, the cruise set speed will
be the High Cruise Control Set Speed Limit. If the
vehicle speed is below the Low Cruise Control Set
Speed Limit, the cruise control can not be set or
resumed. If the engine rpm is above the idle rpm limit
and the driver attempts to set an idle engine rpm the
idle engine rpm will be the Idle rpm Limit. If the driver
attempts to set an Idle engine rpm and the vehicle
speed exceeds the Idle Vehicle Speed Limit, the Idle
will not activate. Refer to Troubleshooting, Cruise
Control Switch Circuit - Test.
2. Connect Cat ET to the data link connector. Check
the status screen for the following kickouts:

Cruise Kickout
If the cruise control pause switch was the cause
of the last kickout, the cruise control pause switch
may be preventing normal operation of the cruise
control.
a. Check the position of the cruise control pause
switch. If the switch is in the ON position, the
switch will prevent normal operation of the
cruise control. Change the switch to the OFF
position. Verify that the repair eliminates the
problem.
b. If the cruise control pause switch is in the OFF
position and the switch is still causing the
cruise kickout, the switch is bad or the wiring
is shorted.

SENR9698-09

c. Check the switch for proper operation. If the


switch is bad, replace the switch. If the switch
is working, the wiring is probably shorted. Refer
to Troubleshooting, Electrical Connectors Inspect.
3. When the PTO is set with a dedicated PTO On/Off
switch, use Cat ET to check the Configuration.
Check the following parameters:

PTO Configuration
PTO Vehicle Speed Limit
PTO Top Engine Limit
PTO Cab Controls RPM Limit
Refer to Troubleshooting, PTO Switch Circuit Test for additional information.
4. Connect Cat ET to the data link connector. Check
the status screen for the following controls:

On/Off switch for cruise control and idle control


PTO on/off switch
Set/Resume switch
Circuit for service brake switch
Transmission neutral switch
Clutch switch
Vehicle speed
a. Turn on the on/off switch for cruise control and
idle control while the status screen on Cat ET
is being viewed. The status screen should
indicate that the switch is changing ON and
OFF. If the problem is related to the on/off
switch for cruise control and idle control, refer
to Troubleshooting, Cruise Control Switch
Circuit - Test.
b. Toggle the set/resume switch from SET to
RESUME while the status screen on Cat ET
is being viewed. The status screen should
indicate that the switch is changing ON and
OFF. If the problem is related to the set/resume
switch, refer to Troubleshooting, Cruise
Control Switch Circuit - Test.
c. Depress the service brake while the status
screen on Cat ET is being viewed. The status
screen should indicate that the pedal is being
depressed or released. If the problem is
related to the service brake switch, refer to
Troubleshooting, Service Brake Pedal Position
(Switch 1) Circuit - Test.

73
Troubleshooting Section

d. Depress the clutch while the status screen


on Cat ET is being viewed. The status
screen should indicate that the pedal is being
depressed or released. If the problem is related
to the clutch switch, refer to Troubleshooting,
Clutch Pedal Position Switch Circuit - Test.
Note: If the neutral switch status indicates Not
Available (software prior to DEC03) ignore the
status.
e. Shift the transmission to NEUTRAL while the
status screen on Cat ET is being viewed.
The status screen should indicate that the
transmission is being shifted to NEUTRAL.
If the problem is related to the transmission
neutral switch, refer to Troubleshooting,
Neutral Switch Circuit - Test. If this parameter
is programmed to NONE, the status will not
change.
f. Check the vehicle speed while the vehicle is
being driven in order to determine that the
vehicle speed that is indicated by Cat ET
does not vary significantly from the vehicle
speed that is indicated by the speedometer.
Possible root causes for problems with the
vehicle speed circuit could be an incorrect
Vehicle Speed Calibration or an intermittent
speed signal. If the problem is not apparent,
refer to Troubleshooting, Vehicle Speed and
Speedometer Circuit - Test.
5. Check the adaptive cruise control for proper
operation.
a. Toggle the cruise control switch to the OFF
position and to the ON position twice within 10
seconds. This will disable the adaptive cruise
control.
b. Attempt to set the cruise control. Operate the
vehicle under the same conditions that caused
the problem.
c. If the problem still exists, then the problem is
not the adaptive cruise control.
d. If the problem is fixed, refer to Eaton for the
proper troubleshooting procedure.

74
Troubleshooting Section

SENR9698-09

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
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 trucks
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.

Yes

Comments

SENR9698-09

75
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 drivers indicated symptoms agree with the symptoms that are associated
with the diagnostic code. If the drivers 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.

76
Troubleshooting Section

SENR9698-09

i02319575

i02504511

ECM Will Not Accept Factory


Passwords

Electronic Service Tool Will


Not Communicate with ECM

SMCS Code: 1901-035

SMCS Code: 0785-035; 1901-035

Probable Causes

Probable Causes

Incorrect information for the password request

Configuration for the communications adapter

Incorrect passwords

J1/P1 connectors for the Engine Control Module

Recommended Actions

(ECM)

Communication adapter and/or cables

Check the Information for the Password


Request

Electrical power supply to the service tool

The information for the password request must be


obtained from the Engine Control Module (ECM) that
is being programmed. Do not use information from
an old ECM in order to program factory passwords
on a replacement ECM.

Caterpillar Electronic Technician (ET) and related

Verify that the information that is used to request


the passwords is identical to the information that is
displayed on the Caterpillar Electronic Technician
(ET).
Engine Serial Number The engine serial number
must be from the Cat ET screen rather than the
engine information plate.
Reason Code Use the reason code from the
factory password screen. Reason codes are assigned
for specific purposes and reason codes are not
interchangeable.

connector
hardware

Electrical power supply to the ECM


Override switches
ATA data link
J1939 data link

Recommended Actions
Attempt to start the engine. If the engine starts, but
the ECM will not communicate with the Cat ET,
continue with this procedure. If the engine will not
start, refer to Troubleshooting, Engine Cranks but
Will Not Start. If the engine will not crank, refer to
Troubleshooting, Engine Will Not Crank.

Turn the key switch to the OFF position. Then, turn


the keyswitch to the ON position. Try to enter the
passwords again.

Configuration for the Communications


Adapter

Incorrect Passwords

1. Access Preferences under the Utilities menu


on Cat ET.

Verify that the correct passwords were entered.


Check each character in each password.
If rechecking the passwords does not correct the
problem, change a customer parameter from the
current value to another value and then change the
customer parameter back to the original value. This
will change the total tattletale. The new total tattletale
will require obtaining new factory passwords. Obtain
new factory passwords and enter the passwords.

2. Verify that the correct Communications Interface


Device is selected.
3. Verify that the correct Port is selected for use by
the communication adapter. The most commonly
used port is COM 1.
4. Check for any hardware that is utilizing the
same port as the communications adapter. If any
devices are configured to use the same port, exit
or close the software programs for that device.

SENR9698-09

77
Troubleshooting Section

J1/P1 ECM Connectors

No communication occurs when the engine is not

Check the J1/P1 ECM connectors for the following


problems:

Perform the following procedure:

Proper torque

1. Turn the keyswitch to the OFF position.

Cleanliness of the terminals

2. Disconnect Cat ET.

Wires and terminals are properly installed into the

3. Turn the keyswitch to the ON position.

connector.

Refer to Troubleshooting, Electrical Connectors Inspect for additional information.

running and the keyswitch is ON.

4. Connect Cat ET.


This may solve the communication problem.

Communication Adapter and/or Cables

ATA Data Link

Verify that the correct cable is being used between


the communication adapter and the service tool
connector. Refer to Troubleshooting, Electronic
Service Tools.

Troubleshoot the ATA data link for possible problems.


Refer to Troubleshooting, ATA (SAE J1587 / J1708)
Data Link Circuit - Test.

If you are using a 171-4401 Communication Adapter


As, ensure that the firmware and software files for
the communication adapter are the most current
files that are available. If the firmware and software
do not match, the communication adapter will not
communicate with Cat ET.

J1939 Data Link


Troubleshoot the J1939 data link for possible
problems. Refer to Troubleshooting, Powertrain
Data Link Circuit - Test.
i02504512

Electrical Power Supply to the Service


Tool Connector
Verify that battery voltage is present between
terminals A and B of the service tool connector. If the
communication adapter is not receiving power, the
communication adapters display will be blank.

Engine Cranks but Will Not


Start
SMCS Code: 1000-035

Probable Causes

Cat ET and Related Hardware

Theft deterrent

In order to eliminate Cat ET and the related hardware


as the problem, connect Cat ET to a different engine.
If the same problem occurs on a different engine,
check Cat ET and the related hardware in order to
determine the cause of the problem.

Diagnostic codes

Electrical Power Supply to the ECM

Engine speed/timing signal

If the ECM is not receiving battery voltage, the ECM


will not communicate. Check the electrical power to
the ECM. Refer to Troubleshooting, Ignition Key
Switch Circuit and Battery Supply Circuit - Test.

ECM flash file


Air inlet shutoff (if equipped)

Keyswitch
Communications between the Engine Control
Module (ECM) and the Caterpillar Electronic
Technician (ET)

Override Switches

Aftermarket engine protection devices

Verify that there are no aftermarket devices that are


preventing battery voltage from reaching the ECM.

Power to ECM

Some type of override switch is interrupting the power


to the ECM if the following conditions are true:

Communication occurs when the engine is running.

Electrical connections to the electronic unit


injectors

Fuel supply

78
Troubleshooting Section

Combustion problem

Recommended Actions
1. If the display screen on Messenger indicates
that the theft deterrent is enabled, the theft
deterrent passwords must be entered before the
engine will start. Ensure that the theft deterrent
(if equipped) is not active. Turn the keyswitch to
the ON position. Observe the display screen on
Messenger.
2. Check for active diagnostic codes.
a. Connect Cat ET to the data link connector.
b. Check for active diagnostic codes. Certain
diagnostic codes will prevent the engine from
starting.
c. Troubleshoot any diagnostic codes that are
present before continuing with this procedure.
3. Check the air inlet shutoff system.
a. If the engine was shut down due to the air inlet
shutoff system, the air inlet shutoff needs to
be manually reset.
4. Check that the latest version of the ECM flash file
has been installed.

SENR9698-09

If an engine rpm is present, check the sensor


installation. If the sensor is not properly
installed, the sensor may read engine speed
but the sensor may not be able to sense the
tooth pattern. The ability to detect the tooth
pattern is necessary to determine the cylinder
position. Engine rpm is present when the
engine rpm is 50 rpm or more.
6. Use Cat ET to check the status of the keyswitch.
a. Access the status for Ignition Key Switch in
Cat ET.
b. Slowly cycle the keyswitch on and off while the
status of the keyswitch is being monitored. The
status should indicate the state of the switch.
If the ECM will not communicate and the
keyswitch is in the ON position, refer to Step 8.
Note: If the engine shutdown output is used, the
status for the keyswitch may indicate that the switch is
on even though the keyswitch is in the OFF position.
7. Check the communications between the ECM and
Cat ET.
a. Ensure that the keyswitch is in the ON position.
Attempt to access one of the status screens
on Cat ET.

Verify that the flash file that is installed matches


the application.

If Cat ET indicates that the ECM will not


communicate go to Step 8. If the ECM
communicates go to Step 10.

A new ECM is not programmed at the factory.


The engine will not start until the ECM flash file
is installed for the specific application. Also, the
ECM will not communicate until the flash file has
been installed.

8. Check aftermarket engine protection devices.


These devices usually interrupt power to the ECM.
This will prevent communications between the
ECM and Cat ET.

Note: Use WinFlash to program a new ECM.


5. Check the engine speed/timing signal.
a. Observe the engine rpm on Cat ET while the
engine is being cranked.
This may require Cat ET to be powered directly
by the vehicle batteries or this may require
Cat ET to be powered directly by a separate
power source. Use the 167-9225 Harness
(SERVICE TOOL ADAPTER).
If Cat ET displays 0 rpm and the engine is
being cranked, there is a problem in the circuit
for the primary engine speed/timing sensor
or in the circuit for the secondary engine
speed/timing sensor. Refer to Troubleshooting,
Engine Speed/Timing Sensor Circuit - Test.

a. Check for the correct installation of the


aftermarket engine protection device.
b. Check for the correct operation of the
aftermarket engine protection device.
c. Verify that the ECM is receiving the correct
battery voltage.
9. Check the electrical power supply to the ECM.
a. Check the power supply connections for the
ECM and the ground connections for the ECM.
b. Verify that the ECM is receiving battery voltage
with the keyswitch in the ON position. Refer to
Troubleshooting, Ignition Key Switch Circuit
and Battery Supply Circuit - Test.
10. Check for proper operation of the ECM.

SENR9698-09

79
Troubleshooting Section

Before replacing the ECM, try to install a


new flash file into the existing ECM. Refer to
Troubleshooting, Flash Programming.

Fuel supply

If the ECM is suspected of being the problem,


temporarily connect a test ECM. This will prove
whether the problem is with the suspect ECM.

Power train data link

11. Check the electrical connections to the electronic


unit injectors. Ensure that the valve cover
connectors are fully connected. Ensure that the
valve cover connectors are free of corrosion and
of moisture.
12. Check the fuel supply.
a. Monitor the exhaust for smoke while the engine
is being cranked.
If no smoke is present, there may be a problem
with the fuel quality or with the fuel supply.
b. Check the fuel quality. Refer to Systems
Operation/Testing and Adjusting, Fuel Quality
- Test. Also refer to Truck Application and
Installation Guide, LEBT5109.
c. Check the operation of the low pressure fuel
system. Refer to Systems Operation/Testing
and Adjusting, Fuel System Pressure - Test.
d. Ensure that the fuel system has been primed.
Refer to Systems Operation/Testing and
Adjusting, Fuel System - Prime.
e. Check for a restriction in the fuel supply lines.
f. Check the fuel filters.
g. If the temperature is below 0 C (32 F), check
for solidified fuel (wax).
13. Check for mechanical problems that may affect
combustion of the fuel.
i02505717

Engine Misfires, Runs Rough


or Is Unstable
SMCS Code: 1000-035

Probable Causes
The probable root causes are listed in order below:
Note: If the problem is intermittent and the problem
can not be duplicated, refer to Troubleshooting,
Intermittent Low Power or Power Cutout.

Individual malfunctioning cylinder

Accelerator pedal position sensor

Engine speed/timing sensors

Recommended Actions
Perform the following diagnostic procedures in order:
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high rpm, full load
and engine operating temperature. Troubleshooting
the symptoms under other conditions can give
misleading results.
1. Check for an individual malfunctioning cylinder.
a. Ensure that the valve cover connectors are
fully connected and ensure that the connectors
are free of corrosion.
b. Ensure that the J2/P2 connectors for the
Engine Control Module (ECM) are fully
connected and free of corrosion.
c. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector. Access
the Cylinder Cutout Test by selecting the
Diagnostics Tests under the Diagnostic
menu. Run the Cylinder Cutout Test in
order to disable each cylinder. Disabling each
cylinder allows the technician to isolate the
misfiring cylinders.
If the misfiring cylinder can be isolated to a
specific cylinder, refer to Troubleshooting,
Injector Solenoid Circuit - Test.
2. Check the fuel supply.
a. Monitor the exhaust for smoke while the engine
is being cranked.
If white smoke is present, there may be a
problem with the fuel quality.
b. Check the fuel quality. Refer to Systems
Operation/Testing and Adjusting, Fuel Quality
- Test. Also refer to the Truck Application and
Installation Guide, LEBT5109.
c. Check the fuel pressure. Refer to Systems
Operation/Testing and Adjusting, Fuel System
Pressure - Test.
d. Ensure that the fuel system has been primed.
Refer to Systems Operation/Testing and
Adjusting, Fuel System - Prime.

80
Troubleshooting Section

e. Check for fuel supply lines that are restricted.


f. Check the fuel filters.
g. If the temperature is below 0 C (32 F), check
for solidified fuel (wax).
h. Check for air in the fuel system. Refer to
Systems Operation/Testing and Adjusting, Air
in Fuel - Test.
3. If the engine is in the cruise control mode and the
problem does not occur, check the accelerator
pedal position sensor.
a. Use the cruise/idle on/off switch to put the
engine in idle mode.
b. Vary the engine rpm with the set/resume
switches.
If both of the following conditions are met,
monitor the status of the accelerator pedal
position sensor.

The engine is stable by using idle mode to


control the engine rpm.

The engine is unstable by using the


accelerator pedal position sensor.

If the status of the accelerator pedal position


sensor is unstable, refer to Troubleshooting,
Accelerator Pedal (Throttle) Position Sensor
Circuit - Test.
4. Check the Powertrain Data Link. Ensure that the
power train data link is not limiting the power.
a. Monitor the Powertrain Data Link status
screen while the vehicle is experiencing
problems.
If the Powertrain Data Link status screen
indicates that the Powertrain Data Link is
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.
5. Check the primary engine speed/timing sensor.

SENR9698-09

If the signal from the primary engine speed/timing


sensor is lost intermittently, the engine may
misfire. The misfiring may occur when the
signal source becomes the secondary engine
speed/timing sensor. Ensure that the primary
engine speed/timing sensor is properly installed.
Also, ensure that the wiring is not damaged or
pulled too tightly. This may cause an intermittent
connection. Also, ensure that the crankshaft gear
and the timing plate are not damaged. Refer to
Troubleshooting, Engine Speed/Timing Sensor
Circuit - Test for more information.
6. Check the secondary engine speed/timing sensor.
If the signal for the secondary engine speed/timing
sensor is lost during engine start-up, additional
time may be required to start the engine. The
engine may also misfire during this time until the
ECM determines the proper firing order. Refer to
Troubleshooting, Engine Speed/Timing Sensor
Circuit - Test for more information.
i02376490

Engine Retarder (Compression


Brake) Will Not Turn ON
SMCS Code: 1129-035

Probable Causes
Programmable parameters
Engine retarder switches
Accelerator pedal position sensor
Clutch switch
PTO on/off switch

Recommended Actions
Check the Programmable Parameters
Use the Caterpillar Electronic Technician (ET) to
check the following parameters while the engine is
not running:
Engine Retarder Mode If the engine retarder
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.

SENR9698-09

81
Troubleshooting Section

Engine Retarder Minimum Vehicle Speed The


engine retarder will not turn on below the value that
is programmed for this parameter.

Check the Clutch Switch

Engine Retarder Minimum Vehicle Speed


Type When vehicle speed drops below the
Engine Retarder Minimum Vehicle Speed and this
parameter is programmed to Hard Limit the engine
retarder turns off. When vehicle speed drops below
the Engine Retarder Minimum Vehicle Speed and
this parameter is programmed to Soft Limit the
engine retarder remains on.

Monitor the status of the clutch switch while you


operate the clutch pedal. Depress the pedal and
release the pedal several times.

Engine Retarder Delay This parameter


provides a programmable delay after the conditions
that turn on the engine retarder are met.
Refer to Troubleshooting, Customer Specified
Parameters for additional information on these
parameters.

Check the Engine Retarder Switches


Note: Some vehicles may have a set of engine
retarder switches on the dash and on the shift lever.
Check both sets of switches, if necessary.
Turn the on/off switch for the engine retarder to the
ON position.
Use Cat ET to monitor the status of the engine
retarder switches while the switches are moved to
the following positions:

Off

Use Cat ET to monitor the status of the clutch switch.

The status of the clutch switch should indicate that


the clutch pedal is being depressed and released.
When the clutch pedal is depressed the status should
indicate ON. When the clutch pedal is released the
status should indicate OFF. If the status of the clutch
switch does not correspond to the position of the
clutch pedal, refer to Troubleshooting, Clutch Pedal
Position Switch Circuit - Test.

Check the PTO On/Off Switch


Note: If the PTO Configuration is programmed to
Cab Switches, to Remote, to Switches, or to
Remote Throttle the engine retarder is disabled
when the PTO is ON.
Use Cat ET to monitor the status of the PTO on/off
switch. If the status of the PTO on/off switch does not
correspond to the position of the PTO on/off switch,
refer to Troubleshooting, PTO Switch Circuit - Test.
i02378773

Engine Vibration
SMCS Code: 1000-035

Low

Probable Causes

Medium

Fan blades

High

Mounting hardware

If the status of the switches does not correspond to


the position of the switches, refer to Troubleshooting,
Retarder (Compression Brake) Solenoid circuit Test.

Missing crankshaft pulley bolts

Check the Accelerator Pedal Position


Sensor
Use Cat ET to monitor the status of the accelerator
pedal position.
Monitor the status of the accelerator pedal position
while you operate the pedal. Depress the pedal and
release the pedal several times.
The status of the accelerator pedal position should
vary between 3 percent and 100 percent. If the
accelerator pedal position does not vary between 3
percent and 100 percent, refer to Troubleshooting,
Pulse Width Modulated Sensor.

Faulty clutch disc


Air compressor

Recommended Actions
Check the Fan Blades
Verify that the engine is off. Inspect the fan blades.
Look for bent blades or broken blades. Replace
parts, if necessary.

Check the Mounting Hardware


Carefully inspect the engine for the following
conditions:

82
Troubleshooting Section

SENR9698-09

Loose fasteners, damaged fasteners, and missing


fasteners

Components in the starting circuit


Flywheel ring gear

Loose mounts or broken mounts

Transmission

Loose brackets or broken brackets


Start the engine. Run the engine through the entire
idle speed range. Inspect the components again.
Repair any faulty components. Replace parts, if
necessary.

PTO
Engine accessory
Hydraulic cylinder lock

Check the Crankshaft Pulley Bolts

Internal engine problem

Verify that all of the crankshaft pulley bolts are


installed.

Recommended Actions
Check the Batteries

Check the Clutch Disc


Run the engine through the entire idle speed range
while the clutch is disengaged.

Check the charge on the vehicles batteries.


Charge the batteries, if necessary. Refer to Special
Instruction, SEHS7633, Battery Test Procedure.

If the vibrations are reduced, there is a balance


problem with the clutch disc or the clutch disc is out
of alignment. Repair the clutch disc or replace the
clutch disc.

Load test the batteries. Refer to Special Instruction,


SEHS9249, Use of 4C-4911 Battery Load Tester for
6, 8 and 12 Volt Lead Acid Batteries.

Check the Starting Circuit

Check the Air Compressor


Remove the air compressor. Refer to the engines
Disassembly and Assembly manual for the correct
procedure.
Run the engine through the entire idle speed
range. If the vibration is eliminated, replace the air
compressor.

Use a Vibration Meter to Isolate the


Cause of the Vibration
Further analysis requires the use of a vibration
meter. Any meter that can accurately measure the
displacement of the vibration and the frequency of
the vibration is sufficient. Refer to Special Instruction,
SEHS7914, Troubleshooting Vibration In Vehicular
Equipment for additional information. This Special
Instruction describes the internal engine components
and components of the drive train that can cause
excessive vibration.
i02310798

Engine Will Not Crank


SMCS Code: 1000-035

Probable Causes
Batteries

1. Check the wiring to the starting motor solenoid.


Refer to the vehicles electrical schematic.
2. Check the engine start switch and the engine start
relay for electrical power.
3. Check the starting motor cables. If the starting
motor cables are corroded, remove the starting
motor cables and clean the starting motor cables.
4. Test the operation of the starting motor.

Check the Flywheel Ring Gear


Inspect the flywheel ring gear for damage.

Check the Transmission


Verify that the driveline moves freely.

Check the PTO


Ensure that the PTO system is operating correctly.

Check the Engine Accessories


Remove engine accessories that may lock up the
engine and inspect the accessories.
The following accessories may lock up the engine:

SENR9698-09

83
Troubleshooting Section

Air compressor
Power steering pump

2. Check the engines valve lash. Refer to Systems


Operation/Testing and Adjusting, Engine Valve
Lash - Inspect/Adjust.

Engine oil pump

3. Check electronic unit injectors.

Check for Hydraulic Cylinder Lock


Check for fluid in the cylinders (hydraulic cylinder
lock) by removing the individual electronic unit
injectors.
Note: Fuel will flow from the cylinder head into the
cylinders when a electronic unit injector is removed.

Check for an Internal Engine Problem


Disassemble the engine. Refer to the engines
Disassembly and Assembly manual. Inspect the
internal components for the following conditions:

Seizure
Broken components

a. Ensure that the valve cover connectors for the


unit injectors are fully connected and ensure
that the valve cover connectors are free of
corrosion.
b. Ensure that the J2/P2 connectors for the Engine
Control Module (ECM) are fully connected and
ensure that the ECM connectors are free of
corrosion.
c. Connect Caterpillar Electronic Technician (ET)
to the service tool connector. Perform the
Cylinder Cutout Test. Access the Cylinder
Cutout Test by selecting the Diagnostic
Tests under the Diagnostics menu. Run the
Cylinder Cutout Test in order to disable each
cylinder. Disabling each cylinder allows the
technician to isolate the misfiring cylinders.
If the misfiring cylinder can be isolated to a
specific cylinder, refer to Troubleshooting,
Injector Solenoid Circuit - Test.

Bent components
i02504514

Excessive Black Smoke


SMCS Code: 1088-035

Probable Causes
The probable root causes are listed in order below:

Air inlet system or exhaust system


Valve lash
Electronic unit injectors
Boost pressure sensor
Atmospheric pressure sensor
Electronic system problem

4. Check the boost pressure sensor and the


atmospheric pressure sensor for correct
operation.
a. While the problem is occurring, check for
diagnostic codes that are related to the boost
pressure sensor and the atmospheric pressure
sensor. If there is an active diagnostic code for
a pressure sensor, refer to Troubleshooting,
Engine Pressure Sensor Open or Short Circuit
- Test.
5. Check for an electronic system problem.
a. Monitor the fuel position, the Rated Fuel Limit
and the FRC Fuel Limit.
While the vehicle is operating under full load,
the parameters should meet the following
conditions:

Personality module

The fuel position is equal to the Rated Fuel

Recommended Actions

The fuel position is less than the FRC Fuel

Perform the following diagnostic procedures in order:


1. Check the air inlet system for restrictions or
leakage. Check the exhaust system for restrictions
or leakage. Refer to Systems Operation/Testing
and Adjusting, Air Inlet and Exhaust System Inspect.

Limit.
Limit.

If the fuel position is equal to the Rated Fuel


Limit and the fuel position is less than the
FRC Fuel Limit, the Electronics are operating
correctly. Go to Step 7.

84
Troubleshooting Section

6. If the fuel position is not equal to the Rated Fuel


Limit and/or the fuel position is not less than the
FRC Fuel Limit, perform the following tests in
order:
a. Without starting the engine, turn the keyswitch
to the ON position. Check the parameter for the
boost pressure on the status screen.
When the engine is off, the boost pressure
should be 0 kPa (0 psi).
b. Monitor the status for Accelerator Pedal
Position Sensor. Fully depress the accelerator
pedal and release the accelerator pedal. The
status should be 0% at low idle and 100% at
high idle.
If the status does not reach 0% or 100%, check
the duty cycle of the accelerator pedal position
sensor. Select Monitor Throttle Position
Sensor from the Calibrations under the
Service menu on Cat ET in order to monitor
the duty cycle of the accelerator pedal position
sensor. Fully depress the accelerator pedal and
release the accelerator pedal. The accelerator
pedal position sensor is within calibration when
both of the following conditions are met:

10 to 22 percent at low idle


75 to 90 percent at high idle
Also, ensure that the duty cycle changes as the
pedal position changes.
If a problem with the accelerator pedal position
sensor is suspected, refer to Troubleshooting,
Accelerator Pedal (Throttle) Position Sensor
Circuit - Test.
7. Use Cat ET to monitor the vehicle speed signal.
Ensure the accuracy of the vehicle speed signal
by comparing the vehicle speed signal to the
actual vehicle speed.
If the vehicle speed is greater than the VSL,
then engine power will be limited. If a problem
is discovered, refer to Troubleshooting, Vehicle
Speed and Speedometer Circuit - Test.
8. Check the Powertrain Data Link. Ensure that the
SAE J1939 Powertrain Data Link is not limiting
the power.
a. Monitor the Powertrain Data Link status
screen while the vehicle is experiencing
problems.

SENR9698-09

If the Powertrain Data Link status screen


indicates that the Powertrain Data Link is
limiting the engine or the rpm, verify that this
is not normal operation. If this is not normal
operation, refer to the vehicles OEM for
repairs.
9. Check that the latest flash file has been installed
into the ECM. Install that latest flash file, if
necessary.
i02310928

Excessive Fuel Consumption


SMCS Code: 1250-035

Probable Causes
Vehicle operation
Environmental conditions
Engine load and vehicle aerodynamics
Fuel quality
Air inlet system or exhaust system

Recommended Actions
Check Vehicle Operation
Use the Caterpillar Electronic Technician to check the
histograms. Look for high values for these items:

Engine speed
Vehicle speed
High engine speeds and high vehicle speeds can
cause excessive fuel consumption.

Check the Environmental Conditions


High winds and excessive moisture (snow) can
adversely affect fuel consumption.

Check the Loads and Aerodynamics


Heavy loads and poor aerodynamics adversely affect
fuel consumption.

Check the Fuel Quality


The grade of the fuel affects the rate of fuel
consumption. Refer to the engines Operation and
Maintenance Manual for additional information.

SENR9698-09

85
Troubleshooting Section

Check the Air Inlet System and the


Exhaust System
Check the air inlet system for restrictions and for
leakage. Check the exhaust system for restrictions
and for leakage. Refer to Systems Operation/Testing
and Adjusting, Air Inlet and Exhaust System.
i02504515

Excessive White Smoke


SMCS Code: 1088-035

Probable Causes
The probable root causes are listed in order below:

Normal operation
Fuel supply
Atmospheric pressure circuit

g. Check for air in the fuel system. Refer to


Systems Operation/Testing and Adjusting for
more information on checking the fuel system
for air. Also refer to Truck Application and
Installation Guide, LEBT5109.
h. If the temperature is below 0 C (32 F), check
for solidified fuel (wax).
3. Check the atmospheric pressure sensor for a
problem.
a. Connect Caterpillar Electronic Technician (ET)
to the service tool connector.
b. Check for diagnostic codes that are related to
the atmospheric pressure sensor.
c. Monitor the status of the atmospheric pressure
sensor on the status screen. Compare the
value for the atmospheric pressure on the
status screen to the actual atmospheric
pressure.

Electronic unit injectors

d. If the atmospheric pressure on the status


screen is at least 7 kPa (1 psi) greater than
the actual atmospheric pressure, inspect the
crankcase breather for restrictions.

Combustion problem

e. Remove one of the valve covers.

Recommended Actions

f. Recheck the atmospheric pressure on the


status screen.

Perform the following diagnostic procedures in order:

g. If removing the crankcase breather solves


the problem, replace the filter element for the
crankcase breather.

Coolant temperature circuit

1. Be aware of normal operating conditions.


Cold ambient temperatures may cause the engine
to produce white smoke.
2. Check the fuel supply.
a. Monitor the exhaust for smoke while the engine
is being cranked.
If no smoke is present, there may be a problem
with the fuel quality. Also, check for a problem
with the supply of fuel.
b. Check the fuel quality.
c. Check the fuel pressure.
d. Ensure that the fuel system has been primed.
e. Check for fuel supply lines that are restricted.
f. Check the fuel filters.

h. If the crankcase breather is not restricted or


removing the valve cover does not eliminate
the problem, proceed to Step 4.
4. Check the coolant temperature sensor for a
problem.
a. Use Cat ET to check for diagnostic codes that
are related to the coolant temperature sensor.
b. Monitor the status of the coolant temperature
sensor on the status screen. If an active
diagnostic code is detected, refer to
Troubleshooting, Engine Temperature Sensor
Open or Short Circuit - Test.
5. Check the electronic unit injectors.
a. Ensure that the valve cover connectors are
fully connected and ensure that the valve cover
connectors are free of corrosion.

86
Troubleshooting Section

SENR9698-09

b. Ensure that the J2/P2 connectors for the


Electronic Control Module (ECM) are fully
connected and ensure that the ECM connectors
are free of corrosion.

1. Connect the Caterpillar Electronic Technician (ET)


to the data link connector. Check the status screen
for the last item that caused the kickout for the
cruise control, the idle control or the PTO control.

c. Use the Cylinder Cutout Test. Access the


Cylinder Cutout Test from the Diagnostics
Test under the Diagnostics menu. Run the
Cylinder Cutout Test in order to disable each
cylinder. Disabling each cylinder allows the
technician to isolate the misfiring cylinders.

Note: Cat ET will only provide access to the last


cause of the Kickout. If power has been cycled to the
ECM since the last occurrence of the problem, then it
may be necessary to take the vehicle for a test drive
in order to repeat the problem. Check Cat ET before
the ECM is turned off by the keyswitch.

If the misfiring cylinder can be isolated to a


specific cylinder, refer to Troubleshooting,
Injector Solenoid Circuit - Test.
6. Check for combustion problems.
Examples of combustion problems are shown in
the following list:

Outside temperatures are too cold.


Mechanical problem with the engine
i02504517

Intermittent Cruise Control,


Idle, or PTO Kickout
SMCS Code: 1915-035

Probable Causes
The probable root causes are listed below:

A clutch pedal position switch that is incorrectly


adjusted

Malfunctioning on/off switch for cruise control and


idle control

Malfunctioning switch for service brake pedal


position
Malfunctioning transmission neutral switch
Vehicle speed circuit problem
Battery power or ground to the Engine Control
Module (ECM)

Adaptive cruise control

Recommended Actions
Perform the following diagnostic procedures in order:

If Cat ET indicates Switch Turned Off, go to Step


2.
If Cat ET indicates Brake, Clutch or Neutral
go to Step 3.
If the Cat ET indicates Bad Vehicle Speed,
Vehicle Speed < Limit or Vehicle Speed >=
Limit go to Step 4.
2. If Cat ET indicates Switch Turned Off, the ECM
has detected an open circuit in the on/off switch
circuit. This pertains to the cruise control, the idle
control or the PTO. Perform the following tests
in order:
a. Ensure that the operator has not actually
turned off the cruise control on/off switch or the
PTO on/off switch.
b. Check the status screen on Cat ET while the
switch is being used. If the problem is not
apparent check the switch and the wiring.
c. If the problem is related to the cruise control or
idle control refer to Troubleshooting, Cruise
Control Switch Circuit - Test, Service Brake
Pedal Position (Switch 1) Circuit -Test, and
Clutch Pedal Position Switch Circuit - Test.
d. If the problem is related to the PTO refer to
Troubleshooting, PTO Switch Circuit - Test.
3. If Cat ET indicates Brake, Clutch or Neutral,
the ECM has detected an open circuit in the switch
circuit for the service brake, the switch circuit
for the clutch or the transmission neutral switch
circuit. Perform the following tests in order:
a. Ensure that the operator has not actually
depressed the service brake pedal or the clutch
pedal. Also ensure that the operator has not
actually shifted the transmission to neutral.

SENR9698-09

b. Check the status screen on Cat ET while the


service brake or the clutch is being used.
If the problem is not apparent, check the
switches. Check the service brake switch for
the air system. Ensure that the treadle valve
is operating freely. A treadle valve that is not
operating freely can cause pressure spikes.
Check the clutch switch adjustment and the
return spring.
c. If the problem is related to the Cruise Control
or Idle Control refer to Troubleshooting, Cruise
Control Switch Circuit - Test, Service Brake
Pedal Position (Switch 1) Circuit - Test, and
Clutch Pedal Position Switch Circuit - Test.
d. If the problem is related to the PTO refer to
Troubleshooting, PTO Switch Circuit - Test.
4. If Cat ET indicates Bad Vehicle Speed, the
vehicle speed signal is erratic or intermittent. This
relates to cruise control only.
If Cat ET indicates Vehicle Speed < Limit, the
vehicle speed signal was lost at least briefly. This
pertains to cruise control only.
If Cat ET indicates Vehicle Speed >= Limit, the
vehicle speed signal exceeded the programmed
Idle/PTO Vehicle Speed Limit or the vehicle
speed limit is erratic or intermittent. This pertains
to idle control and PTO control only.
Perform the following diagnostic procedure in
order:

87
Troubleshooting Section

6. Check for proper operation of the adaptive cruise


control.
a. Toggle the cruise control switch to the OFF
position and to the ON position twice within 10
seconds. This will disable the adaptive cruise
control.
b. Attempt to set the cruise control. Operate the
vehicle under the same conditions that caused
the problem.
c. If the problem still exists, then the problem is
not the adaptive cruise control.
d. If the problem is fixed, refer to Eaton for the
proper troubleshooting procedure.
i02504518

Intermittent Low Power or


Power Cutout
SMCS Code: 1000-035

Probable Causes
The probable root causes are listed in order below:

Active diagnostic codes


Soft cruise control
Poor electrical connections

a. Inspect the vehicle speed sensor for debris on


the sensor. Inspect the vehicle speed circuit.

Battery power or ground to the Engine Control

b. Check the vehicle speed that is displayed


on the status screen on Cat ET while the
vehicle is parked. Adjust the engine rpm up
and down. Also check the vehicle speed
while the vehicle is being driven in order
to determine that the vehicle speed that is
indicated by Cat ET does not vary significantly
from the vehicle speed that is indicated by the
speedometer. If the problem is not apparent,
refer to Troubleshooting, Vehicle Speed and
Speedometer Circuit - Test.

Air inlet system (boost)

c. Inspect both ECM connectors for moisture.


Refer to Troubleshooting, Electrical
Connectors - Inspect.
5. A problem with the battery power, the ground to
the ECM or the vehicle wiring can cause erratic
engine rpm or other more severe problems. If this
is a suspected cause, refer to Troubleshooting,
Ignition Key Switch Circuit and Battery Supply
Circuit Test.

Module (ECM)

Accelerator pedal position sensor


Fuel supply
Vehicle speed circuit
Power train control
Torque limit switch

Recommended Actions
Perform the following diagnostic procedures in order:
1. Certain diagnostic codes may cause poor
performance. These diagnostic codes are
intended to protect the engine.
a. Connect the Caterpillar Electronic Technician
(ET) to the data link connector.

88
Troubleshooting Section

b. Check for active codes and/or logged codes.


Troubleshoot any codes that are present before
continuing with this procedure.
2. If the problem only occurs in cruise control, check
the parameter for Soft Cruise Control.
a. Disable the Soft Cruise Control parameter.
b. Verify that the problems do not return.
c. If the problems do not return, the problem was
due to normal operation.
Soft cruise control provides an 8 km/h (5 mph)
operating range around the cruise control set
speed in order to provide a smoother cruise
control.
d. Enable the Soft Cruise Control.
3. Check the vehicle harness and the connectors.
Refer to Troubleshooting, Electrical Connectors
- Inspect.
4. Check the battery power and the ground circuit
to the ECM.
a. Ensure that the following connectors have
been installed correctly:

J1/P1 and J2/P2 ECM connectors


Valve cover connectors for the unit injectors
Primary engine speed/timing connectors
Secondary engine speed/timing connectors
5. Check for an electronic system problem.
a. Monitor the fuel position, the Rated Fuel Limit
and the FRC Fuel Limit.

SENR9698-09

6. If the fuel position is not equal to the Rated Fuel


Limit and/or the fuel position is not less than the
FRC Fuel Limit, perform the following tests in
order:
a. Turn the keyswitch to the ON position. Check
the boost pressure on the status screen on
Cat ET.
While the engine is not started, the boost
pressure should be 0 kPa (0 psi).
b. Monitor the status of the accelerator pedal
position sensor. Operate the engine at high idle
with the vehicle in neutral.
If the engine can not reach the programmed
Top Engine Limit, check the duty cycle of the
accelerator pedal position in order to ensure
that the signal is within calibration (75 to 90
Percent at high idle).
If the accelerator pedal position is unstable,
check the duty cycle of the accelerator
pedal position. Check the duty cycle of the
accelerator pedal position by slowly operating
the accelerator pedal in order to verify that
the accelerator pedal position sensor is within
calibration. The accelerator pedal position
sensor is within calibration when both of the
following conditions are met:

10 to 22 percent at low idle


75 to 90 percent at high idle
Also, ensure that the duty cycle changes as the
pedal position changes.
If a problem with the accelerator pedal position
sensor is suspected, refer to Troubleshooting,
Accelerator Pedal (Throttle) Position Sensor
Circuit - Test.

While the vehicle is operating under full load,


the parameters should meet the following
conditions:

Note: If the engine exceeds the Top Engine Limit,


the Top Engine Limit with Droop is programmed to
YES.

The fuel position is equal to the Rated Fuel

7. Monitor the vehicle speed signal. Ensure the


accuracy of the vehicle speed signal by comparing
the vehicle speed signal to the actual vehicle
speed.

Limit.

The fuel position is less than the FRC Fuel


Limit.

If the fuel position is equal to the Rated Fuel


Limit and the fuel position is less than the
FRC Fuel Limit, the Electronics are operating
correctly. Go to Step 7.

If the vehicle speed is greater than the VSL,


the power is limited. If a problem is discovered,
refer to Troubleshooting, Vehicle Speed and
Speedometer Circuit - Test.
8. Check the Powertrain Data Link. Ensure that the
power train data link is not limiting the power.

SENR9698-09

a. Monitor the Powertrain Data Link status


screen while the vehicle is experiencing
problems.
If the Powertrain Data Link status screen
indicates that the Powertrain Data Link is
limiting the power or the rpm, verify that this
is not normal operation. If this is not normal
operation, refer to the vehicles OEM for
repairs.
9. Check the fuel supply.
a. Monitor the exhaust for smoke while the engine
is being cranked.
If no smoke is present, there may be a problem
with the fuel quality or there may be a problem
with the fuel supply.
b. Check the fuel quality. Refer to Systems
Operation/Testing and Adjusting, Fuel Quality
- Test. Also refer to the Truck Application and
Installation Guide, LEBT5109.

89
Troubleshooting Section

i02183773

Low Power/Poor or No
Response to Throttle
SMCS Code: 1000-035

Probable Causes
The probable root causes are listed in order below:

Diagnostic codes
Intake valve actuation system
Cold mode
Customer specified parameters (normal operation)
Electronic system problem
Fuel supply
Fuel recirculation system (if equipped)

c. Check the fuel pressure. Refer to Systems


Operation/Testing and Adjusting, Fuel System
Pressure - Test.

Leakage in air-to-air aftercooler core

d. Ensure that the fuel system has been primed.


Refer to Systems Operation/Testing and
Adjusting, Fuel System - Prime.

Individual malfunctioning cylinder

e. Check for a restriction in the fuel supply lines.


f. Check the fuel filters.
g. If the temperature is below 0 C (32 F), check
for solidified fuel (wax).
h. Check for air in the fuel system. Refer to
Systems Operation/Testing and Adjusting, Air
in Fuel - Test.
10. Check the torque limit switch.
a. Check the setting of the parameter for the
Torque Limit.
If the Torque Limit is programmed below
3400 Nm (2500 lb ft), check the status screen
for the torque limit switch. Ensure that the
status screen indicates that the torque limit
switch is OFF. If the status of the torque limit
switch is ON and a torque limit is programmed,
the system is operating correctly. If the switch
that is connected to this signal input is not
switching ON and switching OFF, refer to
Troubleshooting, PTO Switch Circuit - Test.

Air inlet system or exhaust system

Torque limit switch

Recommended Actions
Diagnostic Codes
1. Connect the Caterpillar Electronic Technician (ET)
to the data link connector.
2. Check for active codes and/or logged codes.
Troubleshoot any codes that are present before
continuing with this procedure.
Note: Certain diagnostic codes may cause poor
performance. Also, certain diagnostic codes will limit
the engine speed to low idle.

Intake Valve Actuation System


1. Start the engine.
2. Monitor the status screens on Cat ET.
3. Check for an Intake Vlave System Starting flag
at the top left of any status screen.
Note: The engine will not receive full power until the
Intake Vlave System Starting flag becomes inactive.

90
Troubleshooting Section

Cold Mode
1. Start the engine.
2. Monitor the status screens on Cat ET.
3. Check for a Cold Mode flag at the top of any
status screen.
Note: The engine will not receive full power until the
Cold Mode flag becomes inactive.

Customer Specified Parameters


1. Verify that the complaint is not normal operation
(programmed parameter).
2. Access the Configuration screen on Cat ET.
3. Check the following parameters:

Rating Number
Top Engine Limit
Vehicle Speed Limit
Lower Gears Engine RPM Limit
Intermediate Gears Engine RPM Limit
Gear Down Protction Engine RPM Limit
Note: If the Rating Number is programmed to 0, the
engine is limited to 119 kW (160 hp).
4. Set each parameter to the parameters maximum
value one at a time and determine whether the
problem is corrected.

Electronic System Problem


1. Monitor the fuel position, the rated fuel limit and
the FRC fuel limit.
While the vehicle is operating under full load, the
parameters should meet the following conditions:

The fuel position is equal to the rated fuel limit.


The fuel position is less than the FRC fuel limit.
2. If the fuel position is equal to the rated fuel limit
and if the fuel position is less than the FRC fuel
limit, the electronics are operating correctly. Go
to Step 3.
3. If the fuel position is not equal to the rated fuel
limit and/or if the fuel position is not less than the
FRC fuel limit, perform the following tests in order:

SENR9698-09

4. When the engine is off, turn the key switch to the


ON position. Check the boost pressure on the
status screen.
When the engine is off, the correct boost pressure
is 0 kPa (0 psi).
5. Monitor the status of the accelerator pedal position
sensor. Operate the engine at high idle with the
vehicle in Neutral.
If the engine cannot reach the programmed
Top Engine Limit, check the duty cycle for the
accelerator pedal position sensor in order to
ensure that the duty cycle is within calibration (75
to 90 Percent at high idle).
If the accelerator pedal position is unstable,
check the duty cycle of the accelerator pedal
position sensor. Check the duty cycle by slowly
operating the accelerator pedal in order to verify
that the accelerator pedal position sensor is within
calibration. The accelerator pedal position sensor
is within calibration when both of the following
conditions are met:

10 to 22 percent at low idle


75 to 90 percent at high idle
Also, ensure that the duty cycle changes as the
pedal position changes.
If a problem with the accelerator pedal position
sensor is suspected, refer to Troubleshooting,
Accelerator Pedal (Throttle) Position Sensor
Circuit - Test.
Note: If the engine exceeds the top engine limit,
the Top Engine Limit with Droop is programmed to
YES.
6. Monitor the vehicle speed signal. Ensure the
accuracy of the vehicle speed signal by comparing
the vehicle speed signal to the actual vehicle
speed.
If the vehicle speed is greater than the VSL,
the power is limited. If a problem is discovered,
refer to Troubleshooting, Vehicle Speed and
Speedometer Circuit - Test.
7. Check the Power train Data Link. Ensure that
the power train data link is not limiting the power.
a. Monitor the Power train Data Link status
screen while the vehicle is experiencing
problems.

SENR9698-09

If the Power train Data Link status screen


indicates that the Power train Data Link is
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.

Fuel Supply
1. Monitor the exhaust for smoke while the engine
is being cranked.
If no smoke is present, there may be a problem
with the fuel quality or there may be a problem
with the fuel supply.
2. Check the fuel quality. Refer to Testing and
Adjusting, Fuel Quality - Test. Also refer to
the Truck Application and Installation Guide,
LEBT5109.
3. Check the fuel pressure. Refer to Testing and
Adjusting, Fuel System Pressure - Test.
4. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, Fuel System Prime.
5. Check for fuel supply lines that are restricted.
6. Check the fuel filters.
7. If the temperature is below 0 C (32 F), check
for solidified fuel (wax).
8. Check for air in the fuel system. Refer to Testing
and Adjusting, Air in Fuel - Test.

Fuel Recirculation (if equipped)


If 174-00 is easily repeated, the fuel recirculation
system may be the cause. A system for fuel
recirculation may be installed on this engine in order
to supply warm fuel to the unit injectors during cold
engine operation. The thermostatic valve is in the
open position when the fuel is cold. This allows the
warm fuel to re-enter the fuel transfer pump instead
of going back to the fuel tank. When the fuel reaches
80 C (176 F) the thermostatic valve will close
directing the warm fuel to the fuel tank. If the fuel
temperature rises and the thermostatic valve does not
operate properly, the temperature of recirculating fuel
will rise and the engine could lose power. The engine
could also have poor response and/or acceleration.

Air Inlet System or Exhaust System


1. Check for leakage in the air-to-air aftercooler core
. Refer to Testing and Adjusting, Aftercooler Test.

91
Troubleshooting Section

2. Check the air intake system for restrictions or


leakage. Check the exhaust system for restrictions
or leakage. Refer to Testing and Adjusting, Air
Inlet and Exhaust System - Inspect.

Individual Malfunctioning Cylinder


1. Ensure that the front valve cover connector and
the rear valve cover connector are fully connected
and ensure that the valve cover connectors are
free of corrosion.
2. Ensure that the J2/P2 ECM connector is fully
connected and ensure that the ECM connector is
free of corrosion.
3. Use the Cylinder Cutout Test. Access
the Cylinder Cutout Test by selecting the
Diagnostics Test under the Diagnostic menu.
Run the Cylinder Cutout Test in order to disable
each cylinder. Disabling each cylinder allows the
technician to isolate the misfiring cylinders.
If the misfiring cylinder can be isolated to a
specific cylinder, refer to Troubleshooting, Injector
Solenoid Circuit - Test.
4. Perform a PAR test (Performance Analysis
Report).

Torque Limit Switch


1. Check the setting for the customer parameter for
the Torque Limit.
If the Torque Limit is programmed below
3400 Nm (2500 lb ft), check the status screen
for the torque limit switch. Ensure that the status
screen indicates that the torque limit switch is
OFF. If the status of the torque limit switch is
ON and a Torque Limit is programmed, the
system is operating correctly. If the switch that is
connected to this signal input is not switching ON
and switching OFF, refer to Troubleshooting, PTO
Switch Circuit - Test.
i02183781

Poor Acceleration or Response


SMCS Code: 1000-035

Probable Causes
The probable root causes are listed in order below:

Diagnostic codes
Intake valve actuation system
Cold mode

92
Troubleshooting Section

Customer specified parameters (normal operation)


Individual malfunctioning cylinder

SENR9698-09

Gear Down Protction Engine RPM Limit

Power train data link

4. Set each parameter to the parameters maximum


value one at a time and determine whether the
problem is corrected.

Torque limit switch

Individual Malfunctioning Cylinder

Recommended Actions

1. Ensure that the front valve cover connector and


the rear valve cover connector are fully connected
and ensure that the valve cover connectors are
free of corrosion.

Diagnostic Codes
1. Connect the Caterpillar Electronic Technician (ET)
to the data link connector.
2. Check for active codes and/or for logged codes.
Troubleshoot any codes that are present before
continuing with this procedure.
Note: Certain diagnostic codes may cause poor
performance.

Intake Valve Actuation System


1. Start the engine.
2. Monitor the status screens on Cat ET.
3. Check for an Intake Vlave System Starting flag
at the top left of any status screen.
Note: The engine will not receive full power until the
Intake Vlave System Starting flag becomes inactive.

Cold Mode
1. Start the engine.
2. Monitor the status screens on Cat ET.
3. Check for a Cold Mode flag at the top of any
status screen.
Note: The engine will not receive full power until the
Cold Mode flag becomes inactive.

Customer Specified Parameters


1. Verify that the complaint is not normal operation
(programmed parameter).
2. Access the Configuration screen on Cat ET.
3. Check the following parameters:

Lower Gears Engine RPM Limit


Intermediate Gears Engine RPM Limit

2. Ensure that the J2/P2 ECM connector is fully


connected and ensure that the ECM connector is
free of corrosion.
3. Use the Cylinder Cutout Test. Access
the Cylinder Cutout Test by selecting the
Diagnostics Test under the Diagnostic menu.
Run the Cylinder Cutout Test in order to disable
each cylinder. Disabling each cylinder allows the
technician to isolate the misfiring cylinders.
If the misfiring cylinder can be isolated to a
specific cylinder, refer to Troubleshooting, Injector
Solenoid Circuit - Test.

Power train Data Link


1. Ensure that the power train data link is not limiting
the power.
2. Monitor the Powertrain Data Link status screen
while the vehicle is experiencing problems.
If the Powertrain Data Link status screen
indicates that the Powertrain Data Link is 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.

Torque Limit Switch


1. Check the setting for the customer parameter for
the Torque Limit.
If the Torque Limit is programmed below
3400 Nm (2500 lb ft), check the status screen
for the torque limit switch. Ensure that the status
screen indicates that the torque limit switch is
OFF. If the status of the torque limit switch is
ON and a Torque Limit is programmed, the
system is operating correctly. If the switch that is
connected to this signal input is not switching ON
and switching OFF, refer to Troubleshooting, PTO
Switch Circuit - Test.

SENR9698-09

93
Troubleshooting Section

Troubleshooting with a
Diagnostic Code
i01929511

Diagnostic Codes
SMCS Code: 1900
Table 141

Flash
Code

00

01

12

13

14

17

21

24

25

Diagnostic Code

SPN-FMI Code

52-11

52-11

Air Inlet Shutoff Shutdown

84-14

84-14

Quick Stop Occurrence

166-14

166-14

Rated Engine Power Special Instructions

171-03

171-03

Ambient Air Temperature voltage high

171-04

171-04

Ambient Air Temperature voltage low

171-11

171-11

Ambient Air Temperature Data Lost

246-11

597-11

Brake Pedal Switch #1 Fault

247-11

603-11

Brake Pedal Switch #2 Fault

385-01

2948-01

71-00

Description of Code

Low Intake Valve Actuation System Oil Pressure


Idle Shutdown Override

111-02

111-02

Coolant Level signal invalid

111-03

111-03

Coolant Level voltage high

111-04

111-04

Coolant Level voltage low

174-03

174-03

Fuel Temperature voltage high

174-04

174-04

Fuel Temperature voltage low

224-11

Theft Deterrent Active

224-14

Theft Deterrent Active with Engine Cranking

121-05

1072-05

Low/High Retarder current low

121-06

1072-06

Low/High Retarder current high

122-05

1073-05

Med/High Retarder current low

122-06

1073-06

Med/High Retarder current high

168-01

168-01

Low ECM Battery Power

41-03

678-03

8 Volt Supply voltage high

41-04

678-04

8 Volt Supply voltage low

232-03

620-03

5 Volt Supply voltage high

232-04

620-04

5 Volt Supply voltage low

100-03

100-03

Oil Pressure voltage high

100-04

100-04

Oil Pressure voltage low

102-03

102-03

Boost Pressure voltage high

102-04

102-04

Boost Pressure voltage low


(continued)

94
Troubleshooting Section

SENR9698-09

(Table 141, contd)

Flash
Code

Diagnostic Code

SPN-FMI Code

108-03

108-03

Barometric Pressure voltage high

108-04

108-04

Barometric Pressure voltage low

110-03

110-03

Coolant Temperature voltage high

110-04

110-04

Coolant Temperature voltage low

91-13

91-13

Throttle Position out of Calibration

30-08

644-08

PTO Throttle signal invalid

30-13

644-13

PTO Throttle out of calibration

31

84-01

84-01

Vehicle Speed loss of signal

32

91-08

91-08

Throttle Position Invalid

64-08

723-08

Secondary Engine Speed loss of signal

190-08

190-08

Primary Engine Speed loss of signal

190-00

190-00

Engine Overspeed Warning

84-02

84-02

Vehicle Speed signal invalid

84-08

84-08

Vehicle Speed signal out of range

84-10

84-10

Vehicle Speed signal rate of change

105-03

105-03

Intake Manifold Air Temperature voltage high

105-04

105-04

Intake Manifold Air Temperature voltage low

84-00

84-00

Vehicle Overspeed Warning

22-11

637-11

Primary to Secondary Engine Speed Signal Calibration

22-13

637-13

Engine Speed Signal Calibration Not Performed

100-01

100-01

Low Oil Pressure Warning

100-11

100-11

Very Low Oil Pressure

26

27
28
29

34
35

36

38
41
42

46

47

Description of Code

71-01

Idle Shutdown

71-14

PTO Shutdown

51

168-02

168-02

55

N/A

N/A

253-02

630-02

Check Customer or System Parameters

253-11

630-11

Check Transmission Customer Parameters

231-02

639-02

J1939 Data Incorrect

231-12

639-12

J1939 Device Not Responding

252-11

631-11

Engine Software Incorrect

110-00

110-00

High Coolant Temperature Warning

110-11

110-11

Very High Coolant Temperature

111-01

111-01

Low Coolant Level Warning

111-11

111-11

Very Low Coolant Level

111-14

111-14

Low Coolant Level Warning

56

58
59
61

62

ECM Battery Power Intermittent


No Diagnostic Code Detected

(continued)

SENR9698-09

95
Troubleshooting Section

(Table 141, contd)

Flash
Code
64
65
66

67

Diagnostic Code

SPN-FMI Code

Description of Code

105-00

105-00

High Intake Manifold Air Temperature Warning

105-11

105-11

Very High Intake Manifold Air Temperature

174-00

174-00

High Fuel Temperature Warning

54-05

706-05

Auxiliary Output #06 current low

54-06

706-06

Auxiliary Output #06 current high

55-05

707-05

Auxiliary Output #07 current low

55-06

707-06

Auxiliary Output #07 current high

68

191-07

Transmission Not Responding

71

43-02

Key Switch Fault

72

73

74

91

92

93

1-05

651-05

Cylinder #1 Injector current low

1-06

651-06

Cylinder #1 Injector current high

2-05

652-05

Cylinder #2 Injector current low

2-06

652-06

Cylinder #2 Injector current high

3-05

653-05

Cylinder #3 Injector current low

3-06

653-06

Cylinder #3 Injector current high

4-05

0654-05

Cylinder #4 Injector current low

4-06

654-06

Cylinder #4 Injector current high

5-05

655-05

Cylinder #5 Injector current low

5-06

655-06

Cylinder #5 Injector current high

6-05

656-05

Cylinder #6 Injector current low

6-06

656-06

Cylinder #6 Injector current high

283-07

2949-07

Intake Valve Actuation Oil Pressure not responding

285-05

2950-05

Intake Valve Actuator #1 current low

285-06

2950-06

Intake Valve Actuator #1 current high

285-07

2950-07

Intake Valve Actuator #1 not responding

286-05

2951-05

Intake Valve Actuator #2 current low

286-06

2951-06

Intake Valve Actuator #2 current high

286-07

2951-07

Intake Valve Actuator #2 not responding

287-05

2952-05

Intake Valve Actuator #3 current low

287-06

2952-06

Intake Valve Actuator #3 current high

287-07

2952-07

Intake Valve Actuator #3 not responding

288-05

2953-05

Intake Valve Actuator #4 current low

288-06

2953-06

Intake Valve Actuator #4 current high

288-07

2953-07

Intake Valve Actuator #4 not responding


(continued)

96
Troubleshooting Section

SENR9698-09

(Table 141, contd)

Flash
Code

Diagnostic Code

SPN-FMI Code

289-05

2954-05

Intake Valve Actuator #5 current low

289-06

2954-06

Intake Valve Actuator #5 current high

289-07

2954-07

Intake Valve Actuator #5 not responding

290-05

2955-05

Intake Valve Actuator #6 current low

290-06

2955-06

Intake Valve Actuator #6 current high

290-07

2955-07

Intake Valve Actuator #6 not responding

385-03

2948-03

Intake Valve Actuation System Oil Pressure voltage high

385-04

2948-04

Intake Valve Actuation System Oil Pressure voltage low

283-05

2949-05

Intake Valve Actuation System Oil Pressure Solenoid current low

283-06

2949-06

Intake Valve Actuationr System Oil Pressure Solenoid current high

284-05

2988-05

Engine Coolant Divertor current low

284-06

2988-06

Engine Coolant Divertor current high

94

95

97

98

Description of Code

i02127620

i02183816

No Diagnostic Code Detected


(55)

0001-05 Cylinder #1 Injector


current low (72)

SMCS Code: 1900

SMCS Code: 1290-038

Conditions Which Generate This Code:

Conditions Which Generate This Code:

A flash code 55 indicates that the system has not


detected any system faults since the last powerup.

The Engine Control Module (ECM) detects a

System Response:
This code will not appear on Caterpillar Electronic
Technician (ET). The check engine lamp is used
to display the flash code. For more information on
flash codes, refer to Troubleshooting, Check Engine
Lamp Circuit - Test.
Possible Performance Effect:
None
Troubleshooting:
There are no problems that require troubleshooting.
Results:

OK STOP.

low current condition (open circuit) during five


consecutive attempts to energize the No. 1 injector.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Possible Performance Effect:

Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.

SENR9698-09

97
Troubleshooting Section

Troubleshooting:

i02183822

Perform the following diagnostic procedure: Injector


Solenoid Circuit - Test

0002-05 Cylinder #2 Injector


current low (72)

Results:

SMCS Code: 1290-038

OK STOP.

Conditions Which Generate This Code:


i02183821

0001-06 Cylinder #1 Injector


current high (72)
SMCS Code: 1290-038
Conditions Which Generate This Code:

The Engine Control Module (ECM) detects a

high current condition (short circuit) during five


consecutive attempts to energize the No. 1 injector.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Possible Performance Effect:

The Engine Control Module (ECM) detects a

low current condition (open circuit) during five


consecutive attempts to energize the No. 2 injector.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Possible Performance Effect:

Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.
Troubleshooting:

Engine misfires

Perform the following diagnostic procedure: Injector


Solenoid Circuit - Test

Low power

Results:

The injector will not operate while this diagnostic


code is active.

OK STOP.

Troubleshooting:

i02183830

Perform the following diagnostic procedure: Injector


Solenoid Circuit - Test

0002-06 Cylinder #2 Injector


current high (72)

Results:

SMCS Code: 1290-038

OK STOP.

Conditions Which Generate This Code:

The Engine Control Module (ECM) detects a

high current condition (short circuit) during five


consecutive attempts to energize the No. 2 injector.

The battery voltage is above 9 VDC for the last


two seconds.

98
Troubleshooting Section

SENR9698-09

System Response:

Troubleshooting:

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.

Perform the following diagnostic procedure: Injector


Solenoid Circuit - Test
Results:

OK STOP.

Possible Performance Effect:

i02183838

0003-06 Cylinder #3 Injector


current high (73)

Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.
Troubleshooting:
Perform the following diagnostic procedure: Injector
Solenoid Circuit - Test

SMCS Code: 1290-038


Conditions Which Generate This Code:

The Engine Control Module (ECM) detects a

high current condition (short circuit) during five


consecutive attempts to energize the No. 3 injector.

The battery voltage is above 9 VDC for the last

Results:

two seconds.

OK STOP.

System Response:
i02183835

SMCS Code: 1290-038

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.

Conditions Which Generate This Code:

Possible Performance Effect:

The Engine Control Module (ECM) detects a

Engine misfires

0003-05 Cylinder #3 Injector


current low (73)

low current condition (open circuit) during five


consecutive attempts to energize the No. 3 injector.

Low power

The battery voltage is above 9 VDC for the last

The injector will not operate while this diagnostic


code is active.

System Response:

Troubleshooting:

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.

Perform the following diagnostic procedure: Injector


Solenoid Circuit - Test

two seconds.

Possible Performance Effect:

Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.

Results:

OK STOP.

SENR9698-09

99
Troubleshooting Section

i02183847

0004-05 Cylinder #4 Injector


current low (73)

System Response:

Conditions Which Generate This Code:

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.

The Engine Control Module (ECM) detects a

Possible Performance Effect:

SMCS Code: 1290-038

low current condition (open circuit) during five


consecutive attempts to energize the No. 4 injector.

Engine misfires

The battery voltage is above 9 VDC for the last

Low power

System Response:

The injector will not operate while this diagnostic


code is active.

two seconds.

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.

Troubleshooting:

Possible Performance Effect:

OK STOP.

Perform the following diagnostic procedure: Injector


Solenoid Circuit - Test
Results:

Engine misfires

i02183884

Low power
The injector will not operate while this diagnostic
code is active.
Troubleshooting:

0005-05 Cylinder #5 Injector


current low (74)
SMCS Code: 1290-038
Conditions Which Generate This Code:

Perform the following diagnostic procedure: Injector


Solenoid Circuit - Test
Results:

The Engine Control Module (ECM) detects a

low current condition (open circuit) during five


consecutive attempts to energize the No. 5 injector.

The battery voltage is above 9 VDC for the last

OK STOP.

two seconds.

i02183861

0004-06 Cylinder #4 Injector


current high (73)

System Response:

Conditions Which Generate This Code:

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.

The Engine Control Module (ECM) detects a

Possible Performance Effect:

SMCS Code: 1290-038

high current condition (short circuit) during five


consecutive attempts to energize the No. 4 injector.

The battery voltage is above 9 VDC for the last


two seconds.

Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.

100
Troubleshooting Section

SENR9698-09

Troubleshooting:

i02183910

Perform the following diagnostic procedure: Injector


Solenoid Circuit - Test

0006-05 Cylinder #6 Injector


current low (74)

Results:

SMCS Code: 1290-038

OK STOP.

Conditions Which Generate This Code:


i02183899

0005-06 Cylinder #5 Injector


current high (74)
SMCS Code: 1290-038
Conditions Which Generate This Code:

The Engine Control Module (ECM) detects a

high current condition (short circuit) during five


consecutive attempts to energize the No. 5 injector.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Possible Performance Effect:

The Engine Control Module (ECM) detects a

low current condition (open circuit) during five


consecutive attempts to energize the No. 6 injector.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Possible Performance Effect:

Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.
Troubleshooting:

Engine misfires

Perform the following diagnostic procedure: Injector


Solenoid Circuit - Test

Low power

Results:

The injector will not operate while this diagnostic


code is active.

OK STOP.

Troubleshooting:

i02183935

Perform the following diagnostic procedure: Injector


Solenoid Circuit - Test

0006-06 Cylinder #6 Injector


current high (74)

Results:

SMCS Code: 1290-038

OK STOP.

Conditions Which Generate This Code:

The Engine Control Module (ECM) detects a

high current condition (short circuit) during five


consecutive attempts to energize the No. 6 injector.

The battery voltage is above 9 VDC for the last


two seconds.

SENR9698-09

101
Troubleshooting Section

System Response:

Troubleshooting:

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.

Test Step 1. Engine Overspeed


A. Check the ECM for indications of an engine
overspeed.

Engine misfires

B. If there are indications of an engine overspeed,


check the cluster gear for proper alignment.
Also check the cluster gear for damage. Refer
to Testing and Adjusting, Gear Group (Front) Time.

Low power

Expected Result:

The injector will not operate while this diagnostic


code is active.

The cluster gear is properly aligned and there is no


damage to the cluster gear.

Troubleshooting:

Results:

Perform the following diagnostic procedure: Injector


Solenoid Circuit - Test

OK Proceed to Test Step 2.

Possible Performance Effect:

Not OK The cluster gear is not aligned correctly


or there is damage to the cluster gear.

Results:

OK STOP.

Repair: Align the cluster gear or repair the cluster


gear.
i01942210

0022-11 Primary to Secondary


Engine Speed Signal
Calibration (42)
SMCS Code: 1912-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

A timing calibration has been successfully


completed.

The primary engine speed/timing sensor and the

secondary engine speed/timing sensor are off by


more than three degrees.

System Response:
This code will not be logged. The check engine lamp
will illuminate while this diagnostic code is active.
The ECM will use the default timing.
Possible Performance Effect:
The engine may run rough when this code is active.

Run the engine until the engine reaches operating


temperature.
Verify that the repair eliminates the problem.
STOP.

Test Step 2. Accident


A. Determine whether the vehicle has been involved
in an accident.
If the vehicle was involved in an accident, then the
cluster gear may have been damaged.
B. Check the cluster gear for damage.
Expected Result:
The cluster gear is not damaged.
Results:

OK Proceed to Test Step 3.


Not OK There is damage to the cluster gear.
Repair: Repair the cluster gear.
Run the engine until the engine reaches operating
temperature.
Verify that the repair eliminates the problem.
STOP.

102
Troubleshooting Section

Test Step 3. Cylinder Head


A. Determine whether the cylinder head was
removed.
B. If the cylinder head was removed, the backlash for
the camshaft may be out of the specification.
C. Check the backlash for the camshaft. Refer to
Testing and Adjusting, Gear Group (Front) Time.

SENR9698-09

Repair: Refer to Troubleshooting, Engine


Speed/Timing Sensor Circuit - Test.
STOP.

Not OK There is a problem with the installation


or the wiring of the engine speed/timing sensors.
Repair: Install the sensors properly or repair the
wiring.

Expected Result:

Run the engine until the engine reaches operating


temperature.

The backlash for the camshaft is within specifications.

Verify that the repair eliminates the problem.

Results:

STOP.

OK Proceed to Test Step 4.


Not OK The backlash for the camshaft is not
within specifications.

Repair: Adjust the backlash for the camshaft.

i02127666

0022-13 Engine Speed Signal


Calibration Not Performed (42)
SMCS Code: 1912-038

Refer to Testing and Adjusting, Gear Group


(Front) - Time.

Conditions Which Generate This Code:

Run the engine until the engine reaches operating


temperature.

The Engine Control Module (ECM) detects the


following conditions:

Verify that the repair eliminates the problem.

A timing calibration has never been performed on

STOP.

Test Step 4. Engine Speed/Timing


Sensors
A. Check the engine speed/timing sensors for proper
installation. The engine speed/timing sensors
cannot be interchanged.
B. Verify that the sensor wires are connected
properly. Refer to the electrical schematic for
proper wiring. Make sure that the positive terminal
on the ECM is connected to the positive terminal
on the engine speed/timing sensors. Also, make
sure that the negative terminal on the ECM is
connected to the negative terminal on the engine
speed/timing sensors.

a new ECM or the timing is off by more than three


degrees.

System Response:
This code will not be logged. The check engine lamp
will illuminate while this diagnostic code is active. The
ECM uses default timing.
Possible Performance Effect:
The engine may run rough or the engine may emit
white smoke in the exhaust.
Troubleshooting:
Perform the following diagnostic procedure: Engine
Speed/Timing Sensor - Calibrate

Expected Result:

Results:

The engine speed/timing sensors are properly


installed. Also, the engine speed/timing sensors are
wired correctly.

OK STOP.

Results:

OK

SENR9698-09

103
Troubleshooting Section

i02127764

0030-08 PTO Throttle signal


invalid (29)

The duty cycle of the signal for the PTO throttle is


less than 5 percent or more than 95 percent for
more than two seconds.

The PTO Configuration is programmed to Remote


Throttle.

SMCS Code: 1913-038


Conditions Which Generate This Code:

The ECM has been powered for at least three

The Engine Control Module (ECM) detects the


following conditions:

System Response:

seconds.

The PTO Configuration is programmed to


Remote Throttle.

The ECM is not receiving a valid signal from the


PTO throttle.

The ECM returns the engine to low idle when the


problem is detected. DIAG will be displayed next
to the status for Throttle Position on Caterpillar
Electronic Technician (ET).
Possible Performance Effect:

The ECM has been powered for at least three


seconds.
Note: If the PTO Configuration is programmed to
Remote Throttle, the ECM must receive a proper
signal from the remote throttle at all times. The
remote throttle signal must be present even when the
PTO ON/OFF switch is in the OFF position.

The engine will remain at low idle while the diagnostic


code is active.
Troubleshooting:
Note: The remote accelerator pedal position sensor
can not be calibrated.
Perform the following diagnostic procedure: Remote
PTO Accelerator Position Sensor Circuit - Test

System Response:
The ECM returns the engine to low idle when the
problem is detected. DIAG will be displayed next
to the status for Throttle Position on Caterpillar
Electronic Technician (ET).

Results:

OK STOP.

Possible Performance Effect:

i01942209

The engine will remain at low idle while the diagnostic


code is active.
Troubleshooting:

0041-03 8 Volt Supply voltage


high (21)
SMCS Code: 5574-038

Perform the following diagnostic procedure: Remote


PTO Accelerator Position Sensor Circuit - Test

Conditions Which Generate This Code:

Results:

The Engine Control Module (ECM) detects the


following conditions:

OK STOP.

The 8 volt supply is more than 8.5 VDC for more


than one second.

i02127769

0030-13 PTO Throttle out of


calibration (29)
SMCS Code: 1913-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The ECM has been powered for more than three


seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. An
active diagnostic code may not cause any noticeable
effect on engine response unless the voltage is
above 12 or 13 VDC.

104
Troubleshooting Section

SENR9698-09

Possible Performance Effect:

i02490821

0043-02 Key Switch Fault (71)

The engine may be limited to low idle.


Note: The 8 volt supply provides power to the
accelerator pedal position sensor.
Troubleshooting:
Perform the following diagnostic procedure:
Accelerator Pedal (Throttle) Position Sensor Circuit Test
Results:

OK STOP.
i02127795

0041-04 8 Volt Supply voltage


low (21)
SMCS Code: 5574-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The 8 volt supply is less than 7.5 VDC for more


than one second.
The ECM has been powered for more than three
seconds.

SMCS Code: 1408-038; 1553-038


Conditions Which Generate This Code:
The Engine Control Module (ECM) detects that the
keyswitch was cycled at least three times within one
second.
This indicates that the battery circuit to the keyswitch
has an intermittent condition or a low battery condition
while the engine is running.
Note: This code can be generated by rapidly cycling
the keyswitch. Some control modules on the vehicle
require this action in order to prompt flash codes. If
this occurs, clear the logged diagnostic codes in order
to prevent future confusion or an incorrect diagnosis.
Note: This code can also be generated when there
is an attempt to restart the engine immediately after
a shutdown. The engine may not start if the engine
speed did not reach zero rpm prior to the restart.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM will stop energizing the injector solenoids.
Possible Performance Effect:

System Response:

Engine shutdown

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. An
active diagnostic code may not cause any noticeable
effect on engine response unless the voltage drops
below 6.5 VDC.

Troubleshooting:

Possible Performance Effect:

OK STOP.

Perform the following diagnostic procedure: Ignition


Keyswitch Circuit and Battery Supply Circuit - Test
Results:

The engine may be limited to low idle.


Note: The 8 volt supply provides power to the
accelerator pedal position sensor.
Troubleshooting:
Perform the following diagnostic procedure:
Accelerator Pedal (Throttle) Position Sensor Circuit Test
Results:

OK STOP.

i01942207

0052-11 Air Inlet Shutoff


Shutdown (00)
SMCS Code: 1078-038
Conditions Which Generate This Code:
This code indicates that the engine was shutdown
due to an engine overspeed condition.

SENR9698-09

105
Troubleshooting Section

The Engine Control Module (ECM) detects the


following conditions:

Engine speed is greater than 2500 rpm.


Air Inlet Shutoff Relay Control is programmed to
J2/P2:13.

System Response:
The solenoid that is currently enabled will remain in
the ON position until neutral is detected. Then manual
operation occurs until the system powers down.
Manual operation is defined as both solenoids OFF.
Possible Performance Effect:

There is no detected vehicle speed.

The ECM disables the Eaton Top 2 mode.

There are no active vehicle speed faults.

Troubleshooting:

All required interlocks are set.

Perform the following diagnostic procedure: Eaton


Top 2 Transmission Circuit - Test

System Response:
The ECM will disable the unit injectors and the ECM
will activate the air inlet shutoff relay.
Possible Performance Effect:

Results:

OK STOP.
i02184006

The engine will shut down.

0054-06 Auxiliary Output #06


current high (66)

Troubleshooting:

Talk to the Operator

SMCS Code: 1901-038

Determine the reason for the engine overspeed.


Results:

OK The reason for the engine overspeed was


determined. STOP.
Not OK The reason for the engine overspeed
was not determined.

Repair: If there is a problem with the air inlet


shutoff circuit, refer to Troubleshooting, Air Inlet
Shutoff Circuit - Test.
STOP.
i02184005

0054-05 Auxiliary Output #06


current low (66)

Conditions Which Generate This Code:


The Engine Control Module (ECM) detects the
following conditions:

There is a high current condition (short circuit) in


the circuit for the lockout solenoid for more than
two seconds.

The Transmission Style is programmed to Eaton


Top 2.

System Response:
The solenoid that is currently enabled will remain in
the ON position until neutral is detected. Then manual
operation occurs until the system powers down.
Manual operation is defined as both solenoids OFF.
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 low current condition (open circuit) in

Results:

the circuit for the lockout solenoid for more than


two seconds.

The Transmission Style is programmed to Eaton


Top 2.

OK STOP.

106
Troubleshooting Section

SENR9698-09

i02184021

0055-05 Auxiliary Output #07


current low (67)

System Response:

SMCS Code: 1901-038

The solenoid that is currently enabled will remain in


the ON position until neutral is detected. Then manual
operation occurs until the system powers down.
Manual operation is defined as both solenoids OFF.

Conditions Which Generate This Code:

Possible Performance Effect:

The Engine Control Module (ECM) detects the


following conditions:

The ECM disables the Eaton Top 2 mode.

There is a low current condition (open circuit) in


the circuit for the shift solenoid.

The Transmission Style is programmed to Eaton


Top 2.

Troubleshooting:
Perform the following diagnostic procedure: Eaton
Top 2 Transmission Circuit - Test
Results:

OK STOP.

System Response:
The solenoid that is currently enabled will remain in
the ON position until neutral is detected. Then manual
operation occurs until the system powers down.
Manual operation is defined as both solenoids OFF.
Possible Performance Effect:

i01942351

0064-08 Secondary Engine


Speed loss of signal (34)
SMCS Code: 1912-038

The ECM disables the Eaton Top 2 mode.

Conditions Which Generate This Code:

Troubleshooting:
Perform the following diagnostic procedure: Eaton
Top 2 Transmission Circuit - Test

The Engine Control Module (ECM) detects the


following conditions:

The signal from the secondary engine speed/timing


sensor has been lost and the engine speed did not
pass through the range of 350 rpm to 500 rpm.

Results:

OK STOP.

The engine has been running for more than three


seconds.

i02184022

0055-06 Auxiliary Output #07


current high (67)
SMCS Code: 1901-038

The battery voltage is greater than 9 VDC for more


than two seconds prior to the loss of the signal.

System Response:

The Engine Control Module (ECM) detects the


following conditions:

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will ignore the
secondary engine speed/timing sensor.

There is a high current condition (short circuit) in

Possible Performance Effect:

Conditions Which Generate This Code:

the circuit for the shift solenoid.

The Transmission Style is programmed to Eaton


Top 2.

None
Note: If the signals from both engine speed/timing
sensors are lost, then the engine will shut down.

SENR9698-09

107
Troubleshooting Section

Troubleshooting:

Results:

Perform the following diagnostic procedure: Engine


Speed/Timing Sensor Circuit - Test

OK STOP.
i02215914

Results:

0071-01 Idle Shutdown (47)

OK STOP.

SMCS Code: 1901-038


i02127822

0071-00 Idle Shutdown


Override (01)
SMCS Code: 1901-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects one of
the following conditions:

The Allow Idle Shutdown Override parameter is


programmed to Yes and the status of the brake
switch or the clutch switch changes.

The Allow Idle Shutdown Override parameter

is programmed to J1587 Outside Temp Based


or Outside Temperature Based. The outside
temperature is above the maximum programmed
temperature or the outside temperature is below
the minimum programmed temperature.

Conditions Which Generate This Code:


The Engine Control Module (ECM) detects the
following conditions:

The idle shutdown timer has expired and the


engine has shut down.

The Idle Shutdown Time parameter is


programmed to at least three minutes.

Vehicle speed is zero mph.


Coolant temperature is greater than 38 C (100 F).
System Response:
The ECM remains powered after the engine
shutdown. COUNTING will be displayed next to
the status for Idle Shutdown Status on Caterpillar
Electronic Technician (ET).

The ECM also detects the following conditions:

Customer passwords are required to clear this


diagnostic code.

The idle shutdown timer is within the final 90

Possible Performance Effect:

seconds.

The Idle Shutdown Time parameter is


programmed to at least three minutes.

System Response:
The idle shutdown timer stops counting. OVERRIDE
will be displayed next to the status for Idle Shutdown
Status on Caterpillar Electronic Technician (ET).
Note: The idle shutdown timer will not begin counting
again for shutdown until the vehicle is moved and the
accelerator pedal is depressed.
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:
None
Troubleshooting:
Perform the following diagnostic procedure: Idle
Shutdown Timer - Test

The engine is shut down.


Troubleshooting:
Perform the following diagnostic procedure: Idle
Shutdown Timer - Test
Results:

OK STOP.
i02127845

0071-14 PTO Shutdown (47)


SMCS Code: 1901-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The timer for the PTO has expired and the engine
has shut down.

108
Troubleshooting Section

SENR9698-09

The PTO on/off switch is in the ON position.

Troubleshooting:

The PTO Configuration parameter is programmed

This diagnostic code does not necessarily indicate


that there is an electronic problem. If the vehicle
speed calibration is wrong, perform the following
procedure:

to Cab Switches, Remote Switches, or Remote


Throttle.

The PTO Shutdown Time parameter is


programmed to at least three minutes.

Perform the following diagnostic procedure: Vehicle


Speed Circuit - Calibrate

System Response:
The ECM remains powered after the engine
shutdown. NOT ACTIVE will be displayed next
to the status for PTO Shutdown on Caterpillar
Electronic Technician (ET).
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:

Results:

OK STOP.
i02184035

0084-01 Vehicle Speed loss of


signal (31)
SMCS Code: 7463-038

The engine is shut down.

Conditions Which Generate This Code:

Troubleshooting:
Perform the following diagnostic procedure: PTO
Shutdown Timer - Test

The Engine Control Module (ECM) detects the


following conditions:

The vehicle speed signal indicates that the vehicle


speed is 0 MPH.

Results:

Engine speed is greater than the programmed

OK STOP.
i02138185

0084-00 Vehicle Overspeed


Warning (41)
SMCS Code: 7463-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following condition:

Vehicle speed exceeds the programmable Vehicle


Overspeed Threshold for one second.

System Response:
The ECM will not energize the injector solenoids
while the diagnostic code is active. Vehicle Speed
Limit will be displayed on the status screen.
Customer passwords are required to clear this code.
Possible Performance Effect:
Injection is disabled until the vehicle speed falls
below the programmed Vehicle Overspeed.

VSL Protection minus 100 RPM for at least 0.06


seconds.

Desired engine speed is greater than the


programmed VSL Protection.

The change in engine speed is less than 133 RPM


per second for at least 0.06 seconds.

The VSL Protection parameter is programmed to


a value that is less than 2120 rpm.

The following condition must also be met if the


Vehicle Speed Input is programmed to J1939-ABS
or J1939-Trans.

The message for vehicle speed is not received

over the J1939 data link for more than 0.5 seconds.

System Response:
The ECM will limit engine rpm to the programmed
VSL Protection. If the ECM is providing the
speedometer signal, the speedometer will show 0
rpm. DIAG will be displayed next to the status
for Vehicle Speed on the Caterpillar Electronic
Technician (ET).

SENR9698-09

109
Troubleshooting Section

Possible Performance Effect:

Troubleshooting:

The ECM will limit engine rpm to the programmed


VSL Protection.

This code may indicate tampering with the vehicle


speed circuit.

Note: A fuel system restriction has been known to


cause this diagnostic code although this occurrence
is not common. This situation exists because the
injectors are unable to provide sufficient fuel in
order to achieve the desired rpm under normal load
conditions. Because the ECM cannot reach the
desired rpm under the normal load conditions, the
ECM suspects that the vehicle is under load. This
should only occur when the vehicle is in motion.

Perform the following diagnostic procedure: Vehicle


Speed and Speedometer Circuit - Test

Troubleshooting:
Check the fuel pressure in order to ensure that a fuel
system restriction is not the cause of the problem
when the vehicle is not moving.
Perform the following diagnostic procedure: Vehicle
Speed and Speedometer Circuit - Test
Results:

Results:

OK STOP.
i02184042

0084-08 Vehicle Speed signal


out of range (36)
SMCS Code: 7463-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The vehicle speed signal indicates that vehicle

speed is greater than 127.5 MPH for more than


two seconds.

OK STOP.
i02184041

0084-02 Vehicle Speed signal


invalid (36)
SMCS Code: 7463-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The vehicle speed signal indicates a constant


MPH.

Engine speed is greater than 950 rpm for at least


0.06 seconds.

The VSL Protection parameter is programmed to


a value that is less than 2120 rpm.

System Response:
Vehicle speed is set to 0 km/h (0 mph). If the ECM is
providing the speedometer signal, the speedometer
will not display vehicle speed. DIAG will be
displayed next to the status for Vehicle Speed on
the Caterpillar Electronic Technician (ET).
Possible Performance Effect:
The ECM will limit the engine speed to the
programmed VSL Protection.
Troubleshooting:

The VSL Protection parameter is programmed to

Perform the following diagnostic procedure: Vehicle


Speed and Speedometer Circuit - Test

System Response:

Results:

DIAG will be displayed next to the status for Vehicle


Speed on the Caterpillar Electronic Technician (ET).

OK STOP.

a value that is less than 2120 rpm.

Possible Performance Effect:


Engine rpm is limited to the programmed VSL
Protection for one hour.

110
Troubleshooting Section

SENR9698-09

i01863539

0084-10 Vehicle Speed signal


rate of change (36)
SMCS Code: 7463-038

System Response:
The ECM records the engine speed, vehicle speed,
the throttle position, cruise control status, clutch
switch status and brake switch status.

Conditions Which Generate This Code:

Customer passwords are required to clear this


diagnostic code.

The ECM detects the following conditions:

Possible Performance Effect:

The vehicle speed signal changes more than

None

5 MPH on eight consecutive readings in three


seconds.

Troubleshooting:

The engine speed is greater than the programmed

This diagnostic code does not represent an electronic


system fault.

The VSL Protection parameter is programmed to

An excessive number of occurrences may be caused


by the following circumstance:

Note: If the ABS is the source of the vehicle speed,


the ABS must not be active.

The parameter for the Quick Stop Rate may be

System Response:

Note: This setting can be affected by the load on the


vehicle. If the vehicle is operated without a trailer
or with no load, the vehicle will stop faster than the
same vehicle with a heavy load.

VSL Protection minus 100 rpm.

a value that is less than 2120 rpm.

DIAG will be displayed next to the status for Vehicle


Speed on the electronic service tool. The check
engine lamp will illuminate.
Possible Performance Effect:

set too low.

Expected Result:
Results:

Engine rpm is limited to the programmed VSL


Protection for eight seconds.

OK STOP.

Troubleshooting:

i02303725

Perform the following diagnostic procedure: Vehicle


Speed and Speedometer Circuit - Test
Results:

SMCS Code: 1913-038

OK STOP.

Conditions Which Generate This Code:


i02127996

0084-14 Quick Stop


Occurrence
SMCS Code: 7463-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The vehicle speed slows at a rate that exceeds the


Quick Stop Rate that is programmed.

The service brake is applied.

0091-08 Throttle Position


Invalid (32)

The Engine Control Module (ECM) detects the


following conditions:

The signal frequency from the accelerator pedal

position sensor is less than 150 Hz or the signal


frequency is greater than 1050 Hz for more than
two seconds.

The ECM has been powered for at least three


seconds.

SENR9698-09

111
Troubleshooting Section

System Response:

i01921852

0100-01 Low Oil Pressure


Warning (46)

The ECM sets the Throttle Position to


0%. DIAG will be displayed next
to the status for Throttle Position on
Caterpillar Electronic technician (ET).

SMCS Code: 1924-038

Possible Performance Effect:

Conditions Which Generate This Code:

The engine will remain at low idle while the diagnostic


code is active.

The Engine Control Module (ECM) detects the


following conditions:

Troubleshooting:

The engine oil pressure is below the trip line in

Perform the following diagnostic procedure:


Accelerator Pedal (Throttle) Position Sensor Circuit Test

Illustration 19 or in Illustration 20 for more than


eight seconds.

Results:

OK STOP.
i02184044

0091-13 Throttle Position out


of calibration (28)
SMCS Code: 1913-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The duty cycle for the accelerator pedal position

sensor is less than 5 percent or the duty cycle is


greater than 95 percent for more than two seconds.

The ECM has been powered for at least three

Illustration 19

g00997504

C11 and C13 low oil pressure

seconds.

System Response:
The ECM sets Throttle Position to 0%. DIAG will
be displayed next to the status for Throttle Position
on the Caterpillar Electronic Technician (ET).
Possible Performance Effect:
The engine will remain at low idle while the diagnostic
code is active.
Troubleshooting:
Perform the following diagnostic procedure:
Accelerator Pedal (Throttle) Position Sensor Circuit Test
Results:

OK STOP.

Illustration 20
C15 low oil pressure

g00997505

112
Troubleshooting Section

System Response:
The Caterpillar Electronic Technician (Cat ET) will
display LOW OIL PRESSURE and DIAG next
to the status for Engine Oil Pressure. The check
engine lamp and the warning lamp will illuminate.
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:
None
Troubleshooting:

Test Step 1. Check the Engine Oil Level


A. Check the engine oil level.
Expected Result:
The engine oil level is OK.
Results:

OK The engine oil level is OK. Proceed to Test


Step 2.

Not OK The engine oil level is low.


Repair: Add engine oil to the proper level. Refer to
the Operation and Maintenance Manual for more
information.
STOP.

Test Step 2. Verify Proper Sensor


Installation
A. Check the installation of the engine oil pressure
sensor.
B. Check the wiring of the engine oil pressure sensor.
Refer to the Electrical Schematic for the proper
wiring. Ensure that all of the wires and connectors
are properly connected.
Expected Result:
The sensor is properly installed and the wiring is
correct.
Results:

OK The sensor is properly installed. Proceed


to Test Step 3.

Not OK The sensor is not installed properly.

SENR9698-09

Repair: Install the engine oil pressure sensor


properly. Repair the wiring and/or the connectors
to the sensor.
Verify that the repair eliminates the problem.
STOP.

Test Step 3. Check for Active Diagnostic


Codes
A. Connect Cat ET to the data link connector.
B. Check for active diagnostic codes that are related
to the barometric pressure sensor (atmospheric
pressure) or to the boost pressure sensor.
Expected Result:
There are no diagnostic codes that are related to the
barometric pressure sensor (atmospheric pressure)
or to the boost pressure sensor.
Results:

OK There are no diagnostic codes. Proceed to


Test Step 4.

Not OK There is a diagnostic code that is related


to the barometric pressure sensor (atmospheric
pressure) and/or to the boost pressure sensor.

Repair: Troubleshoot the diagnostic code before


continuing with this procedure.
STOP.

Test Step 4. Check the Status Screen


A. Turn the key switch to the ON position. The engine
should be off.
B. Monitor the status for Boost Pressure and
Engine Oil Pressure on Cat ET.
Expected Result:
Boost Pressure and Engine Oil Pressure are less
than 10 kPa (2 psi).
Results:

OK The boost pressure and the engine oil

pressure are less than 10 kPa (2 psi). Proceed to


Test Step 6.

Not OK - Boost Pressure The boost pressure is

greater than 10 kPa (2 psi). Proceed to Test Step 8.

SENR9698-09

113
Troubleshooting Section

Not OK - Engine Oil Pressure The engine oil

B. Install a 1U-5470 Engine Pressure Group into


the oil gallery with a Tee fitting in the port for the
engine oil pressure sensor.

Not OK - Both The boost pressure and the

C. Connect the engine oil pressure sensor to the


Tee fitting.

pressure is greater than 10 kPa (2 psi). Proceed


to Test Step 9.
engine oil pressure are greater than 10 kPa (2 psi).
Proceed to Test Step 5.

Test Step 5. Check the Supply Voltage to


the Pressure Sensors
A. Disconnect the barometric pressure sensor
(atmospheric pressure), the boost pressure
sensor, and the engine oil pressure sensor.
B. Turn the key switch to the ON position.

D. Turn the key switch to the ON position.


E. Monitor the status for Engine Oil Pressure on
Cat ET.
F. Start the engine and run the engine at low idle.
G. Compare the pressure reading on the gauge to
the pressure reading on Cat ET.

C. Measure the voltage between terminal A (Engine


Pressure Sensor +5V) and terminal B (Engine
Pressure Sensor Common) of each pressure
sensor connector on the engine harness.

H. Monitor the status screen and the gauge while


you increase the engine speed.

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:

OK The voltage is within the range.


Repair: Reconnect the engine oil pressure sensor
and the boost pressure sensor.
Temporarily connect a new barometric pressure
sensor (atmospheric pressure).
If the new sensor fixes the problem, reconnect the
suspect sensor.

Expected Result:

Results:

OK The sensor is functioning properly. Proceed


to Test Step 7.

Not OK The sensor is not functioning properly.


Repair: Temporarily install a new engine oil
pressure sensor.
If the new sensor repairs the problem, reinstall the
suspect sensor.
If the problem returns, replace the sensor.

If the problem returns, permanently 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.


Repair: Check the J2/P2 ECM connector and the
sensor connectors for corrosion and for moisture.

Test Step 7. Compare the Readings to the


Oil Pressure Map
A. Compare the readings from the pressure gauge
to the oil pressure maps in Illustration 19 or
Illustration 20.

Check the 5 volt supply wire. Verify that the wire


is not cut and that the wire is completely inserted
into the connectors for the pressure sensors on
the engine harness.

Expected Result:

Verify that the repair eliminates the problem.

Results:

STOP.

OK The engine oil pressure appears to be OK

Test Step 6. Install a Pressure Gauge


A. Remove the engine oil pressure sensor.

The engine oil pressure is above the trip points in


Illustration 19 or Illustration 20.

at this time. STOP.

114
Troubleshooting Section

Not OK The engine oil pressure is lower than


the trip line on the oil pressure map. There is a
mechanical problem.

Repair: Refer to Testing and Adjusting, Engine


Oil Pressure - Test.
STOP.

Test Step 8. Check the Supply Voltage to


the Boost Pressure Sensor

SENR9698-09

B. Turn the key switch to the ON position.


C. Measure the voltage between terminal A (Engine
Pressure Sensor +5V) and terminal B (Engine
Pressure Sensor Common) of the connector for
the engine oil pressure sensor on the engine
harness.
Expected Result:
The voltage is 5.0 0.16 VDC.

A. Disconnect the boost pressure sensor.

Results:

B. Turn the key switch to the ON position.

OK The voltage is within the range.

C. Measure the voltage between terminal A (Engine


Pressure Sensor +5V) and terminal B (Engine
Pressure Sensor Common) of the connector for
the boost pressure sensor on the engine harness.
Expected Result:

Repair: Temporarily connect a new engine oil


pressure sensor.
If the new sensor fixes the problem, reconnect the
suspect sensor.

The voltage is 5.0 0.16 VDC.

If the problem returns, permanently replace the


sensor.

Results:

Verify that the repair eliminates the problem.

OK The voltage is within the range.

STOP.

Repair: Temporarily connect a new boost pressure


sensor.
If the new sensor fixes the problem, reconnect the
suspect sensor.
If the problem returns, permanently replace the
sensor.
Verify that the repair eliminates the problem.
STOP.

Not OK There is a problem with the 5 volt supply.


Repair: Check the sensor connector for corrosion
and for moisture.
Check the 5 volt supply wire. Verify that the wire
is not cut and that the wire is completely inserted
into the connector for the boost pressure sensor
on the engine harness.
Verify that the repair eliminates the problem.
STOP.

Test Step 9. Check the Supply Voltage to


the Engine Oil Pressure Sensor
A. Disconnect the engine oil pressure sensor.

Not OK There is a problem with the 5 volt supply.


Repair: Check the sensor connector for corrosion
and for moisture.
Check the 5 volt supply wire. Verify that the wire is
not cut and that the wire is completely inserted into
the connector for the engine oil pressure sensor
on the engine harness.
Verify that the repair eliminates the problem.
STOP.
i02195527

0100-03 Oil Pressure voltage


high (24)
SMCS Code: 1924-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The signal voltage from the engine oil pressure


sensor is greater than 4.95 VDC for more than
eight seconds.

SENR9698-09

115
Troubleshooting Section

The ECM has been powered for at least two

The engine is running or atmospheric pressure is

The 168-01 Low ECM Battery Power is not active.

Note: Atmospheric pressures below 79 kPa (12 psi)


may cause this code to become active only when the
engine is running. This low atmospheric pressure
causes the signal voltage to drop below the trip point
of 0.2 VDC in a good circuit.

seconds.

The 232-03 5 Volt Supply voltage high is not active.


The 232-04 5 Volt Supply voltage low is not active.
The engine is not running or the engine coolant
temperature is greater than 38 C (100 F).

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will default to
600 kPa (88 psi) for engine oil pressure.
Note: The engine oil pressure that is displayed on the
Caterpillar Electronic Technician (ET) is the default
value for engine oil pressure.

greater than 80 kPa (12 psi).

Note: Elevations that are higher than 1900 m


(6300 ft) will have atmospheric pressures that are
below 79 kPa (12 psi).
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will default to
600 kPa (88 psi) for engine oil pressure.

Possible Performance Effect:

Note: The engine oil pressure that is displayed on the


Caterpillar Electronic Technician (ET) is the default
value for engine oil pressure minus the atmospheric
pressure.

None

Possible Performance Effect:

Troubleshooting:

None

Perform the following diagnostic procedure: Engine


Pressure Sensor Open or Short Circuit - Test

Troubleshooting:

Results:

Perform the following diagnostic procedure: Engine


Pressure Sensor Open or Short Circuit - Test

OK STOP.

Results:
i02195676

0100-04 Oil Pressure voltage


low (24)

OK STOP.
i01921853

SMCS Code: 1924-038

0100-11 Very Low Oil Pressure


(46)

Conditions Which Generate This Code:

SMCS Code: 1924-038

The Engine Control Module (ECM) detects the


following conditions:

Conditions Which Generate This Code:

The signal voltage from the engine oil pressure

sensor is less than 0.2 VDC for more than eight


seconds.

The ECM has been powered for at least two


seconds.

The 168-01 Low ECM Battery Power is not active.


The 232-03 5 Volt Supply voltage high is not active.
The 232-04 5 Volt Supply voltage low is not active.

The Engine Control Module (ECM) detects the


following conditions:

The engine oil pressure is below the trip line in

Illustration 21 or in Illustration 22 for more than


eight seconds.

116
Troubleshooting Section

SENR9698-09

Possible Performance Effect:


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).
Note: If the Engine Monitoring parameter is
programmed to Shutdown, the engine will be
shutdown after this code has been active for 30
seconds.
Note: If Engine Monitoring is programmed to
Warning the engine power will not be affected.
Troubleshooting:

Test Step 1. Check the Engine Oil Level


A. Check the engine oil level.
Expected Result:
Illustration 21

g00998095

The engine oil level is OK.

C11 and C13 map for very low oil pressure

Results:

OK The engine oil level is OK. Proceed to Test


Step 2.

Not OK The engine oil level is low.


Repair: Add engine oil to the proper level. Refer to
the Operation and Maintenance Manual for more
information.
STOP.

Test Step 2. Verify Proper Sensor


Installation
A. Check the installation of the engine oil pressure
sensor.

C15 map for very low oil pressure

B. Check the wiring of the engine oil pressure sensor.


Refer to the Electrical Schematic for the proper
wiring. Ensure that all of the wires and connectors
are properly connected.

System Response:

Expected Result:

The Caterpillar Electronic Technician (Cat ET) will


display LOW OIL PRESSURE and DIAG next
to the status for Engine Oil Pressure. The check
engine lamp and the warning lamp will illuminate.

The sensor is properly installed and the wiring is


correct.

Customer passwords are required to clear this


diagnostic code.

OK The sensor is properly installed. Proceed

Illustration 22

g00998096

Results:
to Test Step 3.

Not OK The sensor is not installed properly.

SENR9698-09

117
Troubleshooting Section

Repair: Install the engine oil pressure sensor


properly. Repair the wiring and/or the connectors
to the sensor.

Not OK - Both The boost pressure and the

Verify that the repair eliminates the problem.

Test Step 5. Check the Supply Voltage to


the Pressure Sensors

STOP.

engine oil pressure are greater than 10 kPa (2 psi).


Proceed to Test Step 5.

Test Step 3. Check for Active Diagnostic


Codes

A. Disconnect the barometric pressure sensor


(atmospheric pressure), the boost pressure
sensor, and the engine oil pressure sensor.

A. Connect Cat ET to the data link connector.

B. Turn the key switch to the ON position.

B. Check for active diagnostic codes that are related


to the barometric pressure sensor (atmospheric
pressure) or the boost pressure sensor.

C. Measure the voltage between terminal A (Engine


Pressure Sensor +5V) and terminal B (Engine
Pressure Sensor Common) of each pressure
sensor connector on the engine harness.

Expected Result:
There are no diagnostic codes that are related to the
barometric pressure sensor (atmospheric pressure)
or the boost pressure sensor.
Results:

OK There are no diagnostic codes. Proceed to


Test Step 4.

Not OK There is a diagnostic code that is related

Expected Result:
The voltage is 5.0 0.16 VDC.
Results:

OK The voltage is within the range.


Repair: Reconnect the engine oil pressure sensor
and the boost pressure sensor.

to the barometric pressure sensor (atmospheric


pressure) and/or to the boost pressure sensor.

Temporarily connect a new barometric pressure


sensor (atmospheric pressure).

Repair: Troubleshoot the diagnostic code before


continuing with this procedure.

If the new sensor fixes the problem, reconnect the


suspect sensor.

STOP.

If the problem returns, permanently replace the


sensor.

Test Step 4. Check the Status Screen


A. Turn the key switch to the ON position. The engine
should be off.
B. Monitor the status for Boost Pressure and
Engine Oil Pressure on Cat ET.
Expected Result:
Boost Pressure and Engine Oil Pressure are less
than 10 kPa (2 psi).

Verify that the repair eliminates the problem.


STOP.

Not OK There is a problem with the 5 volt supply.


Repair: Check the J2/P2 ECM connector and the
sensor connectors for corrosion and for moisture.

Results:

Check the 5 volt supply wire. Verify that the wire


is not cut and that the wire is completely inserted
into the connectors for the pressure sensors on
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.

Not OK - Boost Pressure The boost pressure is

greater than 10 kPa (2 psi). Proceed to Test Step 8.

Not OK - Engine Oil Pressure The engine oil

pressure is greater than 10 kPa (2 psi). Proceed


to Test Step 9.

STOP.

Test Step 6. Install a Pressure Gauge


A. Remove the engine oil pressure sensor.
B. Install a 1U-5470 Engine Pressure Group into
the oil gallery with a Tee fitting in the port for the
engine oil pressure sensor.

118
Troubleshooting Section

SENR9698-09

C. Connect the engine oil pressure sensor to the


Tee fitting.

Repair: Refer to Testing and Adjusting, Engine


Oil Pressure - Test.

D. Turn the key switch to the ON position.

STOP.

E. Monitor the status for Engine Oil Pressure on


Cat ET.

Test Step 8. Check the Supply Voltage to


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


the pressure reading on Cat ET.

B. Turn the key switch to the ON position.

H. Monitor the status screen and the gauge while


you increase the engine speed.
Expected Result:
The gauge and the status screen are within 35 kPa
(5.0 psi) of each other.

C. Measure the voltage between terminal A (Engine


Pressure Sensor +5V) and terminal B (Engine
Pressure Sensor Common) of the connector for
the boost pressure sensor on the engine harness.
Expected Result:
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.

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 21 or
Illustration 22.

Check the 5 volt supply wire. Verify that the wire


is not cut and that the wire is completely inserted
into the connector for the boost pressure sensor
on the engine harness.

Expected Result:
The engine oil pressure is above the trip points in
Illustration 21 or Illustration 22.
Results:

OK The engine oil pressure appears to be OK


at this time. STOP.

Not OK The engine oil pressure is lower than


the trip line on the oil pressure map. There is a
mechanical problem.

Verify that the repair eliminates the problem.


STOP.

Test Step 9. Check the Supply Voltage to


the Engine Oil Pressure Sensor
A. Disconnect the engine oil pressure sensor.
B. Turn the key switch to the ON position.

SENR9698-09

119
Troubleshooting Section

C. Measure the voltage between terminal A (Engine


Pressure Sensor +5V) and terminal B (Engine
Pressure Sensor Common) of the connector for
the engine oil pressure sensor on the engine
harness.
Expected Result:
The voltage is 5.0 0.16 VDC.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM will default to 100 kPa (14.5 psi) for boost
pressure.
Note: The boost pressure that is displayed on the
Caterpillar Electronic Technician (ET) is the default
value for boost pressure minus the atmospheric
pressure.

Results:

OK The voltage is within the range.


Repair: Temporarily connect a new engine oil
pressure sensor.
If the new sensor fixes the problem, reconnect the
suspect sensor.

Possible Performance Effect:


The engine will experience low power when this
diagnostic code is active.
Troubleshooting:

If the problem returns, permanently replace the


sensor.

Perform the following diagnostic procedure: Engine


Pressure Sensor Open or Short Circuit - Test

Verify that the repair eliminates the problem.

Results:

STOP.

OK STOP.

Not OK There is a problem with the 5 volt supply.


Repair: Check the sensor connector for corrosion
and for moisture.
Check the 5 volt supply wire. Verify that the wire is
not cut and that the wire is completely inserted into
the connector for the engine oil pressure sensor
on the engine harness.
Verify that the repair eliminates the problem.
STOP.

i02128311

0102-04 Boost Pressure


voltage low (25)
SMCS Code: 1917-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The signal voltage from the boost pressure sensor


i02128303

0102-03 Boost Pressure


voltage high (25)
SMCS Code: 1917-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The signal voltage from the boost pressure sensor


is greater than 4.95 VDC for more than two
seconds.

The ECM has been powered for at least two


seconds.

The engine is not running or the rack position is

less than 50 percent with the engine retarder off.

is less than 0.2 VDC for more than one second.

The ECM has been powered for at least two


seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM will default to 100 kPa (14.5 psi) for boost
pressure.
Note: The boost pressure that is displayed on the
Caterpillar Electronic Technician (ET) is the default
value for boost pressure minus the atmospheric
pressure.
Possible Performance Effect:
The engine will experience low power when this
diagnostic code is active.

120
Troubleshooting Section

SENR9698-09

Troubleshooting:
Perform the following diagnostic procedure: Engine
Pressure Sensor Open or Short Circuit - Test
Results:

Note: The engine coolant is used to cool the intake


air after the turbochargers and before the air-to-air
aftercooler.
Expected Result:
The engine coolant level is OK.

OK STOP.

Results:
i02504578

0105-00 High Intake Manifold


Air Temperature Warning (64)

OK The engine coolant level is OK. Proceed to


Test Step 2.

Not OK The engine coolant level is low.

SMCS Code: 1921-038

Repair: Add coolant to the proper level.

Conditions Which Generate This Code:

Verify that the repair eliminates the problem.

The Engine Control Module (ECM) detects the


following conditions:

STOP.

The intake manifold air temperature is greater than


90 C (194 F) for more than four seconds.

The engine has been running for at least 30


seconds.

Test Step 2. Check the Aftercooler


A. Check the air-to-air aftercooler for debris and/or
restriction to the air flow.
Expected Result:

The engine coolant temperature is above 99 C

There are no restrictions to the air flow through the


air-to-air aftercooler.

System Response:

Results:

DIAG will be displayed next to the status for Intake


Manifold Air Temperature on Caterpillar Electronic
Technician (ET). The warning lamp will turn on
if the Engine Monitoring Lamps parameter is
programmed to Warning Lamp. The check engine
lamp will turn on if the Engine Monitoring Lamps
parameter is programmed to Option 1.

OK There are no restrictions in the air flow.

(210 F).

Customer passwords are required to clear this


diagnostic code.

Repair: Determine the cause of the high


temperatures. Heavy loads and high ambient air
temperatures could cause the temperature to be
above the trip point.
STOP.

Not OK There are restrictions in the air flow.

Possible Performance Effect:

Repair: Remove the restrictions in the air flow.

There are no performance effects.

Verify that the repair eliminates the problem.

Troubleshooting:

STOP.

This diagnostic code indicates an excessive


temperature in the intake manifold.

Test Step 1. Check the Coolant Level


A. Allow the engine to cool.
B. Check the engine coolant level.

SENR9698-09

121
Troubleshooting Section

i02195490

i02195519

0105-03 Intake Manifold Air


Temperature voltage high (38)

0105-04 Intake Manifold Air


Temperature voltage low (38)

SMCS Code: 1921-038

SMCS Code: 1921-038

Conditions Which Generate This Code:

Conditions Which Generate This Code:

The Engine Control Module (ECM) detects the


following conditions:

The Engine Control Module (ECM) detects the


following conditions:

The signal voltage from the intake manifold air

The signal voltage from the intake manifold air

Engine coolant temperature is above 10 C

The ECM has been powered for at least two

The ECM has been powered for at least two

The 168-01 Low ECM Battery Power is not active.

temperature sensor is greater than 4.95 VDC for


more than eight seconds.
(15 F).

seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will default to
40 C (104 F) for the intake manifold air temperature.
The ECM will turn on the cooling fan if the boost
pressure is above 70 kPa (10 psi).
This diagnostic code will be suppressed if the
following conditions exist:

The ambient air temperature is below 30 C


(22 F).

The ECM has activated extreme cold mode for the


engine.

The application is equipped with an ambient air


temperature sensor.

If all of the conditions are satisfied, the ambient


air temperature will be used for the intake manifold
temperature until the engine exits extreme cold mode.

temperature sensor is less than 0.2 VDC for more


than eight seconds.
seconds.

The 105-00 High Intake Manifold Air Temperature


Warning is not active.

The 105-11 Very High Intake Manifold Air


Temperature is not active.

Note: Intake manifold air temperatures that are


above 140 C (285 F) may cause this code to
become active.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will default to
40 C (104 F) for the intake manifold air temperature.
The ECM will turn on the cooling fan if the boost
pressure is above 70 kPa (10 psi).
Possible Performance Effect:
None
Troubleshooting:

Possible Performance Effect:

Perform the following diagnostic procedure: Engine


Temperature Sensor Open or Short Circuit - Test

None

Results:

Troubleshooting:

OK STOP.

Perform the following diagnostic procedure: Engine


Temperature Sensor Open or Short Circuit - Test
Results:

OK STOP.

122
Troubleshooting Section

SENR9698-09

i02184086

0105-11 Very High Intake


Manifold Air Temperature (64)
SMCS Code: 1921-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The intake manifold air temperature is greater than


110 C (230.0 F) for more than two seconds.

Not OK The engine coolant level is low.


Repair: Add coolant to the proper level.
Verify that the repair eliminates the problem.
STOP.

Test Step 2. Check the Aftercooler


A. Check the air-to-air aftercooler for debris and/or
restriction to the air flow.
Expected Result:

The engine has been running for at least 30

There are no restrictions to the air flow through the


air-to-air aftercooler.

The engine coolant temperature is above 99 C

Results:

seconds.

(210.0 F).

System Response:
DIAG will be displayed next to the status for
Intake Manifold Air Temperature on the Caterpillar
Electronic Technician (ET). The warning lamp will
turn on if the Engine Monitoring Lamps parameter
is programmed to Warning Lamp. The check engine
lamp will turn on if the Engine Monitoring Lamps
parameter is programmed to Option 1.
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:

OK There are no restrictions in the air flow.


Repair: Determine the cause of the high
temperatures. Heavy loads and high ambient air
temperatures could cause the temperature to be
above the trip point.
STOP.

Not OK There are restrictions in the air flow.


Repair: Remove the restrictions in the air flow.
Verify that the repair eliminates the problem.
STOP.

None
Troubleshooting:

i01942355

This diagnostic code indicates an excessive


temperature in the intake manifold.

0108-03 Barometric Pressure


voltage high (26)

Test Step 1. Check the Coolant Level

SMCS Code: 1923-038

A. Allow the engine to cool.

Conditions Which Generate This Code:

B. Check the engine coolant level.

The Engine Control Module (ECM) detects the


following conditions:

Note: The engine coolant is used to cool the intake


air after the turbochargers and before the air-to-air
aftercooler.

The signal voltage from the atmospheric pressure

Expected Result:
The engine coolant level is OK.
Results:

OK The engine coolant level is OK. Proceed to


Test Step 2.

sensor is greater than 4.95 VDC for more than 30


seconds.

The ECM has been powered for at least two


seconds.

SENR9698-09

123
Troubleshooting Section

System Response:

Results:

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM will default to 100 kPa (15 psi) for atmospheric
pressure.

OK STOP.
i02184094

Possible Performance Effect:

0110-00 High Coolant


Temperature Warning (61)

The engine power will be derated by 10 percent.

SMCS Code: 1906-038

Troubleshooting:

Conditions Which Generate This Code:

Perform the following diagnostic procedure: Engine


Pressure Sensor Open or Short Circuit - Test

The Engine Control Module (ECM) detects the


following conditions:

Results:

The engine coolant temperature is greater than


109 C (228 F) for more than ten seconds.

OK STOP.

The engine has been running for at least 30


i01942348

0108-04 Barometric Pressure


voltage low (26)
SMCS Code: 1923-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The signal voltage from the atmospheric pressure


sensor is less than 0.2 VDC for more than 30
seconds.

The ECM has been powered for at least two


seconds.

The engine is not running or the engine has been


running for more than ten seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM will default to 100 kPa (15 psi) for atmospheric
pressure.

seconds.

System Response:
DIAG will be displayed next to the status for Engine
Coolant Temperature on the Caterpillar Electronic
Technician (ET). The check engine lamp and the
warning lamp will illuminate.
Note: If a high coolant temperature lamp is installed,
the high coolant temperature lamp will turn on instead
of the warning lamp.
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:
The engine will be derated. The engine power and
the vehicle speed will be limited. The amount of
derate depends on the engine coolant temperature.
Note: If the Engine Monitoring parameter is
programmed to Warning, the engine power is not
affected.
Troubleshooting:

Check the Cooling System

Possible Performance Effect:

Refer to Testing and Adjusting, Cooling System Check.

The engine power will be derated by 10 percent.

Results:

Troubleshooting:

OK STOP.

Perform the following diagnostic procedure: Engine


Pressure Sensor Open or Short Circuit - Test

124
Troubleshooting Section

SENR9698-09

i01942347

0110-03 Coolant Temperature


voltage high (27)
SMCS Code: 1906-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The signal voltage from the engine coolant

temperature sensor is greater than 4.95 VDC for


more than eight seconds.

The ECM has been powered for at least two


seconds.

The engine has been running for more than seven


minutes.

The ECM has been powered for at least two


seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will default to
90 C (194 F) for engine coolant temperature. The
ECM will activate the cooling fan after this code has
been active for more than eight seconds.
Troubleshooting:
None
Perform the following diagnostic procedure: Engine
Temperature Sensor Open or Short Circuit - Test
Results:

OK STOP.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will default to
90 C (194 F) for engine coolant temperature. The
ECM will activate the cooling fan after this code has
been active for more than eight seconds.

0110-11 Very High Coolant


Temperature (61)

Possible Performance Effect:

Conditions Which Generate This Code:

None

The Engine Control Module (ECM) detects the


following conditions:

Troubleshooting:

i02184109

SMCS Code: 1906-038

The engine coolant temperature is greater than

Perform the following diagnostic procedure: Engine


Temperature Sensor Open or Short Circuit - Test

110 C (230 F) for more than 20 seconds.

The engine has been running for at least 30


seconds.

Results:

System Response:

OK STOP.
i01942349

0110-04 Coolant Temperature


voltage low (27)
SMCS Code: 1906-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The signal voltage from the engine coolant

temperature sensor is less than 0.2 VDC for more


than eight seconds.

DIAG will be displayed next to the status for Engine


Coolant Temperature on the Caterpillar Electronic
Technician (ET). The check engine lamp and the
warning lamp will illuminate.
Note: If a high coolant temperature lamp is installed,
the high coolant temperature lamp will turn on instead
of the warning lamp.
Customer passwords are required to clear this
diagnostic code.

SENR9698-09

125
Troubleshooting Section

Possible Performance Effect:

Possible Performance Effect:

The engine will be derated by 25 percent for each


1 C (1.8 F) above 110 C (230 F) up to 100
percent. A 100 percent derate means that the ECM
will use a default torque map and vehicle speed will
be limited to 72.4 km/h (45 mph).

None

Note: If the Engine Monitoring parameter is


programmed to Shutdown, the engine will be
shutdown once this code has been active for 20
seconds.
Note: If the Engine Monitoring parameter is
programmed to Warning, the engine power is not
affected.
Troubleshooting:

Troubleshooting:

Test Step 1. Check the Coolant Level


A. Check the engine coolant level. Refer to the
Operation and Maintenance Manual for more
information.
Expected Result:
The engine coolant level is normal.
Results:

OK The engine coolant level is normal.

Check the Cooling System


Refer to Testing and Adjusting, Cooling System Check.
Results:

Repair: Ensure that the coolant level sensor is


properly installed.
STOP.

Not OK The engine coolant level is low.

OK STOP.
i02184299

0111-01 Low Coolant Level


Warning (62)

Repair: Add coolant to the engine. Refer to the


Operation and Maintenance Manual for more
information.
Proceed to Test Step 2.

SMCS Code: 5574-038-CLT

Test Step 2. Check for Leaks in the


Cooling System

Conditions Which Generate This Code:

A. Check for leaking engine coolant.

The Engine Control Module (ECM) detects the


following conditions:

B. Check for coolant in the engine oil.

The coolant level is low for more than ten seconds.


The Coolant Level Sensor parameter is

programmed to 4-pin or 2-wire Float Sensor.

The engine has been running for at least 30


seconds.

System Response:
The ECM will display Low and DIAG next to the
status for Engine Coolant Level on the Caterpillar
Electronic Technician (ET). The check engine lamp
and the warning lamp will turn on while this code is
active.
Note: If a lamp for low coolant level is installed, the
lamp for low coolant level will turn on instead of the
warning lamp.
Factory passwords are required to clear this
diagnostic code.

Expected Result:
There are no leaks. There is no coolant in the engine
oil.
Results:

OK The engine is not losing any engine coolant.


Repair: Ensure that the engine coolant level is
normal.
Run the engine until the engine reaches normal
operating temperatures.
Stop the engine and allow the engine to cool.
Recheck the engine coolant level. If the coolant
level is low, add more engine coolant.
STOP.

126
Troubleshooting Section

SENR9698-09

Not OK The engine is leaking engine coolant or


there is coolant in the engine oil.

i02184407

Repair: Repair the leaks.

0111-03 Coolant Level voltage


high (12)

Verify that the repair eliminates the problem.

SMCS Code: 5574-038-CLT

STOP.

Conditions Which Generate This Code:


i02184401

0111-02 Coolant Level signal


invalid (12)
SMCS Code: 5574-038-CLT
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The coolant level sensor is sending an invalid


signal for more than ten seconds.

The Engine Control Module (ECM) detects the


following conditions:

The signal voltage from the coolant level sensor is


greater than 4.5 VDC for more than ten seconds.

The Coolant Level Sensor parameter is


programmed to 2-wire Float Sensor.

The ECM has been powered for at least two


seconds.

System Response:

The Coolant Level Sensor parameter is

The ECM will default to OK for coolant level.


DIAG will be displayed next to the status for
Engine Coolant Level on the Caterpillar Electronic
Technician (ET).

The ECM has been powered for at least two

Possible Performance Effect:

programmed to 4-pin or 2-wire Float Sensor.


seconds.

System Response:
The ECM will default to OK for engine coolant
level. DIAG will be displayed next to the status for
Engine Coolant Level on the Caterpillar Electronic
Technician (ET).
Possible Performance Effect:
None

None
Troubleshooting:
Perform the following diagnostic procedure: Coolant
Level Sensor Circuit - Test
Results:

OK STOP.

Troubleshooting:

i02184416

Perform the following diagnostic procedure: Coolant


Level Sensor Circuit - Test

0111-04 Coolant Level voltage


low (12)

Results:

SMCS Code: 5574-038-CLT

OK STOP.

Conditions Which Generate This Code:


The Engine Control Module (ECM) detects the
following conditions:

The signal voltage from the coolant level sensor is


less than 0.5 VDC for more than ten seconds.

The Coolant Level Sensor parameter is


programmed to 2-wire float sensor.

SENR9698-09

127
Troubleshooting Section

The ECM has been powered for at least two

Possible Performance Effect:

System Response:

The engine power is derated by 35 percent at a rate


of 1 percent per second. The vehicle speed is limited
to a maximum of 72 km/h (45 mph).

seconds.

The ECM will default to OK for coolant level.


DIAG will be displayed next to the status for
Engine Coolant Level on the Caterpillar Electronic
Technician (ET).

Note: If Engine Monitoring is programmed to


Shutdown, the engine will be shutdown once this
diagnostic code has been active for 30 seconds.

Possible Performance Effect:

Troubleshooting:

None

Test Step 1. Check the Coolant Level

Troubleshooting:

A. Check the engine coolant level. Refer to the


Operation and Maintenance Manual for more
information.

Perform the following diagnostic procedure: Coolant


Level Sensor Circuit - Test
Results:

Expected Result:
The engine coolant level is normal.

OK STOP.

Results:
i02184422

0111-11 Very Low Coolant


Level (62)
SMCS Code: 5574-038-CLT
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The coolant level is very low for more than 30


seconds.

OK The engine coolant level is normal.


Repair: Ensure that the coolant level sensor is
properly installed.
STOP.

Not OK The engine coolant level is low.


Repair: Add coolant to the engine. Refer to the
Operation and Maintenance Manual for more
information.
Proceed to Test Step 2.

The Coolant Level Sensor parameter is

Test Step 2. Check for Leaks in the


Cooling System

The engine has been running for at least 30

A. Check for leaking engine coolant.

programmed to 4-pin or to 2-wire Float Sensor.


seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp
will illuminate while this diagnostic code is active.
The ECM will display Low next to the status for
Engine Coolant Level on the Caterpillar Electronic
Technician (ET).
Note: If a lamp for low coolant level is installed, the
lamp for low coolant level will illuminate instead of the
warning lamp.
Factory passwords are required to clear this
diagnostic code.

B. Check for coolant in the engine oil.


Expected Result:
There are no leaks. There is no coolant in the engine
oil.
Results:

OK The engine is not losing any engine coolant.


Repair: Ensure that the engine coolant level is
normal.
Run the engine until the engine reaches normal
operating temperatures.
Stop the engine and allow the engine to cool.

128
Troubleshooting Section

SENR9698-09

Recheck the engine coolant level. If the coolant


level is low, add more engine coolant.
STOP.

Troubleshooting:

Test Step 1. Check the Coolant Level

there is coolant in the engine oil.

A. Check the engine coolant level. Refer to the


Operation and Maintenance Manual for more
information.

Repair: Repair the leaks.

Expected Result:

Verify that the repair eliminates the problem.

The engine coolant level is normal.

STOP.

Results:

Not OK The engine is leaking engine coolant or

i02129292

0111-14 Low Coolant Level


Warning
SMCS Code: 5574-038-CLT
Conditions Which Generate This Code:

OK The engine coolant level is normal.


Repair: Ensure that the coolant level sensor is
properly installed.
STOP.

Not OK The engine coolant level is low.

The Engine Control Module (ECM) detects the


following conditions:

Repair: Add coolant to the engine. Refer to the


Operation and Maintenance Manual for more
information.

The coolant level sensor indicates that the coolant

Proceed to Test Step 2.

level is low.

The Coolant Level Sensor is programmed to 4


Pin or 2-wire Float Sensor.

The engine has less than six hours of total


operating time.

Note: This diagnostic code will only occur in the first


six hours of engine operation. No passwords are
required to clear this diagnostic code.
System Response:
The ECM will display Low and DIAG next to the
status for Engine Coolant Level on Caterpillar
Electronic Technician (ET). The check engine lamp
and the warning lamp will turn on while this code is
active.
Note: If a lamp for low coolant level is installed, the
lamp for low coolant level will turn on instead of the
warning lamp.
Possible Performance Effect:
None

Test Step 2. Check for Leaks in the


Cooling System
A. Check for leaking engine coolant.
B. Check for coolant in the engine oil.
Expected Result:
There are no leaks. There is no coolant in the engine
oil.
Results:

OK The engine is not losing any engine coolant.


Repair: Ensure that the engine coolant level is
normal.
Run the engine until the engine reaches normal
operating temperatures.
Stop the engine and allow the engine to cool.
Recheck the engine coolant level. If the coolant
level is low, add more engine coolant.
STOP.

Not OK The engine is leaking engine coolant or


there is coolant in the engine oil.

SENR9698-09

129
Troubleshooting Section

The engine retarder switch is in the low or high

Repair: Repair the leaks.


Verify that the repair eliminates the problem.
STOP.
i01945532

0121-05 Low/High Retarder


current low (14)
SMCS Code: 1129-038

position.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active.
Possible Performance Effect:
The engine retarder may not activate.
Troubleshooting:

Conditions Which Generate This Code:


The Engine Control Module (ECM) detects the
following conditions:

The ECM detects a low current condition (open

circuit) for one second while the ECM is attempting


to energize the solenoid for cylinders 3 and 4.

The engine retarder switch is in the low or high


position.

System Response:

Perform the following diagnostic procedure: Retarder


(Compression Brake) Solenoid Circuit - Test
Results:

OK STOP.
i01945534

0122-05 Med/High Retarder


current low (14)

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active.

SMCS Code: 1129-038

Possible Performance Effect:

The Engine Control Module (ECM) detects the


following conditions:

The engine retarder may not activate.

Conditions Which Generate This Code:

The ECM detects a low current condition (open

Troubleshooting:
Perform the following diagnostic procedure: Retarder
(Compression Brake) Solenoid Circuit - Test

circuit) for one second while the ECM is attempting


to energize the solenoids for cylinders 1, 2, 5, and
6.

The engine retarder switch is in the medium or


high position.

Results:

OK STOP.

System Response:
i01945533

0121-06 Low/High Retarder


current high (14)

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active.
Possible Performance Effect:

SMCS Code: 1129-038

The engine retarder may not activate.

Conditions Which Generate This Code:

Troubleshooting:

The Engine Control Module (ECM) detects the


following conditions:

Perform the following diagnostic procedure: Retarder


(Compression Brake) Solenoid Circuit - Test

The ECM detects a high current condition (short

Results:

circuit) for one second while the ECM is attempting


to energize the solenoid for cylinders 3 and 4.

OK STOP.

130
Troubleshooting Section

SENR9698-09

i01945535

0122-06 Med/High Retarder


current high (14)

System Response:
The ECM will limit power.

SMCS Code: 1129-038

Customer passwords are required to clear this


diagnostic code.

Conditions Which Generate This Code:

Possible Performance Effect:

The Engine Control Module (ECM) detects the


following conditions:

The engine will be derated by three percent when


the engine coolant temperature is 103 C (217 F).
The engine will be derated by six percent when the
engine coolant temperature is 104 C (219 F).

The ECM detects a high current condition (short

circuit) for one second while the ECM is attempting


to energize the solenoids for cylinders 1, 2, 5, and
6.

The engine retarder switch is in the medium or


high position.

Check the Coolant System


Refer to Systems Operation/Testing and Adjusting,
Cooling System - Check.
Results:

System Response:

OK STOP.

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active.
Possible Performance Effect:
The engine retarder may not activate.

i02490820

0168-01 Low ECM Battery


Power (17)
SMCS Code: 1401-038

Troubleshooting:

Conditions Which Generate This Code:

Perform the following diagnostic procedure: Retarder


(Compression Brake) Solenoid Circuit - Test
Results:

The Engine Control Module (ECM) detects the


following conditions:

The battery voltage to the ECM is less than 9.0

VDC for 12 volt systems or 18.0 VDC for 24 volt


systems.

OK STOP.
i02504592

0166-14 Rated Engine Power


Special Instructions

The engine is running.


System Response:

SMCS Code: 1901-038

The ECM will use a default torque map. The check


engine lamp will illuminate.

Conditions Which Generate This Code:

Possible Performance Effect:

The Engine Control Module (ECM) detects the


following conditions:

The engine will be derated.

The engine coolant temperature is at least 103 C


(217 F) for more than eight seconds.

The Engine Coolant Temperature Derate Enable


Status parameter is programmed to Enabled.

The engine has been running for at least three


minutes.

Troubleshooting:
This diagnostic code could indicate a faulty charging
system or poor battery connections.
Perform the following diagnostic procedure: Ignition
Keyswitch Circuit and Battery Supply Circuit - Test

SENR9698-09

131
Troubleshooting Section

Results:

i02184436

0171-04 Ambient Air


Temperature voltage low

OK STOP.
i02184426

0171-03 Ambient Air


Temperature voltage high

SMCS Code: 1928-038


Conditions Which Generate This Code:

SMCS Code: 1928-038

The Engine Control Module (ECM) detects the


following conditions:

Conditions Which Generate This Code:

The signal voltage from the ambient air temperature

The Engine Control Module (ECM) detects the


following conditions:

The signal voltage from the ambient air temperature


sensor is greater than 4.92 VDC for more than
eight seconds.

The signal voltage from the ambient air temperature


sensor is greater than 4.95 VDC for more than
eight seconds. Only engines with software after
DEC 03

The Allow Idle Shutdown Override parameter is


programmed to Outside Temperature Based or
J1587 Outside Temperature Based.

sensor is less than 0.2 VDC for more than eight


seconds.

The Allow Idle Shutdown Override parameter is


programmed to Outside Temperature Based or
J1587 Outside Temperature Based.

The ECM has been powered for at least two


seconds.

System Response:
The ECM will default to 65 C (149 F) for outside
air temperature. DIAG will be displayed next to
the status for Outside Temperature Sensor on the
Caterpillar Electronic Technician (ET).

The ECM has been powered for at least two

Possible Performance Effect:

System Response:

Allow Idle Shutdown Override is disabled while this


code is active.

seconds.

The ECM will default to 65 C (149 F) for outside


air temperature. DIAG will be displayed next to
the status for Outside Temperature Sensor on the
Caterpillar Electronic Technician (ET).

Troubleshooting:

Possible Performance Effect:

Results:

Allow Idle Shutdown Override is disabled while this


code is Active.

OK STOP.

Perform the following diagnostic procedure: Engine


Temperature Sensor Open or Short Circuit - Test

Troubleshooting:

i02184441

Perform the following diagnostic procedure: Engine


Temperature Sensor Open or Short Circuit - Test

0171-11 Ambient Air


Temperature Data Lost

Results:

SMCS Code: 1928-038

OK STOP.

Conditions Which Generate This Code:


The Engine Control Module (ECM) detects the
following conditions:

The ECM is not receiving information about the

ambient air temperature from the SAE J1587 data


link.

The Allow Idle Shutdown Override is programmed


to the J1587 Outside Temp Based option.

132
Troubleshooting Section

SENR9698-09

System Response:

i01956975

The temperature based idle shutdown override is


disabled. Outside air temperature is set to 65 C
(149 F).

0174-03 Fuel Temperature


voltage high (13)
SMCS Code: 1922-038

Possible Performance Effect:

Conditions Which Generate This Code:

None
Troubleshooting:

The Engine Control Module (ECM) detects the


following conditions:

Perform the following diagnostic procedure: ATA


(SAE J1587 / J1708) Data Link Circuit - Test

The signal voltage from the fuel temperature

Results:

sensor is greater than 4.95 VDC for more than


eight seconds.

Engine coolant temperature is above 10 C

OK STOP.

(15 F).

i02184446

The ECM has been powered for at least two


seconds.

0174-00 High Fuel Temperature


Warning (65)

System Response:

SMCS Code: 1922-038

The ECM will default to the lower of engine coolant


temperature or 50 C (122 F) for fuel temperature.

Conditions Which Generate This Code:

Possible Performance Effect:

The Engine Control Module (ECM) detects the


following conditions:

None

The fuel temperature is above 90 C (194 F) for


more than 30 seconds.

The engine has been running for at least three


minutes.

System Response:
DIAG is displayed next to the status for Fuel
Temperature on the Caterpillar Electronic Technician
(ET).
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:
None

Troubleshooting:
Perform the following diagnostic procedure: Engine
Temperature Sensor Open or Short Circuit - Test
Results:

OK STOP.
i01956976

0174-04 Fuel Temperature


voltage low (13)
SMCS Code: 1922-038
Conditions Which Generate This Code:

Troubleshooting:

The Engine Control Module (ECM) detects the


following conditions:

No troubleshooting is required.

The signal voltage from the fuel temperature

Results:

OK STOP.

sensor is less than 0.2 VDC for more than eight


seconds.

The ECM has been powered for at least two


seconds.

SENR9698-09

133
Troubleshooting Section

System Response:

i02184454

The ECM will default to the lower of engine coolant


temperature or 50 C (122 F) for fuel temperature.

0190-08 Primary Engine Speed


Loss of Signal (34)

Possible Performance Effect:

SMCS Code: 1912-038

None

Conditions Which Generate This Code:

Troubleshooting:

The Engine Control Module (ECM) detects the


following conditions:

Perform the following diagnostic procedure: Engine


Temperature Sensor Open or Short Circuit - Test

The signal from the primary engine speed/timing

sensor has been lost and the engine speed did not
pass through the range of 350 rpm to 500 rpm.

Results:

OK STOP.

The engine has been running for more than three


seconds.

i02294513

0190-00 Engine Overspeed


Warning (35)
SMCS Code: 1912-038
Conditions Which Generate This Code:
The engine speed exceeded 2600 rpm for more than
one second.
System Response:
The Electronic Control Module (ECM) will log the
event.
Possible Performance Effect:
Fuel injection will be disabled until engine speed
drops below the Top Engine Limit.
Troubleshooting:

The battery voltage is greater than 9 VDC for more


than two seconds prior to the loss of the signal.

System Response:
The ECM will use the default timing. The ECM will
use the secondary engine speed/timing sensor.
Possible Performance Effect:
None
Note: If the signals from both engine speed/timing
sensors are lost, then the engine will shut down.
Troubleshooting:
Perform the following diagnostic procedure: Engine
Speed/Timing Sensor Circuit - Test
Results:

OK STOP.

The operator may be operating the engine incorrectly.

Talk to the Operator


Determine the events that caused the overspeed of
the engine.
Results:

OK STOP.

i02504603

0191-07 Transmission Not


Responding (68)
SMCS Code: 3174-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

Three attempts to complete an Eaton Top 2 shift


were unsuccessful.

The Transmission Style is programmed to Eaton


Top 2.

134
Troubleshooting Section

SENR9698-09

System Response:

Results:

The solenoid that is currently enabled will remain


in the ON position until neutral is detected. Manual
operation continues until the system powers down.
Manual operation is defined as both solenoids are off.

OK STOP.

Possible Performance Effect:

The ECM disables the Eaton Top 2 mode.

i02490295

0212-04 5 Volt Sensor Supply


#1 voltage low
SMCS Code: 5574-038

Troubleshooting:

Conditions Which Generate This Code:

Perform the following diagnostic procedure: Eaton


Top 2 Transmission Circuit - Test
Results:

The Engine Control Module (ECM) detects the


following conditions:

The 5 volt supply is less than 4.84 VDC for more


than one second.

OK STOP.
i02490292

0212-03 5 Volt Sensor Supply


#1 voltage high
SMCS Code: 5574-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The 5 volt supply is greater than 5.16 VDC for


more than one second.

The ECM has been powered for at least three


seconds.

The ECM has been powered for at least three


seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM sets all of the pressure sensors to the default
values below:

Atmospheric Pressure 100 kPa (15 psi)


Intake manifold pressure 0 kPa (0 psi)
Engine Oil Pressure 500 kPa (73 psi)
Possible Performance Effect:

System Response:

Low power

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM sets all of the pressure sensors to the default
values below:

Troubleshooting:

Atmospheric Pressure 100 kPa (15 psi)


Intake manifold pressure 0 kPa (0 psi)
Engine Oil Pressure 500 kPa (73 psi)
Possible Performance Effect:
Low power
Troubleshooting:
Perform the following diagnostic procedure: 5 Volt
Engine Pressure Sensor Supply Circuit - Test

Perform the following diagnostic procedure: 5 Volt


Engine Pressure Sensor Supply Circuit - Test
Results:

OK STOP.

SENR9698-09

135
Troubleshooting Section

i02129525

0224-11 Theft Deterrent Active


(00)
SMCS Code: 1901-038
Conditions Which Generate This Code:
The theft deterrent feature has been enabled. The
correct password must be entered in order to disable
the theft deterrent. Then, the engine can be started.
Note: This diagnostic code represents an event. This
diagnostic code does not represent an electronic
system fault.
The Engine Control Module (ECM) will operate in the
Secure Idle mode if the theft deterrent password
is entered. The engine must be running in order to
operate in the Secure Idle mode. The ECM will be
in the Secure Idle mode until the theft deterrent
password is entered again.

The engine is cranking.


The theft deterrent is active.
System Response:
The diagnostic code is active only. The diagnostic
code will be active when the theft deterrent is
enabled and the engine is cranking for more than five
seconds.
Possible Performance Effect:
The engine will not start until the correct password
is entered.
Troubleshooting:
Enter the correct passwords.
There are no problems that require troubleshooting.
Results:

OK STOP.

System Response:
The diagnostic code is active only. The diagnostic
code will be active when the theft deterrent feature
is enabled.
Caterpillar Electronic Technician (ET) will not display
a status. The check engine lamp will be illuminated.
Possible Performance Effect:

i02184459

0231-02 J1939 Data Incorrect


(58)
SMCS Code: 1901-038
Conditions Which Generate This Code:

The engine will not start until the correct password is


entered. The engine will be limited to the low idle rpm
if the Secure Idle mode is active.

The Engine Control Module (ECM) detects the


following condition:

Troubleshooting:

The parameter Powertrain Data Link must be

This diagnostic code indicates that the theft deterrent


feature has been enabled. There is no electronic
system fault.

The ECM also detects one of the following conditions:

programmed to J1939.

The ECM is unsuccessful in receiving a specific


message from a device.

No Troubleshooting is required.
Results:

or

OK STOP.

The device is broadcasting a fault code.


or
i02129561

0224-14 Theft Deterrent Active


with Engine Cranking (00)
SMCS Code: 1901-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The device is broadcasting a code that is not


supported.

136
Troubleshooting Section

SENR9698-09

System Response:

i02184467

J1939 communications to the engine and from the


engine are terminated for the specific message while
this code is active. The functionality of some features
may be affected while this code is active. Traction
control or transmission controls may be disabled.
Diag or J1939 No Support will be displayed next
to the status on the Caterpillar Electronic Technician
(ET).
Possible Performance Effect:
Features that utilize the J1939 data link may not work
properly or the features may be disabled.
Perform the following diagnostic procedure:
Powertrain Data Link Circuit - Test

0246-11 Brake Pedal Switch #1


Fault
SMCS Code: 1435-038-BRK
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The status of the service brake pedal position


switch 1 and the service brake pedal position
switch 2 do not match for at least 15 seconds.

The engine is running.


The ECM has been powered for at least three

Results:

seconds.

OK STOP.
i02129842

0231-12 J1939 Device Not


Responding
SMCS Code: 1901-038
Conditions Which Generate This Code:

Note: The Transmission Style parameter must be


programmed to Automatic Option 2 or Automatic
Option 3.
System Response:
This diagnostic code will prevent cruise control, PTO
operation, or idle operation.
Possible Performance Effect:

The Engine Control Module (ECM) detects the


following conditions:

The engine will disengage or the engine will not allow


the setting of the Cruise Control, the PTO, or the
Idle speed.

The ECM is unsuccessful in receiving a message

Troubleshooting:

The ECM is not receiving a valid message from a

Perform the following diagnostic procedure: Service


Brake Pedal Position (Switch 1) Circuit -Test

from a J1939 source.


J1939 source.

System Response:
The ECM will disable features that require an input
from the J1939 device.

Results:

OK STOP.
i02184475

Possible Performance Effect:


The J1939 device may not operate correctly. Certain
control systems may not operate correctly.
Troubleshooting:
Perform the following diagnostic procedure:
Powertrain Data Link Circuit - Test
Results:

OK STOP.

0247-11 Brake Pedal Switch #2


Fault
SMCS Code: 1435-038-BRK
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The status of the service brake pedal position

switch 2 and the service brake pedal position


switch 1 do not match for more than 15 seconds.

SENR9698-09

137
Troubleshooting Section

The engine is running.

Results:

The ECM has been powered for at least three

OK STOP.

seconds.

Note: The Transmission Style parameter must be


programmed to Automatic Option 2 or Automatic
Option 3.
System Response:

i02504614

0253-02 Check Customer or


System Parameters (56)
SMCS Code: 1901-038

This diagnostic code will prevent cruise control, PTO


operation, or idle operation.
Possible Performance Effect:
The engine will disengage or the engine will not
allow setting of the cruise control, the PTO, or the
idle speed.
Troubleshooting:
Perform the following diagnostic procedure: Service
Brake Pedal Position (Switch 2) Circuit - Test
Results:

Conditions Which Generate This Code:


This condition indicates a customer specified
parameter or a system configuration parameter that
requires programming has not been programmed.
System Response:
When a new Engine Control Module (ECM) is initially
powered up, the following parameters must be
programmed in order to avoid this diagnostic code:

Full Load Setting (FLS)


Full Torque Setting (FTS)

OK STOP.

Vehicle speed calibration


i02336574

0252-11 Engine Software


Incorrect (59)
SMCS Code: 1901-038
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects incorrect
engine software .

Rating number
Engine serial number
Injector trim files
Note: If the Rating Number has not been
programmed, the ECM will limit the engine power
to 119 kW (160 hp).
Possible Performance Effect:

System Response:

The ECM may limit the engine speed to low idle.

The ECM will turn on the check engine lamp.

Troubleshooting:

Factory passwords are required to clear this


diagnostic code.

Perform the following diagnostic procedure: ECM


Memory - Test

Possible Performance Effect:

Results:

The engine will not start.

OK STOP.

Troubleshooting:
The flash file in the ECM is from the wrong engine
family.
Perform the following diagnostic procedure: ECM
Memory - Test

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Troubleshooting Section

SENR9698-09

i01225847

0253-11 Check Transmission


Customer Parameters (56)

System Response:

SMCS Code: 1901-038

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours.

Conditions Which Generate This Code:

Possible Performance Effect:

This condition indicates that the Transmission Style


parameter is programmed to the Eaton Top 2 and any
one of the following parameters are not programmed:

None

Top Gear Ratio

Perform the following diagnostic procedure: Intake


Valve Actuation System Oil Pressure Circuit - Test
Results:

Top Gear Minus One Ratio

OK STOP.

Top Gear Minus Two Ratio


i01945529

System Response:
Engine Response The engine will not operate above
low idle.
Troubleshooting:
Program the Transmission Style parameter that is
Eaton Top 2 to the correct setting. If an Eaton Top
2 Transmission is not used, program the correct
Transmission Style parameter to the correct setting.
Results:

0283-06 Intake Valve Actuation


System Oil Pressure Solenoid
current high (97)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The ECM is attempting to activate the intake valve

OK STOP.

actuation pressure solenoid and the ECM detects


greater than 2.4 A for at least eight seconds.

i01945528

0283-05 Intake Valve Actuation


System Oil Pressure Solenoid
current low (97)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:

The intake valve actuation pressure solenoid is on.


System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will continue
to attempt to energize the intake valve actuation
pressure solenoid.

The Engine Control Module (ECM) detects the


following conditions:

Possible Performance Effect:

The ECM is not attempting to activate the intake

None

valve actuation pressure solenoid and the ECM


detects less than 25 A for at least eight seconds.

The intake valve actuation pressure solenoid is off.


Note: The ECM continually applies a small current
to the intake valve actuation pressure solenoid. If a
voltage source that is greater than 1.3 VDC is applied
to the system, the current will fall below the trip point.

Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuation System Oil Pressure Circuit - Test
Results:

OK STOP.

SENR9698-09

139
Troubleshooting Section

i01940032

System Response:

0283-07 Intake Valve Actuation


Oil Pressure not responding
(91)

The ECM will log the diagnostic code. The check


engine lamp will illuminate once this diagnostic code
has been active for 30 seconds. In cold climates, the
temperature in the cab may be low.

SMCS Code: 5479-038-IL

Possible Performance Effect:

Conditions Which Generate This Code:

None

The Engine Control Module (ECM) detects the


following conditions:

Perform the following diagnostic procedure: Engine


Coolant Diverter Circuit - Test

The intake valve actuation pressure solenoid was

Results:

cycled ten times and there was no change in the


intake valve actuation pressure.

OK STOP.

The ECM has been powered for at least two


seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot.

i01945531

0284-06 Engine Coolant


Diverter current high (98)
SMCS Code: 5479-038-CLT

Possible Performance Effect:

Conditions Which Generate This Code:

None

The Engine Control Module (ECM) detects the


following conditions:

Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Response - Test

The ECM is attempting to activate the engine

coolant diverter and the ECM detects greater than


3.5 A for at least eight seconds.

Results:

The engine coolant diverter is on.

OK STOP.

System Response:
i01945530

0284-05 Engine Coolant


Diverter current low (98)

The ECM will log the diagnostic code. The ECM will
continue to attempt to energize the engine coolant
diverter.
Possible Performance Effect:

SMCS Code: 5479-038-CLT

None

Conditions Which Generate This Code:

Troubleshooting:

The Engine Control Module (ECM) detects the


following conditions:

Perform the following diagnostic procedure: Engine


Coolant Diverter Circuit - Test

The ECM is not attempting to activate the engine

Results:

coolant diverter and the ECM detects less than 25


A for at least eight seconds.

The engine coolant diverter is off.


Note: The ECM continually applies a small current to
the engine coolant diverter. If a voltage source that
is greater than 1.3 VDC is applied to the system, the
current will fall below the trip point.

OK STOP.

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SENR9698-09

i02184789

0285-05 Intake Valve Actuator


#1 current low (92)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The ECM detects a low current condition (open

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 1.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
Possible Performance Effect:
The engine will have low power. Engine power will be
restored if five consecutive attempts to energize the
intake valve actuator are successful.
Troubleshooting:

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.

Perform the following diagnostic procedure: Intake


Valve Actuator Circuit - Test
Results:

OK STOP.
i02184794

Possible Performance Effect:


The engine will have low power. Engine power will be
restored if five consecutive attempts to energize the
intake valve actuator are successful.
Troubleshooting:

0285-07 Intake Valve Actuator


#1 not responding (92)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:

Perform the following diagnostic procedure: Intake


Valve Actuator Circuit - Test
Results:

The Engine Control Module (ECM) detects the


following conditions:

The intake valve actuator for cylinder 1 is not


working properly.

OK STOP.

The intake valve actuator is active.


i02184792

0285-06 Intake Valve Actuator


#1 current high (92)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The ECM detects a high current condition (short

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 1.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten seconds. The ECM will use a
default torque map.
Possible Performance Effect:
The engine will be derated while this diagnostic code
is active.

SENR9698-09

141
Troubleshooting Section

Note: Full power will be restored if the diagnostic


code becomes inactive.
Note: If this code is logged several times, the engine
will be derated until the code is cleared with the
Caterpillar Electronic Technician (ET). If the condition
is not resolved, the engine will be derated again.

i02184796

0286-06 Intake Valve Actuator


#2 current high (92)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:

Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Response - Test

The Engine Control Module (ECM) detects the


following conditions:

The ECM detects a high current condition (short

Results:

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 2.

OK STOP.

The battery voltage is above 9 VDC for the last


i02184795

0286-05 Intake Valve Actuator


#2 current low (92)

two seconds.

System Response:

The Engine Control Module (ECM) detects the


following conditions:

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.

The ECM detects a low current condition (open

Possible Performance Effect:

The battery voltage is above 9 VDC for the last

The engine will have low power. Engine power will be


restored if five consecutive attempts to energize the
intake valve actuator are successful.

SMCS Code: 5479-038-IL


Conditions Which Generate This Code:

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 2.
two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
Possible Performance Effect:
The engine will have low power. Engine power will be
restored if five consecutive attempts to energize the
intake valve actuator are successful.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test
Results:

OK STOP.

Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test
Results:

OK STOP.
i02184797

0286-07 Intake Valve Actuator


#2 not responding (92)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The intake valve actuator for cylinder 2 is not


working properly.

The intake valve actuator is active.

142
Troubleshooting Section

SENR9698-09

System Response:

Possible Performance Effect:

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten seconds. The ECM will use a
default torque map.

The engine will have low power. Engine power will be


restored if five consecutive attempts to energize the
intake valve actuator are successful.

Possible Performance Effect:

Perform the following diagnostic procedure: Intake


Valve Actuator Circuit - Test

The engine will be derated while this diagnostic code


is active.
Note: Full power will be restored if the diagnostic
code becomes inactive.

Troubleshooting:

Results:

OK STOP.
i02184803

Note: If this code is logged several times, the engine


will be derated until the code is cleared with the
Caterpillar Electronic Technician (ET). If the condition
is not resolved, the engine will be derated again.

0287-06 Intake Valve Actuator


#3 current high (93)

Troubleshooting:

SMCS Code: 5479-038-IL

Perform the following diagnostic procedure: Intake


Valve Actuator Response - Test

Conditions Which Generate This Code:

Results:

The Engine Control Module (ECM) detects the


following conditions:

OK STOP.

The ECM detects a high current condition (short


i02184801

0287-05 Intake Valve Actuator


#3 current low (93)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The ECM detects a low current condition (open

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 3.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 3.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
Possible Performance Effect:
The engine will have low power. Engine power will be
restored if five consecutive attempts to energize the
intake valve actuator are successful.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test
Results:

OK STOP.

SENR9698-09

143
Troubleshooting Section

i02184806

0287-07 Intake Valve Actuator


#3 not responding (93)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The intake valve actuator for cylinder 3 is not


working properly.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
Possible Performance Effect:

The intake valve actuator is active.

The engine will have low power. Engine power will be


restored if five consecutive attempts to energize the
intake valve actuator are successful.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten seconds. The ECM will use a
default torque map.

Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test

Possible Performance Effect:

Results:

The engine will be derated while this diagnostic code


is active.

OK STOP.

Note: Full power will be restored if the diagnostic


code becomes inactive.
Note: If this code is logged several times, the engine
will be derated until the code is cleared with the
Caterpillar Electronic Technician (ET). If the condition
is not resolved, the engine will be derated again.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Response - Test

i02184814

0288-06 Intake Valve Actuator


#4 current high (93)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The ECM detects a high current condition (short

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 4.

Results:

OK STOP.

The battery voltage is above 9 VDC for the last


two seconds.

i02184810

0288-05 Intake Valve Actuator


#4 current low (93)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The ECM detects a low current condition (open

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 4.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.

144
Troubleshooting Section

SENR9698-09

Possible Performance Effect:

Results:

The engine will have low power. Engine power will be


restored if five consecutive attempts to energize the
intake valve actuator are successful.

OK STOP.

Troubleshooting:

0289-05 Intake Valve Actuator


#5 current low (94)

Perform the following diagnostic procedure: Intake


Valve Actuator Circuit - Test
Results:

i02185408

SMCS Code: 5479-038-IL


Conditions Which Generate This Code:

OK STOP.
i02184815

The Engine Control Module (ECM) detects the


following conditions:

0288-07 Intake Valve Actuator


#4 not responding (93)

The ECM detects a low current condition (open

SMCS Code: 5479-038-IL

The battery voltage is above 9 VDC for the last

Conditions Which Generate This Code:


The Engine Control Module (ECM) detects the
following conditions:

The intake valve actuator for cylinder 4 is not


working properly.

The intake valve actuator is active.


System Response:

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 5.
two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten seconds. The ECM will use a
default torque map.

Possible Performance Effect:

Possible Performance Effect:

Troubleshooting:

The engine will be derated while this diagnostic code


is active.

Perform the following diagnostic procedure: Intake


Valve Actuator Circuit - Test

Note: Full power will be restored if the diagnostic


code becomes inactive.

Results:

Note: If this code is logged several times, the engine


will be derated until the code is cleared with the
Caterpillar Electronic Technician (ET). If the condition
is not resolved, the engine will be derated again.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Response - Test

The engine will have low power. Engine power will be


restored if five consecutive attempts to energize the
intake valve actuator are successful.

OK STOP.

SENR9698-09

145
Troubleshooting Section

i02185477

0289-06 Intake Valve Actuator


#5 current high (94)
SMCS Code: 5489-038-IL
Conditions Which Generate This Code:

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten seconds. The ECM will use a
default torque map.
Possible Performance Effect:

The Engine Control Module (ECM) detects the


following conditions:

The ECM detects a high current condition (short

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 5.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.

The engine will be derated while this diagnostic code


is active.
Note: Full power will be restored if the diagnostic
code becomes inactive.
Note: If this code is logged several times, the engine
will be derated until the code is cleared with the
Caterpillar Electronic Technician (ET). If the condition
is not resolved, the engine will be derated again.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Response - Test
Results:

OK STOP.

Possible Performance Effect:

i02185503

The engine will have low power. Engine power will be


restored if five consecutive attempts to energize the
intake valve actuator are successful.

0290-05 Intake Valve Actuator


#6 current low (94)

Troubleshooting:

SMCS Code: 5479-038-IL

Perform the following diagnostic procedure: Intake


Valve Actuator Circuit - Test

Conditions Which Generate This Code:

Results:

The Engine Control Module (ECM) detects the


following conditions:

OK STOP.

The ECM detects a low current condition (open

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 6.

i02185495

0289-07 Intake Valve Actuator


#5 not responding (94)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

The intake valve actuator for cylinder 5 is not


working properly.

The intake valve actuator is active.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.

146
Troubleshooting Section

SENR9698-09

Possible Performance Effect:

i02185507

The engine will have low power. Engine power will be


restored if five consecutive attempts to energize the
intake valve actuator are successful.

0290-07 Intake Valve Actuator


#6 not responding (94)
SMCS Code: 5479-038-IL

Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test
Results:

Conditions Which Generate This Code:


The Engine Control Module (ECM) detects the
following conditions:

The intake valve actuator for cylinder 6 is not

OK STOP.

working properly.

i02185504

0290-06 Intake Valve Actuator


#6 current high (94)
SMCS Code: 5479-038-IL
Conditions Which Generate This Code:

The intake valve actuator is active.


System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten seconds. The ECM will use a
default torque map.

The Engine Control Module (ECM) detects the


following conditions:

Possible Performance Effect:

The ECM detects a high current condition (short

The engine will be derated while this diagnostic code


is active.

circuit) during five consecutive attempts to energize


the intake valve actuator for cylinder 6.

The battery voltage is above 9 VDC for the last


two seconds.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
Possible Performance Effect:
The engine will have low power. Engine power will be
restored if five consecutive attempts to energize the
intake valve actuator are successful.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test
Results:

OK STOP.

Note: Full power will be restored if the diagnostic


code becomes inactive.
Note: If this code is logged several times, the engine
will be derated until the code is cleared with the
Caterpillar Electronic Technician (ET). If the condition
is not resolved, the engine will be derated again.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Response - Test
Results:

OK STOP.
i02185510

0385-01 Low Intake Valve


Actuation System Oil Pressure
SMCS Code: 5574-038-IL
Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
following conditions:

SENR9698-09

147
Troubleshooting Section

The intake valve actuation pressure is lower than


the expected intake valve actuation pressure.

There is at least one intake valve actuator that is


not responding.

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM will use a default torque map.
Possible Performance Effect:
The engine will be derated while this diagnostic code
is active.
Note: Full power will be restored if the diagnostic
code becomes inactive.
Note: If this code is logged several times, the engine
will be derated until the code is cleared with the
Caterpillar Electronic Technician (ET). If the condition
is not resolved, the engine will be derated again.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Response - Test

System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than four hours. The ECM will not use a
default value.
Possible Performance Effect:
None
Troubleshooting:
Perform the following diagnostic procedure: Engine
Pressure Sensor Open or Short Circuit - Test
Results:

OK STOP.
i01941381

0385-04 Intake Valve Actuation


System Oil Pressure voltage
low (95)
SMCS Code: 5574-038-IL
Conditions Which Generate This Code:

Results:

The Engine Control Module (ECM) detects the


following conditions:

OK STOP.
i01941380

0385-03 Intake Valve Actuation


System Oil Pressure voltage
high (95)

The signal voltage from the intake valve actuator

oil pressure sensor is less than 0.4 VDC for more


than eight seconds.

The ECM has been powered for at least two


seconds.

SMCS Code: 5574-038-IL

System Response:

Conditions Which Generate This Code:

The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than four hours. The ECM will not use a
default value.

The Engine Control Module (ECM) detects the


following conditions:

The signal voltage from the intake valve actuator


oil pressure sensor is greater than 4.6 VDC for
more than eight seconds.

The ECM has been powered for at least two


seconds.

Possible Performance Effect:


None
Troubleshooting:
Perform the following diagnostic procedure: Engine
Pressure Sensor Open or Short Circuit - Test
Results:

OK STOP.

148
Troubleshooting Section

SENR9698-09

Diagnostic Functional
Tests
i02490878

5 Volt Engine Pressure Sensor


Supply Circuit - Test
SMCS Code: 5574-038
System Operation Description:
Use this procedure to troubleshoot the system when
one of the following diagnostic codes is active or
easily repeated:

212-03 5 Volt Sensor Supply #1 voltage high


212-04 5 Volt Sensor Supply #1 voltage low
232-03 5 Volt Supply voltage high
232-04 5 Volt Supply voltage low
Also, use this procedure to troubleshoot the system
when you have been directed here by another
troubleshooting procedure.
The following background information is related
to this procedure:
The Engine Control Module (ECM) supplies the
following sensors with regulated 5 VDC:

Atmospheric pressure sensor


Boost pressure sensor
Engine oil pressure sensor
Oil pressure sensor for the intake valve actuator
The supply for the +5 V engine pressure sensor is
routed from the ECM to terminal A of each pressure
sensor connector. The supply voltage is 5.0 0.16
VDC.
The +5 V diagnostic code is probably caused by a
short circuit to ground or a short circuit to another
voltage source in the harness.

SENR9698-09

Illustration 23

149
Troubleshooting Section

g00970385

Schematic

Illustration 24
P2 ECM connector

g00970387

150
Troubleshooting Section

SENR9698-09

Not OK The 5 volt diagnostic codes are still


active.

Repair: Connect a test ECM.


If the test ECM fixes the problem, reconnect the
suspect ECM.
If the problem returns, permanently install the new
ECM.
Verify that the repair eliminates the problem.
STOP.

Test Step 2. Disconnect the Sensors


A. Turn the keyswitch to the ON position.
B. Monitor the active diagnostic code screen on Cat
ET.
Illustration 25

g00810608

Sensor connector

Test Step 1. Disconnect the ECM


Connector and Check for Active
Diagnostic Codes

C. Disconnect the pressure sensors one at a time.


Wait for 30 seconds after each pressure sensor is
disconnected.

A. Turn the keyswitch to the OFF position.

Note: The 5 volt diagnostic code will become inactive


if a pressure sensor is the cause of the 5 volt
diagnostic code.

B. Connect the Caterpillar Electronic Technician (Cat


ET) to the data link connector.

D. Ensure that all of the pressure sensors are


disconnected.

C. Disconnect the P2 ECM connector from the ECM.

Expected Result:

D. Check the ECM connector for corrosion and


moisture.

The 5 volt diagnostic code is still active when all of


the pressure sensors are disconnected.

E. Turn the keyswitch to the ON position.


F. Check for active diagnostic codes on Cat ET.
Note: A voltage high diagnostic code (open circuit)
should be active for all of the engine pressure
sensors.
Expected Result:
The 5 volt diagnostic codes are not active. A voltage
high diagnostic code (open circuit) is active for all of
the engine pressure sensors.
Results:

OK The 5 volt diagnostic codes are not active.


Repair: Reconnect the P2 ECM connector.
Proceed to Test Step 2.

Results:

OK The 5 volt diagnostic code is still active.


Repair: Leave all of the pressure sensors
disconnected.
Proceed to Test Step 4.

Not OK The 5 volt diagnostic code disappears


when the pressure sensors are disconnected.

Repair: Reconnect all of the pressure sensors


except the suspect sensor.
Proceed to Test Step 3.

Test Step 3. Check the Signal Wire


A. Turn the keyswitch to the ON position.
Note: The suspect sensor should be disconnected.

SENR9698-09

B. Measure the voltage between terminal C (Signal)


and terminal B (Pressure Sensor Common) of the
connector for the suspect sensor on the engine
harness.
Expected Result:
The voltage is less than 7.0 VDC.
Results:

OK The voltage is within the range.


Repair: Temporarily connect a new sensor.

151
Troubleshooting Section

B. Measure the voltage between terminal A


(Pressure Sensor +5V) and chassis ground for
each pressure sensor.
Expected Result:
The voltage is 5.0 0.16 VDC.
Results:

OK The 5 volt supply is within the range.


Proceed to Test Step 6.

Not OK The voltage is greater than 5.16 volts.

If the problem is resolved with the new sensor,


reconnect the suspect sensor.

Repair: Check the 5 volt supply wire for a short to


a higher voltage source.

If the problem returns, replace the suspect sensor.

Repair the 5 volt supply wire or replace the 5 volt


supply wire.

Verify that the repair eliminates the problem.


STOP.

Not OK The voltage is greater than 7.0 VDC.


Repair: Inspect the signal wire for a short circuit to
a voltage source.
Repair the signal wire or replace the signal wire.
Verify that the repair eliminates the problem.
STOP.

Test Step 4. Determine the Condition that


is Present
A. Turn the keyswitch to the ON position.

Verify that the repair eliminates the problem.


STOP.

Test Step 6. Check the Common Wire


A. Turn the keyswitch to the ON position.
B. Measure the voltage between terminal A (Pressure
Sensor +5V) and terminal B (Pressure Sensor
Common) on all of the pressure sensors.
C. While the voltage is monitored, perform a 45 N
(10 lb) pull test on the common wires for the 5 volt
supply.

P2:3 (Pressure Sensor Common)


P2:42 (Pressure Sensor Common (Actuator))

B. Access the active diagnostic code screen on Cat


ET.

Expected Result:

Expected Result:

The voltage is 5.0 0.16 VDC.

232-03 or 232-04 is active.

Results:

Results:

OK The voltage is within the range.

232-03 Proceed to Test Step 5.


232-04 Proceed to Test Step 7.
Test Step 5. Measure the 5 Volt Supply to
the Sensor
A. Turn the keyswitch to the ON position.
Note: All of the pressure sensors should be
disconnected.

Repair: If the problem is intermittent, refer to


Troubleshooting, Electrical Connectors - Inspect.
STOP.

Not OK The voltage is not within the range.


Repair: Inspect the common wire for an open
circuit.
Repair the common wire or replace the common
wire.

152
Troubleshooting Section

SENR9698-09

Verify that the repair eliminates the problem.

This procedure covers the following diagnostic codes:

STOP.

41-03 8 Volt Supply voltage high

Test Step 7. Check the Resistance of the


Harness
A. Turn the keyswitch to the OFF position.
B. Verify that all of the sensors are disconnected.
C. Measure the resistance between terminal A
(Pressure Sensor +5V) and terminal B (Pressure
Sensor Common) of each connector for the
pressure sensor on the engine harness.
Expected Result:
The resistance is greater than 20,000 Ohms, or OL
is displayed on the multimeter.
Results:

OK The 5 volt supply and the pressure sensor


common are not shorted.

Repair: Check the 5 volt supply for a short to


ground.
Repair the 5 volt supply wire or replace the 5 volt
supply wire.
Verify that the repair eliminates the problem.
STOP.

Not OK There is a short between the 5 volt


supply and the pressure sensor common.

Repair: Locate the short between the 5 volt supply


and the pressure sensor common.
Repair the faulty wiring or replace the faulty wiring.
Verify that the repair eliminates the problem.
STOP.
i02506987

Accelerator Pedal (Throttle)


Position Sensor Circuit - Test
SMCS Code: 1913-038
System Operation Description:
Use this procedure to troubleshoot any suspect
problems with the accelerator pedal position sensor.

41-04 8 Volt Supply voltage low


91-08 Throttle Position Invalid
91-13 Throttle Position out of calibration
The accelerator pedal position sensor is used to
provide a throttle position signal to the Engine
Control Module (ECM). Sensor output is a constant
frequency signal with a pulse width that varies with
the pedal position. This output signal is referred to
as either a duty cycle or a pulse width modulated
signal (PWM) and this output signal is expressed as
a percentage between 3 and 100 percent.
The accelerator pedal position sensor is attached
directly to the accelerator pedal assembly. The
accelerator pedal position sensor requires no
adjustment.
The accelerator pedal position sensor will produce
a duty cycle of 10 to 22 percent at low idle and 75
to 90 percent when the accelerator pedal is fully
depressed. The percent of duty cycle is translated
in the ECM into an accelerator pedal position of 3
to 100 percent.
Note: When the ECM automatically calibrates new
duty cycle values for the low idle throttle position and
the high idle throttle position the ECM assumes 22
percent duty cycle at low idle and 75 percent duty
cycle at high idle. As a result, you may notice that
the throttle position status reaches 100 percent well
before the accelerator pedal is fully depressed. This
is normal. After some cycling of the accelerator pedal
to the high idle position, the ECM will adjust the
calibration automatically. The ECM will adjust the
calibration automatically provided that the high idle
stop position is within the 75 to 90 percent duty cycle
range, and the low idle is in the 10 to 22 percent
duty cycle range. During normal operation, you may
also notice that more movement of the accelerator
pedal is required for the throttle position status to
increase above 3 percent. You may also observe that
the status reaches the 100 percent value prior to the
limit of the high idle position. This is done in order
to ensure that the throttle reaches these two critical
points for engine operation.
The accelerator pedal position sensor is powered by
the ECM supply voltage (+8 VDC) from connector
P1-4 to terminal A of the accelerator pedal position
sensor connector. The accelerator pedal position
sensor can be replaced separately from the pedal
assembly. An incorrectly calibrated pedal assembly
can not be adjusted. The entire pedal assembly must
be replaced.

SENR9698-09

153
Troubleshooting Section

If the vehicle is in PTO mode, the accelerator pedal


position sensor will be ignored while the engine
is in PTO mode and the PTO Configuration is
programmed to one of the following options:

Remote switches
Remote throttle
Note: In the configuration for the cab switches, the
vehicles accelerator pedal can be used in order
to control the engine rpm for the PTO operation.
The accelerator pedal can also be ignored in the
Cab Switches PTO configuration. Programming
of customer parameters is required in order to
ignore the accelerator pedal in the Cab Switches
configuration.
The ECM is in PTO mode if the PTO On/Off Switch
is on. This can be checked with the Caterpillar
Electronic Technician (ET). Refer to Troubleshooting,
PTO Switch Circuit - Test for testing if the PTO is
being used.

g00642016

Illustration 26
Schematic for the accelerator pedal position sensor

Test Step 1. Monitor the Status for the


Accelerator Pedal Position
A. Turn the keyswitch to the OFF position.

Results:

OK Cat ET is reporting the correct status for the


Accelerator Pedal Position.

D. Access the status for the Accelerator Pedal


Position.

Repair: The accelerator pedal position sensor is


operating correctly. There may be an intermittent
electrical problem in the circuit for the throttle
position sensor. If an intermittent problem is
suspected, refer to Troubleshooting, Electrical
Connectors - Inspect.

E. While the status is monitored, depress the


accelerator pedal and release the accelerator
pedal.

Verify that the engine is not in PTO mode. PTO


mode may cause the accelerator pedal position
sensor to be ignored.

B. Connect Cat ET to the service tool connector.


C. Turn the keyswitch to the ON position.

The correct status for the Accelerator Pedal


Position is 100 percent when the accelerator
is fully depressed. The correct status for the
Accelerator Pedal Position is less than 5 percent
when the accelerator is fully released.
F. Turn the keyswitch to the OFF position.
Expected Result:
Cat ET is reporting the correct status for the
Accelerator Pedal Position.

Verify that all required parameters are


programmed. Certain unprogrammed parameters
may cause the engine to be limited to low idle.
Refer to Troubleshooting, System Configuration
Parameters.
STOP.

Not OK Cat ET is not reporting the correct

status for the Accelerator Pedal Position. The


accelerator pedal position sensor is not operating
correctly. Proceed to Test Step 2.

154
Troubleshooting Section

Test Step 2. Monitor the Duty Cycle


A. Turn the keyswitch to the ON position.

SENR9698-09

Test Step 3. Inspect the Electrical


Connectors and the Wiring

B. Access the following display screen in order:

Service
Calibrations
Monitor Throttle Position Sensor
C. While the duty cycle is being monitored, depress
the accelerator pedal and release the accelerator
pedal.
The correct duty cycle is 10 percent to 22 percent
when the accelerator pedal is released. The
correct duty cycle is 75 percent to 90 percent
when the accelerator pedal is depressed.
D. Turn the keyswitch to the OFF position.
Expected Result:
Cat ET is reporting the correct duty cycle for the
sensor.
Results:

OK Cat ET is reporting the correct duty cycle


for the sensor.

Repair: The duty cycle is within the specified


range. There may be an intermittent electrical
problem in the circuit for the throttle position sensor.
If an intermittent problem is suspected, refer to
Troubleshooting, Electrical Connectors - Inspect.
Verify that the engine is not in PTO mode. PTO
mode may cause the accelerator pedal position
sensor to be ignored.
Verify that all required parameters are
programmed. Certain unprogrammed parameters
may cause the engine to be limited to low idle.
Refer to Troubleshooting, System Configuration
Parameters.
STOP.

Not OK Cat ET is reporting the correct duty cycle


for the sensor. The duty cycle is not within the
range. Proceed to Test Step 3.

Illustration 27

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

A. Thoroughly inspect the J1/P1 ECM connector, the


firewall bulkhead connector and the accelerator
pedal position sensor connector. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.

SENR9698-09

155
Troubleshooting Section

B. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the accelerator pedal position sensor.
C. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
D. Check the harness and wiring for abrasion and
pinch points from the accelerator pedal position
sensor to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion or of pinch points.
Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 4.

Not OK There is a problem with the connectors


and/or wiring.

Repair: Perform the following repair:


Repair the connectors or wiring and/or replace
the connectors or wiring. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled.
Illustration 28

g01255058

Terminal locations at the P1 ECM connector for the throttle position


sensor
(P1-4) Sensor supply (8 V)
(P1-5) Sensor return
(P1-66) Accelerator pedal position sensor

Verify that the repair eliminates the problem.


STOP.

Test Step 4. Check for Active Diagnostic


Codes
A. Turn the keyswitch to the ON position.
B. Check for the following active diagnostic codes
on Cat ET:

91-08
91-13
41-03
41-04
Illustration 29

g01159881

C. Turn the keyswitch to the OFF position.

Sensor connector

Expected Result:

(Terminal A) Sensor supply


(Terminal B) Sensor return
(Terminal C) Sensor signal

One of the diagnostic codes that are listed above


are active.

156
Troubleshooting Section

Results:

Active 91-08 or 91-13 There is a problem with


the throttle signal. Proceed to Test Step 5.

SENR9698-09

Test Step 6. Check the Duty Cycle of the


Sensor at the ECM
A. Disconnect the J1/P1 ECM connectors.

Active 41-03 A high voltage is detected in the

B. Remove the wire from terminal location P1-66


(accelerator pedal position sensor) at the ECM
connector.

Active 41-04 A low voltage is detected in the

C. Install a 208-0059 Adapter Cable As (70-PIN


BREAKOUT) at the J1/P1 ECM connector.
Connect the J1/P1 ECM connector.

Test Step 5. Check the Duty Cycle at the


Sensor

D. Turn the keyswitch to the ON position.

supply circuit that is for the accelerator pedal


position sensor. Proceed to Test Step 8.

supply circuit for the throttle position sensor.


Proceed to Test Step 9.

A. Remove the signal wire from terminal C at the


harness side of the connector for the throttle
position sensor.
B. Install a 7X-6370 Adapter Cable As (3-PIN
BREAKOUT) at the connector for the throttle
position sensor.
C. Turn the keyswitch to the ON position.
D. Use a multimeter that can read a duty cycle to
measure the signal between terminals C and B
at the breakout t.
E. While the duty cycle is being monitored on the
multimeter, depress the accelerator pedal and
release the accelerator pedal.
The correct measurement is a duty cycle that
is between 10 percent and 22 percent when the
accelerator pedal is fully released. The correct
measurement is a duty cycle that is between 75
percent and 90 percent when the accelerator
pedal is fully depressed.
F. Turn the keyswitch to the OFF position.
Expected Result:
The measurements agree with the duty cycles that
are stated above.

E. Use a multimeter to measure the duty cycle


between terminal locations 5 (sensor return) at
the breakout t and the loose end of the signal wire
that was removed from terminal location P1-66.
F. While the duty cycle output of the accelerator
pedal position sensor is being monitored on the
multimeter, depress the accelerator pedal and
release the accelerator pedal.
The correct measurement is a duty cycle that
is between 10 percent and 22 percent when the
accelerator pedal is fully released. The correct
measurement is a duty cycle that is between 75
percent and 90 percent when the accelerator
pedal is fully depressed.
G. Turn the keyswitch to the OFF position. Restore
the wiring to the original configuration.
Expected Result:
The measurements agree with the duty cycles that
are stated above.
Results:

OK The measurements agree with the results


that are stated above.

Results:

Repair: The correct signal is reaching the ECM.


Verify that the ECM is receiving the proper battery
voltage. If the ECM is receiving the proper battery
voltage, there is a problem with the ECM.

OK The measurements agree with the results

1. Temporarily connect a test ECM.

that are stated above. The accelerator pedal


position sensor and the throttle pedal assembly are
working correctly. Restore the wiring to the original
configuration. Proceed to Test Step 6.

Not OK The measurements do not agree with the

results that are stated above. There is a problem


with the throttle position sensor. There may be a
problem with the throttle pedal assembly. Leave
the breakout t in the circuit. Proceed to Test Step 7.

Refer to Troubleshooting, Replacing the ECM.


2. Perform this procedure again.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.

SENR9698-09

If the problem is not resolved with the test ECM,


install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.

Not OK The measurements do not agree with

the duty cycles that are stated above. The signal


is OK at the sensor connector, but the correct
signal is not reaching the ECM. There is a problem
with signal wire for the accelerator pedal position
sensor that is in the vehicle wiring harness. Repair
the signal wire in the harness or replace the signal
wire in the harness. Verify that the repair corrects
the original problem.

157
Troubleshooting Section

158
Troubleshooting Section

SENR9698-09

Test Step 7. Remove the Sensor from the


Pedal Assembly

g00706977

Illustration 30
Accelerator pedal assembly

A. Remove the accelerator pedal position sensor


from the accelerator pedal assembly. Record
the sensors orientation in the accelerator pedal
assembly. Also, note the routing of the sensors
pigtail prior to removal. Thoroughly inspect the
pigtail for signs of abrasion and damage.
Note: When the sensor is removed from the
accelerator pedal assembly, a 91-13 Throttle Sensor
Calibration may be generated. This is normal. The
diagnostic code should disappear when the sensor is
properly assembled back into the accelerator pedal
assembly.

B. Connect the multimeter between terminal C


(sensor signal) and terminal B (sensor return) at
the breakout t.
C. Turn the keyswitch to the ON position.
D. Measure the duty cycle of the throttle position
sensor while the slot is released. Use a
screwdriver to advance the sensor slot to the
maximum position. Again, measure the duty cycle
of the sensor.

SENR9698-09

When the sensor is removed from the accelerator


pedal assembly and the sensor slot is released,
the correct duty cycle is 10 percent or less. When
the sensor slot is moved to the maximum position,
the correct duty cycle will become 90 percent or
more.
E. Turn the keyswitch to the OFF position.
Expected Result:
When the sensor is removed from the accelerator
pedal assembly, the accelerator pedal position
sensor generates the correct signal.
Results:

OK When the sensor is removed from the

accelerator pedal assembly, the accelerator pedal


position sensor generates the correct signal.
Repair: The accelerator pedal position sensor is
operating correctly. There appears to be a problem
with the accelerator pedal assembly. Clear any
diagnostic codes that were caused by performing
this test procedure. Refer to the OEM dealer
for correct replacement of the accelerator pedal
assembly.
STOP.

Not OK When the sensor is removed from the

accelerator pedal assembly, the accelerator pedal


position sensor does not generate the correct
signal.
Repair: The accelerator pedal position sensor
is faulty. Check the accelerator pedal assembly
in order to ensure that the accelerator pedal
assembly is not causing damage to the sensor. If
the accelerator pedal assembly is causing damage
to the sensor, refer to the OEM dealer for correct
replacement of the accelerator pedal assembly.
If the accelerator pedal assembly appears OK,
replace the accelerator pedal position sensor.
STOP.

Test Step 8. Short the +8 Volt Supply at


the Sensor Connector
A. Install a 7X-6370 Adapter Cable As (3-PIN
BREAKOUT) at the connector for the throttle
position sensor.
B. Fabricate a jumper wire that is long enough to
create a short circuit between two terminals at the
breakout t. Crimp connector pins to each end of
the jumper wire.
C. Use the jumper wire to create a short circuit
between terminal A (sensor supply) and terminal
B (sensor return) of the breakout T.

159
Troubleshooting Section

D. Turn the keyswitch to the ON position.


E. Use Cat ET to check for active diagnostic codes.
F. Turn the keyswitch to the OFF position.
Expected Result:
The 41-03 changes to 41-04 when the short circuit
is installed.
Results:

OK The 41-03 changes to 41-04 when the short


circuit is installed.

Repair: The problem is with the accelerator


pedal position sensor. Restore the wiring to the
original configuration. Temporarily connect a new
sensor. If the new sensor eliminates the problem,
reconnect the suspect sensor. If the problem
returns, permanently replace the sensor. Verify that
the repair eliminates the problem.
STOP.

Not OK The 41-03 remains active when the short


circuit is installed at the sensor connector. The
ECM did not see the short at the sensor. Proceed
to Test Step 10.

Test Step 9. Create an Open Circuit at the


Sensor Connector
A. Disconnect the accelerator pedal position sensor
at the harness connector.
B. Turn the keyswitch to the ON position.
C. Use Cat ET to check for active diagnostic codes.
D. Turn the keyswitch to the OFF position.
Expected Result:
The 41-04 changes to 41-03 when the sensor is
disconnected from the harness.
Results:

OK The 41-04 changes to 41-03 when the


sensor is disconnected from the harness.

Repair: The problem is with the accelerator


pedal position sensor. Restore the wiring to the
original configuration. Temporarily connect a new
sensor. If the new sensor eliminates the problem,
reconnect the suspect sensor. If the problem
returns, permanently replace the sensor. Verify that
the repair eliminates the problem.
STOP.

160
Troubleshooting Section

Not OK The 41-04 remains active when the short


circuit is installed at the sensor connector. The
ECM did not detect the open circuit at the sensor
connector. Proceed to Test Step 10.

Test Step 10. Check the Operation of the


ECM
A. Disconnect the J1/P1 ECM connectors.
B. Fabricate two jumper wires that are long enough
to create a short circuit at the P1 ECM connector.
Crimp connector sockets to one end of each
jumper wire.
C. Remove the wires from terminal locations P1-4
(sensor supply) and P1-5 (sensor return). Install a
jumper wire into each of these terminal locations.
D. Connect the J1/P1 ECM connectors.
E. Check for an open circuit condition at the
ECM:
a. Hold the loose ends of the jumper wires away
from any ground source in order to create an
open circuit condition.
b. Turn the keyswitch to the ON position.
c. Use Cat ET to check for active diagnostic
codes.
For an ECM that is operating correctly, a 41-03
code will be active with the circuit for the sensor
supply open at the ECM.
d. Turn the keyswitch to the OFF position.
F. Check for an short circuit condition at the
ECM:
a. Short circuit the loose ends of the jumper wires
in order to create a short circuit condition at
the ECM.
b. Turn the keyswitch to the ON position.
c. Use Cat ET to check for active diagnostic
codes.
For an ECM that is operating correctly, a 41-04
code will be active when the sensor supply is
short circuited.
d. Turn the keyswitch to the OFF position.
G. Restore the wiring to the original configuration.

SENR9698-09

Expected Result:
Cat ET reported the correct diagnostic codes for the
conditions that were present.
Results:

OK Cat ET reported the correct diagnostic codes


for the conditions that were present.

Repair: The ECM is reading the circuit conditions


correctly. The problem is in the vehicle wiring
harness between the ECM connector and the
connector for the accelerator pedal position sensor.
Repair the harness or replace the harness. Verify
that the repair eliminates the problem.
STOP.

Not OK One of the following conditions are

present: A 41-03 code was not active with the


circuit for the sensor supply open at the ECM. A
41-04 code was not active with the short circuit at
the ECM.
Repair: The ECM is not detecting the circuit
conditions correctly. There is a problem with the
ECM. Perform the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.

2. Perform this procedure again.


If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.

SENR9698-09

161
Troubleshooting Section

i02049032

Air Inlet Shutoff Circuit - Test


SMCS Code: 1078-038
System Operation Description:
The air inlet shutoff is available for certain engine
ratings that operate in areas with large amounts of
combustible gases. When an overspeed is detected,
a relay activates the air inlet shutoff system and fuel
injection is disabled. This is accomplished by closing
a flap in order to cut off the air supply to the engine.
Once the air inlet shutoff is activated the flap must
be manually reset to the open position, before the
engine can be restarted.
Air Inlet Shutoff System Control Test
The Air Inlet Shutoff System Control Test is
available to test the air inlet shutoff system. This
test will determine if the air inlet shutoff system is
working correctly. When the test is activated the air
inlet shutoff will activate and the engine will shut
down. The following conditions must be met before
this test can be used:

Engine speed is 1500 rpm 100 rpm.


The transmission is in neutral.
Air Inlet Shutoff Relay Output
The Air Inlet Shutoff Relay Output test is available
to energize the air inlet shutoff relay. When the test is
activated, a one second pulse is sent to the air inlet
shutoff relay. The following conditions must be met
before this test can be used:

Engine speed is 0 rpm.


The transmission is in neutral.
Air Inlet Shutoff Switch
The air inlet shutoff switch can be used to manually
activate the air inlet shutoff. When the switch is
depressed, a one second pulse is sent to the air inlet
shutoff relay. The following condition must be met
before the air inlet shutoff switch will work:

The transmission is in neutral.

162
Troubleshooting Section

SENR9698-09

g01051166

Illustration 31
Schematic

g01017869

Illustration 32
P1 and P2 ECM connectors

Test Step 1. Perform the Air Inlet Shutoff


System Control Test

B. Connect the Caterpillar Electronic Technician (Cat


ET) to the data link connector.

A. Turn the key switch to the OFF position.

C. Turn the key switch to the ON position.


D. Place the transmission in the neutral position.

SENR9698-09

E. Start the engine. Increase the engine speed from


low idle to 1500 rpm 100 rpm.
F. Access the Air Inlet Shutoff System Control Test
in the Diagnostic Tests under the Diagnostics
menu on Cat ET.
G. Start the test.

163
Troubleshooting Section

Expected Result:
The status is On when the wires are connected.
The status is Off when the wires are disconnected.
Results:

OK The switch is not working properly.

H. Wait for the engine to stop.

Repair: Replace the air inlet shutoff switch.

I. Stop the test.

Verify that the repair eliminates the problem.

Expected Result:

STOP.

Fuel injection is disabled. The air inlet shutoff is


activated and the engine is shutdown.
Results:

OK The engine is shutdown when the Air Inlet


Shutoff System Control Test is activated. The air
inlet shutoff is working correctly.
Repair: Reset the air inlet shutoff system.
Proceed to Test Step 2.

Not OK The engine did not shut down. Proceed


to Test Step 4.

Test Step 2. Check the Air Inlet Shutoff


Switch
A. Turn the key switch to the ON position.
B. Monitor the status for the air inlet shutoff switch
while the switch is depressed.
Expected Result:
The status is On when the switch is depressed. The
status is Off when the switch is released.
Results:

OK The switch is operating correctly. The air


inlet shutoff system is working properly. STOP.

Not OK The switch is not operating correctly.


Proceed to Test Step 3.

Test Step 3. Check the Circuit to the Air


Inlet Shutoff Switch
A. Turn the key switch to the OFF position.
B. Remove the air inlet shutoff switch.
C. Turn the key switch to the ON position.
D. Monitor the status for the air inlet shutoff switch
while the two wires from the switch are connected.

Not OK There is a problem between the ECM


and the air inlet shutoff switch.

Repair: Inspect the wiring between the ECM and


the air inlet shutoff switch.
Repair the wiring or replace the wiring.
Verify that the repair eliminates the problem.
STOP.

Test Step 4. Check the Interlock for the


Air Inlet Shutoff
A. Verify that J1/P1:62 is connected to the +Battery.
Note: J1/P1:62 is used for the transmission neutral
switch. If a transmission neutral switch is installed,
the transmission must be in neutral.
Expected Result:
J1/P1:62 is connected to the +Battery or the
transmission is in neutral.
Results:

OK J1/P1:62 is connected to the +Battery.


Repair: Check the status for the Transmission
Neutral Switch while the transmission is in neutral.
The status should be On.
If the status is Off, refer to Troubleshooting,
Neutral Switch Circuit - Test.
Proceed to Test Step 5.

Not OK J1/P1:62 is not connected to the


+Battery.

Repair: Connect J1/P1:62 to the +Battery.


Repeat Test Step 1.

164
Troubleshooting Section

Test Step 5. Inspect Electrical Connectors


and Wiring
A. Turn the key switch to the OFF/RESET position.
B. Thoroughly inspect the J2/P2 ECM connector
and all other connectors in the circuit. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.
C. Perform a 45 N (10 lb) pull test on the wires that
are associated with the air inlet shutoff system.
D. Check the ECM connector (allen head screw) for
the proper torque of 6.0 Nm (55 lb in).

SENR9698-09

Expected Result:
The relay is active.
Results:

OK A click is heard. The relay is active. Proceed


to Test Step 7.

Not OK There is a problem with the relay circuit.


Proceed to Test Step 9.

Test Step 7. Check the Supply Voltage to


the Air Inlet Shutoff Solenoid

E. Check the harness and wiring for abrasion and for


pinch points from the sensors back to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion or of pinch points.
Results:

OK All the wires and connections are OK.


Proceed to Test Step 6.

Not OK

Illustration 33

g00850138

Air inlet shutoff solenoid

Repair: Perform the following repair:

A. Turn the key switch to the ON position.

Repair the connectors or wiring and/or replace


the connectors or wiring. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled.

B. Proceed to the Air Inlet Shutoff Relay Output test


on Cat ET.

Verify that the repair eliminates the problem.

C. Use a voltage test lamp to check the voltage


across the two terminals of the air inlet shutoff
solenoid.

STOP.

D. Activate the relay for the air inlet shutoff solenoid.

Test Step 6. Perform the Air Inlet Shutoff


Relay Output Test

Note: The output for the air inlet shutoff will be active
for only one second.

A. Turn the key switch to the OFF position.

Expected Result:

B. Connect Cat ET to the data link connector.

The voltage test lamp illuminates when the test is


active.

C. Turn the key switch to the ON position. Do not


start the engine.

Results:

D. Go to the Air Inlet Shutoff Relay Output test on


Cat ET.
E. Start the test and listen for a click from the relay
for the air inlet shutoff.

OK The ECM is properly controlling the relay for

the air inlet shutoff solenoid, but the air inlet shutoff
solenoid is not working. Proceed to Test Step 8.

Not OK The air inlet shutoff solenoid is not

receiving the correct signal. Proceed to Test Step


12.

SENR9698-09

165
Troubleshooting Section

Test Step 8. Check the Resistance of the


Solenoid
A. Disconnect the wires for the air inlet shutoff
solenoid.

Expected Result:
The resistance is between 5 Ohms and 10 Ohms.
Results:

B. Measure the resistance of the air inlet shutoff


solenoid.

OK The resistance of the relay is OK. Proceed

C. Reconnect the wires for the air inlet shutoff


solenoid.

Not OK The relay is faulty.

Expected Result:
The resistance is between 15 Ohms and 20 Ohms.
Results:

OK The resistance of the air inlet shutoff


solenoid is OK.

to Test Step 10.

Repair: Replace the relay.


Verify that the repair eliminates the problem.
STOP.

Test Step 10. Check the Signal Voltage


to the Relay

Repair: Check electrical connections. Refer to


Troubleshooting, Electrical Connectors - Inspect
for more information.
STOP.

Not OK The resistance of the solenoid is out of


the specification.

Repair: Replace the air inlet shutoff solenoid.


Verify that the repair eliminates the problem.
STOP.

Illustration 35

Test Step 9. Check the Resistance of the


Relay

g00850154

Schematic for the Relay Signal

A. Unplug the relay for the air inlet shutoff solenoid


from the ECM.
B. Turn the key switch to the ON position.
C. Proceed to the Air Inlet Shutoff Relay Output test
on Cat ET.
D. Check the voltage between P520:1 (Solenoid
Common) and P520:2 (Air Inlet Shutoff Output)
with a voltage test lamp.
Note: The output for the air inlet shutoff system will
be active for only one second.

Illustration 34

g00850059

E. Activate the system for the air inlet shutoff


solenoid.

Relay Terminals

A. Turn the key switch to the OFF/RESET position.


B. Unplug the relay for the air inlet shutoff solenoid.
C. Measure the resistance between J520:1 (Solenoid
Common) and J520:2 (Air Inlet Shutoff Output).

Expected Result:
The voltage test lamp illuminates when the test is
active.

166
Troubleshooting Section

SENR9698-09

Results:

OK The relay is receiving the signal from the

Test Step 12. Check the Output Voltage


of the Relay

ECM. Proceed to Test Step 11.

Not OK The relay is not receiving the signal from


the ECM. Proceed to Test Step 13.

Test Step 11. Check the Power Supply to


the Relay

Illustration 37

g00850141

Air Inlet Shutoff Relay

A. Ensure that all connectors are connected to the


wiring harness.
B. Turn the key switch to the ON position.
Illustration 36

g00850141

Air Inlet Shutoff Relay

A. Measure the voltage between the +Battery


terminal of the relay and the engine ground.
Expected Result:
The voltage is 12.0 4.0 VDC.
Results:

OK The relay is receiving power. Proceed to


Test Step 12.

Not OK There is a problem in the wiring between

C. Go to the Air Inlet Shutoff Relay Output test on


Cat ET.
D. Check the voltage from the output terminal on
the relay to the engine ground with a voltage test
lamp.
Note: The output for the air inlet shutoff system will
be active for only one second.
E. Activate the system for the air inlet shutoff
solenoid.
Expected Result:

the relay and the +Battery terminal.

The voltage test lamp illuminates when the test is


active.

Repair: Repair the circuit.

Results:

Verify that the repair eliminates the problem.

OK There is a problem in the wiring between the

STOP.

relay and the air inlet shutoff solenoid.


Repair: Repair the circuit.

Verify that the repair eliminates the problem.


STOP.

Not OK The relay is not sending power to the air


inlet shutoff solenoid. The relay is bad.

Repair: Replace the relay for the air inlet shutoff.


Verify that the repair eliminates the problem.
STOP.

SENR9698-09

Test Step 13. Check for Shorts in the


Wiring Harness between the Relay and
the ECM

167
Troubleshooting Section

Results:

OK The ECM is supplying the correct voltage.


There is an open circuit in the harness.

A. Ensure that the key switch is in the OFF/RESET


position.

Repair: Repair the circuit.

B. Disconnect the J2/P2 ECM connector.

Verify that the repair eliminates the problem.

C. Unplug the relay for the air inlet shutoff.

STOP.

D. Measure the resistance between P2:13 (Air Inlet


Shutoff Output) and P2:9 (Solenoid Common).

Not OK The ECM is not supplying the correct


voltage.

The resistance is greater than 20,000 Ohms.

Repair: Verify your results. Replace the ECM.


Refer to Troubleshooting, Replacing the ECM
before replacing the ECM.

Results:

Verify that the repair eliminates the problem.

OK There are no shorts in the wiring harness.

STOP.

Expected Result:

Proceed to Test Step 14.

Not OK There is a short in the wiring harness

i02507189

Repair: Repair the circuit.

ATA (SAE J1587 / J1708) Data


Link Circuit - Test

Verify that the repair eliminates the problem.

SMCS Code: 1901-038

STOP.

System Operation Description:

between the ECM and the relay.

Test Step 14. Check the Relay Signal at


the ECM
A. Turn the key switch to the OFF/RESET position.
B. Remove the wire from P2:13 (Air Inlet Shutoff
Output) in the P2 ECM connector.
C. Turn the key switch to the ON position.
D. Check the voltage between the open terminal at
P2:13 (Air Inlet Shutoff Output) and P2:9 (Solenoid
Common) with a voltage test lamp.
Note: The output for the air inlet shutoff system will
be active for only one second.
E. Activate the Air Inlet Shutoff Relay Output test
on Cat ET.
F. Turn the key switch to the OFF/RESET position.
G. Reinstall the wire to P2:13 (Air Inlet Shutoff
Output).
Expected Result:
The voltage test lamp illuminates when the test is
active.

Use this procedure under the following situation:


Use this procedure if Caterpillar Electronic Technician
(ET) will not power up. Also, use this procedure if
Cat ET will not communicate with the Engine Control
Module (ECM) through the data link connector.
The following background information is related
to this procedure:
The ATA data link (American Trucking Association) is
the data link that is used by the ECM to communicate
with electronic service tools. The SAE specification
J1587 defines the format of the messages and
data that is being communicated over the data
link. The SAE specification J1708 defines the
hardware requirements and the protocol of the serial
communications. Some electronic dashboards use
this data link to receive information. Some automatic
transmissions also receive information from this data
link.
The ECM provides communications for the data link
at two terminals that are available to the P1 vehicle
harness connector :

J1-8 ATA data link (+)


J1-9 ATA data link ()

168
Troubleshooting Section

SENR9698-09

The Original Equipment Manufacturer (OEM) for the


vehicle provides twisted pair wiring from the ECM to
the data link connector.
There are potentially several devices that are
installed in the vehicle. Each of these devices will
use the ATA data link for communications. These
devices may include dash displays, trip recorders,
and transmission controls. These devices may be
the cause of potential problems with the data link.
Problems with any one of these devices can disrupt
communications for the engine ECM.
Communication
The ECM will not communicate with Cat ET with the
keyswitch in the OFF position. You may experience
several outages for communications during test
procedures that will require cycling of the keyswitch.
During usage, Cat ET may indicate The version
of the ECM is not recognized and the integrity of
the changed parameters and displayed data is not
guaranteed.. This message will indicate that the
latest version of Cat ET has not been installed or this
message will indicate that the software in the ECM is
newer than the software for Cat ET.

Illustration 38
Schematic for ATA data link with 6-pin connector

Test Step 1. Inspect the Electrical


Connectors and the Wiring
A. Turn the keyswitch to the OFF position.

g00650338

SENR9698-09

Illustration 39

169
Troubleshooting Section

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

B. Thoroughly inspect the J1/P1 ECM connectors.


Also, thoroughly inspect the data link connectors,
the firewall bulkhead connectors, and the
electronic service tool connectors. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.

Illustration 40

g01255291

Terminal locations at the P1 ECM connector for the ATA data link
(8) ATA data link (+)
(9) ATA data link ()

170
Troubleshooting Section

SENR9698-09

g00650354

Illustration 41
Different types of data link connectors

C. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the ATA data link.
D. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
E. Check the harness and wiring for abrasion and for
pinch points from the connector to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion or of pinch points.
Results:

Test Step 2. Determine the Type of


Problem
A. Connect Cat ET to the data link connector.
B. Attempt to start the engine.
C. Turn the keyswitch to the OFF position.
Expected Result:
Result 1 The engine starts. Cat ET powers up and
Cat ET communicates without error.
Result 2 The engine starts. Cat ET powers up but
an error is displayed.
Result 3 The engine cranks but the engine will not
start regardless of the condition of Cat ET.

OK The harness and connectors appear to be

Result 4 The engine will not crank regardless of the


condition of Cat ET.

Not OK There is a problem with the connectors

Result 5 The engine starts but Cat ET does not


power up.

OK. Proceed to Test Step 2.


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.
STOP.

Note: Check the display screen or check the


communication adapter display in order to determine
if Cat ET has powered up. Cat ET will display
information that shows if the tool is getting power. If
Cat ET or the communication adapter powers up, the
data link connector is receiving power.

SENR9698-09

171
Troubleshooting Section

Results:

Results:

Result 1 The engine starts. Cat ET powers up

OK The voltage is between 11.0 and 13.5 VDC

and Cat ET communicates without error.

Repair: There is not a problem with the ATA data


link at this time. There may be an intermittent
electrical problem in the harness or in a connector.
If an intermittent condition is suspected, refer to
Troubleshooting, Electrical Connectors - Inspect
for information that is related to troubleshooting
intermittent problems.
STOP.

Result 2 Cat ET displays an error message. The


ECM is receiving battery power. Proceed to Test
Step 5.

Result 3 The engine cranks but the engine will


not start.

Repair: Refer to Troubleshooting, Engine Cranks


But Will Not Start for information that is related to
troubleshooting this problem.
STOP.

Result 4 The engine will not crank.


Repair: Refer to Troubleshooting, Engine Will
Not Crank for information that is related to
troubleshooting this problem.
STOP.

Result 5 Cat ET does not power up or the

communications adapter does not power up. The


ECM may not be receiving the correct battery
power. Proceed to Test Step 3.

Test Step 3. Check the Battery Voltage to


the Data Link Connector
A. Turn the keyswitch to the ON position.
B. Use a multimeter to measure the voltage between
the terminal for the +Battery and the terminal for
the Battery at the data link connector.
Refer to Illustration 41.
Expected Result:
The voltage is between 11.0 and 13.5 VDC for a 12
volt system or between 22.0 and 27.0 VDC for a 24
volt system.

for a 12 volt system or between 22.0 and 27.0


VDC for a 24 volt system. The data link connector
is currently receiving the correct voltage. Proceed
to Test Step 4.

Not OK The voltage is not between 11.0 and

13.5 VDC for a 12 volt system or between 22.0


and 27.0 VDC for a 24 volt system.
Repair: The data link connector is not receiving the
correct voltage. Inspect the wiring, the connectors,
and the circuit protection for the circuit. Repair
the wiring or batteries and/or replace the wiring
or batteries, as required. Send the vehicle to the
OEM dealer for repair, if necessary. Verify that the
repair eliminates the problem.
STOP.

Test Step 4. Confirm the Operation of Cat


ET on another Engine
A. If another vehicle with a Caterpillar electronic
engine is available, connect Cat ET to the other
vehicle. Use the same cables to make the
connection.
a. Turn the keyswitch to the ON position.
b. Determine if Cat ET communicates correctly
with the other ECM.
c. Turn the keyswitch to the OFF position.
B. If another engine is not available, use a different
set of cables to connect to the engine. Ensure
that the set of electronic service tool cables is a
complete set.
a. Connect Cat ET to the data link connector by
using the new cables.
b. Turn the keyswitch to the ON position.
c. Determine if Cat ET communicates correctly
with the other ECM.
d. If changing cables allows Cat ET to operate
properly, use the following procedure:
Replace the pieces from the old set of cables
into the new set of cables that operates.
Replace one piece at a time.
Repower Cat ET after each of the pieces is
replaced. Use this method to find the faulty
piece.

172
Troubleshooting Section

e. If changing cables does not allow Cat ET to


operate properly, connect another electronic
service tool.

SENR9698-09

Test Step 5. Check the Battery Voltage at


the ECM

Turn the keyswitch to the OFF position.


Expected Result:
Result 1 The original electronic service tool works
on another vehicle.
Result 2 A different electronic service tool works on
the original vehicle while the engine is being tested.
Results:

Result 1 The original electronic service tool

works on another vehicle. Proceed to Test Step 5.

Result 2 A different electronic service tool works


on the original vehicle while the engine is being
tested.

Repair: Send the faulty electronic service tool for


repairs.
STOP.

Illustration 42

g01255300

Terminal locations at the P1ECM connector for the ECM battery


connection
(48)
(52)
(53)
(63)
(65)
(67)
(70)

Unswitched +Battery
Unswitched +Battery
Unswitched +Battery
Battery
Battery
Battery
Ignition keyswitch

A. Disconnect the J1/P1 ECM connector.


B. Turn the keyswitch to the ON position.
C. Measure the voltage between P1-48 (unswitched
+Battery) and P1-63 (Battery).
D. Measure the voltage between P1-52 (unswitched
+Battery) and P1-65 (Battery).
E. Measure the voltage between P1-53 (unswitched
+Battery) and P1-67 (Battery).

SENR9698-09

173
Troubleshooting Section

F. Measure the voltage between P1-70 (ignition


keyswitch) and P1-65 (Battery).
G. Turn the keyswitch to the OFF position.
Expected Result:
The voltage is between 11.0 and 13.5 VDC for a 12
volt system or between 22.0 and 27.0 VDC for a 24
volt system.
Results:

OK The voltage is between 11.0 and 13.5 VDC

for a 12 volt system or between 22.0 and 27.0 VDC


for a 24 volt system. The ECM is currently receiving
the correct voltage. Proceed to Test Step 6.

Not OK The voltage is not between 11.0 and

13.5 VDC for a 12 volt system or between 22.0


and 27.0 VDC for a 24 volt system.

Repair: The ECM is not receiving the correct


voltage. Ensure that there is not an aftermarket
engine protection switch that is overriding battery
power to the ECM. Refer to Troubleshooting,
Ignition keyswitch Circuit and Battery Supply
Circuit - Test.
STOP.

Test Step 6. Install a Bypass Harness

Illustration 43
Schematic of the bypass harness

g01017846

174
Troubleshooting Section

SENR9698-09

g01104227

Illustration 44
Schematic of the ECM battery circuit

Batteries give off flammable fumes which can explode.


To avoid injury or death, do not strike a match,
cause a spark, or smoke in the vicinity of a battery.

Note: This bypass directly connects the circuit for the


keyswitch to the ECM. The ECM will remain powered
until the connection to the unswitched +Battery is
disconnected. Remove the three 10 Amp fuses from
the in-line fuse holder to power down the ECM. Do
not connect the bypass to the battery posts or do not
remove the bypass from the battery posts without
first removing the 10 Amp in-line fuses.

NOTICE
Do Not connect the Bypass Harness to the battery
until all three of the 10 Amp in-line fuses have been
removed from the +Battery line. If the fuses are not
removed before connection to the battery a spark may
result.

C. Turn the keyswitch to the ON position.

A. Disconnect the J1/P1 ECM connectors.

OK Cat ET is operating correctly.

B. Install a 167-9225 Harness (SERVICE TOOL


ADAPTER) at the J1 ECM connector.

Expected Result:
Cat ET is operating correctly.
Results:

SENR9698-09

Repair: There is a problem in the vehicle wiring, or


another device in the vehicle is causing problems
on the data link. Either determine the device that
is causing the problem or send the vehicle to
the OEM dealer for repair. Verify that the repair
eliminates the problem.
STOP.

Not OK Cat ET is not operating correctly. Verify

that the three 10 Amp fuses in the bypass harness


are not open. A fuse that is open is a blown fuse.
Proceed to Test Step 7.

Test Step 7. Connect Cat ET and the ECM


to another Battery

175
Troubleshooting Section

2. Recheck the circuit in order to ensure that the


original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.
i02507296

Batteries give off flammable fumes which can explode.


To avoid injury or death, do not strike a match,
cause a spark, or smoke in the vicinity of a battery.
NOTICE
Do Not connect the Bypass Harness to the battery
until all three of the 10 Amp in-line fuses have been
removed from the +Battery line. If the fuses are not
removed before connection to the battery a spark may
result.
A. Connect the battery wires from the bypass
harness to a different battery that is not on the
vehicle.
Expected Result:
Cat ET is operating correctly.
Results:

OK Cat ET is operating correctly.


Repair: The vehicle battery is causing the problem.
Refer to Troubleshooting, Ignition keyswitch
Circuit and Battery Supply Circuit - Test for
troubleshooting information.
STOP.

Not OK Cat ET is operating correctly.


Repair: There is a problem with the ECM. Perform
the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.

Auxiliary Brake Circuit - Test


SMCS Code: 1129-038-AX
System Operation Description:
Use this procedure to determine if the auxiliary brake
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 vehicles braking is poor.
Background Information
The Engine Control Module (ECM) has an output
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
output. The OEM provides the wiring from terminal
P1-12 to the systems components.
Typically, the ECM output energizes a relay. The
relays contacts apply battery power to the other
components in the system. A switch on the dashboard
interrupts the signal from the relay. This allows the
operator to deactivate the system, if necessary.
The ECM continuously monitors the vehicles
operating conditions. The ECM provides battery
voltage to terminal P1-12 when all of the following
conditions are met:

Engine speed is above 800 rpm.


The percent of accelerator pedal position is less
than eight percent.

The clutch pedal is released.


When the cruise control is ON, the auxiliary brake
output is related to the position of the service brake
pedal. The ECM response depends on the mode of
operation of the cruise control:

176
Troubleshooting Section

Coast Mode Depressing the service brake pedal


disengages the cruise control. The auxiliary brake
output is activated. The output is deactivated when
the driver releases the service brake pedal.
Latch Mode Depressing the service brake pedal
disengages the cruise control. The auxiliary brake
output is activated. The output remains active until
the ECM detects a change in the conditions that
are monitored. For example, the accelerator pedal
is above seven percent.
Manual Mode Depressing the service brake pedal
has no effect on the auxiliary brake output.
If the PTO Configuration is programmed to Cab
Switches, Remote Switches, or Remote Throttle,
the auxiliary brake output is disabled whenever the
PTO On/Off circuit is ON.
If the vehicle is equipped with an Anti-Lock Brake
System (ABS), the vehicle may have an additional
relay in the circuit for the auxiliary brake. This allows
the ABS system to disable the auxiliary brake, if
necessary.
Engines that are equipped with engine retarders
The auxiliary brake output is disabled when the
vehicle speed is below the value that is programmed
for the Engine Retarder Minimum Vehicle Speed
parameter. The Engine Retarder Minimum VSL
Type parameter provides the following two options:
Hard Limit (default) As the vehicle speed
decreases, the auxiliary brake output is deactivated
when the vehicle speed goes below the Engine
Retarder Minimum Vehicle Speed.
Soft Limit As the vehicle speed decreases, the
auxiliary brake output remains activated when the
vehicle speed goes below the Engine Retarder
Minimum Vehicle Speed.
The Engine Retarder Delay parameter provides a
programmable delay after all of the basic conditions
that are required to turn on the auxiliary brake are
met. Once the conditions are met the ECM will
delay the activation of the auxiliary brake by the
programmed additional time. The programmable
range is 0 to 3.0 seconds in 0.1 second increments.
The following components can cause problems with
the auxiliary brake:

Wiring or an electrical connector


A circuit component
ECM

SENR9698-09

The most likely cause of a problem is the wiring or a


connector. The least likely cause is a problem with
the ECM.

SENR9698-09

177
Troubleshooting Section

g01255307

Illustration 45
Typical circuit for the auxiliary brake output

Test Step 1. Inspect the Electrical


Connectors and the Wiring
A. Turn the keyswitch to the OFF position.

Illustration 46

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

B. Thoroughly inspect J1/P1 ECM connector. Also,


thoroughly inspect the firewall bulkhead connector.
Refer to Troubleshooting, Electrical Connectors Inspect for details.
Illustration 47

g01255305

Terminal locations at the P1 ECM connector for the auxiliary brake


(P1-12) Output No. 3

178
Troubleshooting Section

C. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the auxiliary brake circuit.
D. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
E. Check the circuits wiring for abrasion and for
pinch points.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, and of pinch points.
Results:

SENR9698-09

Not OK At least one parameter is programmed


incorrectly.

Repair: Program the parameter to the correct


value. Road test the vehicle. Continue with this
procedure, if necessary.
STOP.

Test Step 3. Check the Status Parameters


A. Access the status screen on Cat ET for the
accelerator pedal position.
B. Turn the keyswitch to the ON position.
C. While the status screen is being monitored,
depress the accelerator pedal several times and
release the accelerator pedal several times.

OK The harness and connectors appear to be

D. Access the status screen on Cat ET for the clutch


pedal position switch.

Not OK There is a problem with the connectors

E. While the status screen is being monitored,


depress the clutch pedal several times and
release the clutch pedal several times.

OK. Proceed to Test Step 2.


and/or wiring.

Repair: Repair the wiring or replace the wiring, if


necessary. Repair the connectors or replace the
connectors, if necessary. Ensure that all of the
seals are in the proper place. Ensure that all of the
connectors are connected properly. Verify that the
problem is resolved.
STOP.

Test Step 2. Check the Parameter


Settings
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
B. Turn the keyswitch to the ON position.
C. Use Cat ET to verify that the following parameters
are programmed correctly:

Auxiliary Brake
Engine Retarder Minimum Vehicle Speed (if
applicable)

D. Turn the keyswitch to the OFF position.


Expected Result:
The parameters are programmed correctly.

F. Turn the keyswitch to the OFF position.


Expected Result:
The status parameters indicate that the circuits are
operating correctly.
Note: The clutch pedal position switch is ON when
the clutch pedal is depressed. The clutch pedal
position switch is OFF when the clutch pedal is
released.
Results:

OK The status parameters indicate that the

circuits are operating correctly. Proceed to Test


Step 4.

Not OK There is a problem with the accelerator


pedal position.

Repair: Refer to Troubleshooting, Accelerator


Pedal (Throttle) Position Sensor Circuit - Test.
STOP.

Not OK There is a problem with the clutch pedal


position.

Results:

Repair: Refer to Troubleshooting, Clutch Pedal


Position Switch Circuit - Test.

OK The parameters are programmed correctly.

STOP.

Proceed to Test Step 3.

SENR9698-09

179
Troubleshooting Section

Test Step 4. Use Cat ET to Check the


Relay and Solenoids

E. Access the Auxiliary Brake Special Test on Cat


ET.

A. Turn the keyswitch to the ON position.

F. While you monitor the voltage test lamp, cycle the


Special Test from ON position to OFF and back
to ON.

B. Click on the following menus in order to access


the Auxiliary Brake Special Test on Cat ET:

Diagnostics

G. Stop the Special Test.

Diagnostic Tests

H. Turn the keyswitch to the OFF position. Restore


the wiring to the original configuration.

Auxiliary Brake Special Test

Expected Result:

C. Set the dash switches to the High Braking Level


for the auxiliary brake.
D. While you listen for the relay and solenoids to
click, cycle the Auxiliary Brake Special Test from
the ON to OFF and back to ON.
Note: You may need to be near the engine in order
to hear the click of the relay and solenoids.
E. Turn the keyswitch to the OFF position.
Expected Result:
There is an audible click from the relay and the
solenoids.
Results:

OK There is an audible click from the relay and

the solenoids. The ECM is operating correctly. The


circuit is operating correctly.
Repair: If the auxiliary brake is not operating
correctly, there is a problem with a component in
the circuit. Send the vehicle to the OEM dealer for
repair.
STOP.

Not OK There is no audible click from the relay


or the solenoids. Proceed to Test Step 5.

Test Step 5. Use Cat ET to Check the ECM


A. Disconnect the J1/P1 ECM connectors.

The voltage test lamp turns on when the test is


active. The voltage test lamp turns off when the test
is not active.
Results:

OK The voltage test lamp turns on when the test


is active. The voltage test lamp turns off when the
test is not active.
Repair: The ECM is operating correctly. The
problem is in the components that are provided
by the OEM. Inspect the vehicle wiring and then
repair the vehicle wiring. Send the vehicle to the
OEM dealer for repair, if necessary.
STOP.

Not OK The voltage test lamp remained off while


the test was active.

Repair: There is probably a short circuit in the


wiring between the ECM and the relay. However, it
is easier to test the ECM first. Perform the following
procedure:
1. Temporarily connect a test ECM.
2. Use the Auxiliary Brake Output Special Test
on Cat ET in order to test the ECM.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.

B. Install a 208-0059 Adapter Cable As (70-PIN


BREAKOUT) at the J1/P1 ECM connector.

If the problem is not resolved with the test ECM,


install the original ECM. There is a problem in
the wiring between the ECM and the relay.

C. Connect a voltage test lamp between terminals 65


(Battery) and 12 (Output 3) at the breakout T.

Send the vehicle to the OEM dealer for repair,


if necessary.

Note: A multimeter cannot be used in place of the


voltage test lamp when the ECM outputs are being
tested.
D. Turn the keyswitch to the ON position.

STOP.

180
Troubleshooting Section

SENR9698-09

Check Engine Lamp Circuit Test

During the final 30 seconds of the operation of the


idle shutdown timer, the check engine lamp will
begin to flash. The flashing of the check engine lamp
indicates that an engine shutdown is near.

SMCS Code: 7431-038

Flashing Out Diagnostic Flash Codes

System Operation Description:

The flash codes are two-digit representations of


diagnostic codes. The PID-FMI diagnostic code
should be used for troubleshooting. The PID is the
Parameter Identifier. The FMI is the Failure Mode
Identifier. A 110-03 is an example of a PID-FMI
diagnostic code. Flash codes provide the operator
with a visual warning that the Engine Control Module
(ECM) has detected a problem with the engine. Flash
codes are not as specific as diagnostic codes. Flash
codes only indicate that a problem is occurring. Flash
codes do not indicate the specific type of failure. For
example, the flash code (27) is used for a 110-03 fault
code and a 110-04 fault code. Flash codes should
not be used for troubleshooting.

i02504635

Use this procedure under the following situation:


The check engine lamp is suspected of operating
incorrectly.
Note: The check engine lamp is the only standard
lamp on these engines. All other lamps are optional.
The following background information is related
to the following procedure:
Check Engine Lamp
The check engine lamp is used to provide the
following functions:

Indicate the existence of an active diagnostic code.


Indicate driver alert status of the idle shutdown
timer.

Display diagnostic flash codes.


Power Up Lamp Check
At powerup, the lamp will turn on for five seconds.
The lamp will continue to flash if there is an active
diagnostic code.
Operation with an Active Diagnostic Code
While the engine is operating, the lamp will turn on
for a minimum of five seconds when certain fault
conditions exist. While these conditions exist, the
lamp will operate in the following manner:

The check engine lamp will turn on for five seconds.


The check engine lamp will turn off for a short time.
The check engine lamp will turn on for another
five seconds.

The check engine lamp will continue to operate in


this manner while the fault condition exists.
Indication of the Driver Alert Status of the Idle
Shutdown Timer

Diagnostic flash codes that are active can be


viewed at any time. To view a code, turn the cruise
control On/Off switch to the OFF position. Hold the
set/resume switch in either the SET position or the
RESUME position until the lamp begins to flash.
Then release the set/resume switch.
The flash code is communicated by the blinking of
the check engine lamp. The lamp will blink for the
first digit of the flash code, and the lamp will pause
for five seconds. Then, the lamp will blink for the
second digit of the code.
Some vehicles are equipped with a diagnostic enable
switch. The diagnostic enable switch is used to flash
the diagnostic codes by grounding the input of the
diagnostic enable switch from P1-46 (Input 7) to P1-5
(sensor common).
Electrical Connection of the Check Engine Lamp
One terminal of the check engine lamp requires a
connection to battery voltage. The other terminal is
wired to the ECM at terminal location P1-28 (check
engine lamp).
A low side ECM driver is used to control the operation
of the lamp.

SENR9698-09

181
Troubleshooting Section

g01253817

Illustration 48
Schematic for the check engine lamp

Test Step 1. Inspect the Electrical


Connectors and the Wiring
A. Turn the keyswitch to the OFF position.

Illustration 49

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

B. Thoroughly inspect the J1/P1 ECM connector and


the vehicles firewall bulkhead connector. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.
Illustration 50

g01253832

Terminal locations at the P1 ECM connector for the check engine


lamp
(28) Check engine lamp

C. Perform a 45 N (10 lb) pull test on each of the


wires at the ECM connector that are associated
with the check engine lamp.
D. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
E. Check the harness and wiring for abrasion and for
pinch points from the battery to the ECM.

182
Troubleshooting Section

Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, and of pinch points.
Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 2.

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
STOP.

Test Step 2. Check for Normal Operation


of the Lamp
A. Monitor the check engine lamp.
a. Turn the keyswitch to the ON position. The
lamp will turn on for five seconds. The lamp
will then turn off.
b. The lamp will continue flashing if there is an
active diagnostic code. If there is an active
diagnostic code, connect the Caterpillar
Electronic Technician (ET) in order to read
the active diagnostic code. Troubleshoot the
problem.
B. Turn the keyswitch to the OFF position.
Expected Result:
The check engine lamp turns on and the check
engine lamp turns off per the above description.
Results:

OK The check engine lamp turns on and

the check engine lamp turns off per the above


description.

Repair: The check engine lamp appears to


operating correctly at this time. There may be
an intermittent electrical problem in the harness
or in a connector. If an intermittent problem is
suspected, refer to Troubleshooting, Electrical
Connectors - Inspect for information that is related
to troubleshooting intermittent electrical problems.
STOP.

SENR9698-09

Not OK The check engine lamp does not turn

on or the check engine lamp does not turn off per


the above description. Check that the bulb for the
lamp is not blown. Check any circuit protection that
may be tripped. If the bulb is OK and the circuit
protection is not tripped, then there is a problem
in the circuit for the check engine lamp. Proceed
to Test Step 3.

Test Step 3. Test the Lamp Circuit


A. Disconnect the J1/P1 ECM connector.
B. Fabricate a jumper wire that is long enough to
create a short circuit across two terminals at the
ECM connector. Crimp connector pins to both
ends of the jumper wire.
C. Install the jumper wire across terminal P1-28
(check engine lamp) and terminal P1-65
(Battery).
D. Turn the keyswitch to the ON position.
E. Check for illumination of the check engine lamp
while you insert the jumper wire into the circuit.
Also, check for illumination of the check engine
lamp after you remove the jumper wire from the
circuit.
F. Turn the keyswitch to the OFF position.
G. Remove the jumper wire from the circuit. Leave
the J1/P1 ECM connectors disconnected.
Expected Result:
The check engine lamp turns on while the jumper
wire is installed. The check engine lamp turns off
when the jumper wire is removed.
Results:

OK The check engine lamp turns on while the

jumper wire is installed. The check engine lamp


turns off when the jumper wire is removed. The
circuit for the check engine lamp is functioning
properly. There may be a problem with the ECM.
Proceed to Test Step 4.

Not OK Either of the following conditions are

present: The check engine lamp does not turn on


while the jumper wire is installed in the circuit.
The check engine lamp does not turn off when the
jumper wire is removed from the circuit.

SENR9698-09

Repair: There is a problem in the OEM wiring


harness that is between the ECM connector and
the power supply for the check engine lamp.
Repair the circuit or send the vehicle to the OEM
dealer for repairs.
STOP.

Test Step 4. Check the Operation of the


ECM
A. Fabricate a jumper wire that is long enough to
provide a test circuit at the ECM connector. Crimp
a connector socket to one end of the jumper wire.
B. Remove the wire from terminal location P1-28 at
the ECM connector. Insert the jumper wire into
this terminal location.
C. Connect the J1/P1 ECM connectors.
D. Install a test lamp between the loose end of the
jumper wire and a source of battery voltage that is
known to be powered.
E. Check for illumination of the test lamp while you
turn the keyswitch to the ON position.
The test lamp will turn on with the keyswitch and
the test lamp will remain on for five seconds.
Note: If there is an active diagnostic code, the
lamp will begin flashing after the first five seconds.
If an active diagnostic code is indicated, connect
Cat ET in order to read the active diagnostic code.
Troubleshoot the problem.
F. Turn the keyswitch to the OFF position.
The test lamp will turn off with the keyswitch.
Expected Result:
The check engine lamp turns on and the check
engine lamp turns off per the above description.

183
Troubleshooting Section

Not OK The check engine lamp does not turn

on or the check engine lamp does not turn off per


the above description.
Repair: There is a problem with the ECM. Perform
the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Recheck the circuit in order to ensure that the
original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.
i02507409

Clutch Pedal Position Switch


Circuit - Test
SMCS Code: 1435-038-P9
System Operation Description:
Use this procedure under the following situation:
The clutch pedal position switch is suspected of
preventing normal operation of the cruise control, the
idle set speed, or the Power Take-Off (PTO).

Results:

The following switch circuits can also prevent the


correct operation of the cruise control, idle set speed
or PTO operation:

OK The check engine lamp turns on and

Service brake pedal position (switch 1)

the check engine lamp turns off per the above


description.
Repair: The ECM is operating correctly and the
circuit for the check engine lamp appears to be
in good repair. There may be an intermittent
electrical problem in the harness or in a connector.
If an intermittent problem is suspected, refer to
Troubleshooting, Electrical Connectors - Inspect
for information that is related to troubleshooting
intermittent electrical problems.
STOP.

Service brake pedal position (switch 2)


Neutral switch
Cruise control set/resume switch
Cruise control on/off switch
PTO on/off switch
These switches are described in the respective
diagnostic functional tests in the Troubleshooting
manual.

184
Troubleshooting Section

All of the following customer programmable


parameters can affect cruise control, idle set speed,
and PTO operation:

Low Cruise Control Speed Set Limit


High Cruise Control Speed Set Limit
Idle Vehicle Speed Limit
Cruise/Idle/PTO Switch Configuration
Idle/PTO Bump rpm
Idle/PTO rpm Ramp Rate
PTO Vehicle Speed Limit
The vehicle speed calibration can also affect the
cruise control, the idle set speed, and the PTO if the
vehicle speed calibration is incorrectly programmed.
Refer to Troubleshooting, Customer Specified
Parameters.
Clutch Pedal Position Switch
The clutch pedal position switch is normally closed
when the pedal is released. Depressing the clutch
pedal should open the circuit. This switch is supplied
and the circuitry is installed by the Original Equipment
Manufacturer (OEM). The clutch pedal position
switch is typically a limit switch that is activated by
the pedal assembly. The clutch pedal position switch
is usually adjustable.
The following background information is related
to this procedure:
The kickout switch refers to the switch that is used to
exit the cruise control, the PTO, or the idle set speed.
The cruise controls control strategy for the Caterpillar
electronic engine is similar to the strategy of the
cruise controls that are installed in automobiles.
The operation of the cruise controls idle setting and
speed setting for the PTO is similar to the operation
of the cruise control except that the idle control and
the PTO control govern engine rpm instead of vehicle
speed.
Note: Idle in this procedure is an engine idle rpm
above the programmed low idle rpm. Idle is set
by using the cruise control on/off switch and the
set/resume switch. Refer to Troubleshooting, PTO
Switch Circuit - Test for additional information
regarding the programmable options for the
dedicated PTO.
Usage of Transmission Style Switches

SENR9698-09

The Transmission Style parameter defines the


configuration of the switches for the application. The
Engine Control Module (ECM) can be configured to
detect inputs from the following switches:

Clutch pedal position switch


Neutral switch
Service brake pedal position (switch 1)
Service brake pedal position (switch 2)
Table 142 defines the combinations of switches that
are necessary for the different parameter settings.
Table 142

Setting For
Transmission
Style
Parameter

Necessary Switches
Service Service
Brake
Brake
(Switch (Switch
1)
2)

Manual Option
1

Automatic
Option 1

Automatic
Option 2

Automatic
Option 3

Automatic
Option 4

Eaton Top 2

Clutch

Neutral

X
X
X

If the Transmission Style parameter is programmed


to one of the following options, the input for the clutch
pedal position switch is not used:

Automatic Option 1
Automatic Option 2
Automatic Option 3
Automatic Option 4
The clutch pedal position switch connects to the ECM
at terminal location P1-22. The status of the clutch
pedal position switch can also be reported over the
J1939 data link.

SENR9698-09

185
Troubleshooting Section

g01255422

Illustration 51
Schematic for the clutch pedal position switch

Test Step 1. Check the Status for the


Clutch Pedal Position Switch
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
B. Turn the keyswitch to the ON position.
C. Monitor the status of the clutch pedal position
switch on Cat ET while you depress the clutch
pedal. Release the clutch pedal and allow the
clutch pedal to return. Check the status of the
clutch pedal position switch.
The correct status for the clutch pedal position
switch is Off when the clutch is released. The
correct status for the clutch pedal position switch
is On when the clutch is depressed.
D. Turn the keyswitch to the OFF position.
Expected Result:
Cat ET reports the correct status for the clutch pedal
position switch.
Results:

OK Cat ET reports the correct status for the


clutch pedal position switch.

Repair: The clutch pedal position switch appears


to operating correctly at this time. There may be
an intermittent electrical problem in the harness
or in a connector. If an intermittent problem is
suspected, refer to Troubleshooting, Electrical
Connectors - Inspect for information that is related
to troubleshooting intermittent electrical problems.
STOP.

Not OK Cat ET is not reporting the correct status


for the clutch pedal position switch. The clutch
pedal position switch is not operating correctly.
Proceed to Test Step 2.

Test Step 2. Determine the Configuration


of the Clutch Pedal Position Switch
A. Determine if the fan override switch is wired
directly to the ECM, or if the switch position is
reported on the J1939 data link.

B. Verify that the Clutch Pedal Position Switch


parameter is programmed to reflect the current
wiring for the circuit.
Expected Result:
The clutch pedal position switch is wired directly to
the ECM at terminal location P1-22.
Results:

OK The clutch pedal position switch is wired


directly to the ECM.

Repair: Verify that the Clutch Pedal Position


Switch parameter is programmed to J1/P1:22.
Proceed to Test Step 3.

Not OK The clutch pedal position switch is not


wired to the ECM.

Repair: The switch position is reported to the ECM


via the J1939 data link. Verify that the Clutch
Pedal Position Switch parameter is programmed
to J1939 - Body Controller, to J1939 - Cab
Controller, or to J1939 - Instrument Cluster.
Refer to Troubleshooting, Powertrain Data Link
Circuit - Test for information that is related to
troubleshooting the J1939 data link.
STOP.

186
Troubleshooting Section

SENR9698-09

Test Step 3. Inspect the Electrical


Connectors and the Wiring

Illustration 52

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

A. Thoroughly inspect the J1/P1 ECM connector, the


connectors, and the firewall bulkhead connectors.
Refer to Troubleshooting, Electrical Connectors Inspect for details.

Illustration 53

g01255450

Terminal locations at the P1 ECM connector for the clutch pedal


position switch
(P1-5) AP sensor/switch sensor return
(P1-22) Clutch pedal position switch

B. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the suspect switch circuit.
C. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
D. Check the harness and the wiring for abrasion and
pinch points from the battery to the ECM. Then,
check the wiring from the keyswitch to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.

SENR9698-09

Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 4.

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.
STOP.

Test Step 4. Create a Short Circuit at the


Switch
A. Fabricate a jumper wire that is long enough to
create a short circuit across the terminals at the
harness connector for the clutch pedal position
switch.
B. Disconnect the switch from the harness.
C. Install the jumper wire across the two switch
terminals at the harness connector for the clutch
pedal position switch.
D. Turn the keyswitch to the ON position.
E. Use Cat ET to monitor the status of the Clutch
Pedal Position Switch. While the status for the
Clutch Pedal Position Switch is monitored,
remove the jumper wire and then insert the jumper
wire.
The correct status for the Clutch Pedal Position
Switch is On when the jumper wire is inserted.
The correct status for the Clutch Pedal Position
Switch is Off when the jumper wire is removed.

187
Troubleshooting Section

Not OK Cat ET does not report the correct

status. There is a problem in the wire harness


between the clutch pedal position switch and the
ECM. There may be a problem with the ECM.
Restore the wiring to the original configuration.
Proceed to Test Step 5.

Test Step 5. Check for Proper Operation


of the ECM
A. Disconnect the J1/P1 ECM connectors.
B. Fabricate two jumper wires that are long enough
to create a test circuit at the ECM connector.
Crimp a connector socket to one end of each of
the jumper wires.
C. Remove the wire from terminal location P1-22
(clutch pedal position) at the ECM connector. Also,
remove the wire from terminal location P1-5 (AP
sensor/switch sensor return). Install one of the
jumper wires into each of these terminal locations.
D. Connect the J1/P1 ECM connectors.
E. Turn the keyswitch to the ON position.
F. Monitor the status of the Clutch Pedal Position
Switch while you short the loose ends of the
jumper wires. Provide an open circuit for the loose
ends of the jumper wires. Recheck the switch
status.
The correct status for the Clutch Pedal Position
Switch is On when the jumper wires are shorted
together. The correct status for the Clutch Pedal
Position Switch is Off when the jumper wires
are open.
G. Turn the keyswitch to the OFF position.
H. Restore all wiring to the original configuration.

F. Turn the keyswitch to the OFF position.

Expected Result:

Expected Result:

Cat ET is reporting the correct status for the switch.

Cat ET is reporting the correct status for the switch.

Results:

Results:

OK Cat ET is reporting the correct status for

OK Cat ET is reporting the correct status.

the switch.

Repair: The wiring harness and the ECM are OK.


There is a problem with the switch. Replace the fan
override switch. Verify that the repair eliminates
the problem.

Repair: The ECM is functioning properly at this


time. There is a problem in the OEM wiring harness
that is between the ECM connector and the clutch
pedal position switch. Repair the circuit or send the
vehicle to the OEM dealer for repairs.

STOP.

STOP.

Not OK Cat ET does not report the correct status


for the switch.

188
Troubleshooting Section

SENR9698-09

Repair: The ECM is not reading the switch input


properly. There is a problem with the ECM. Perform
the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Recheck the circuit in order to ensure that the
original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.
i02507581

Coolant Level Sensor Circuit


- Test

The coolant level sensor is used to indicate the


presence or the absence of coolant at the sensor
probe. Typical installation of the coolant level is in the
upper tank of the engines radiator.
There are two types of coolant level sensors that can
be recognized by the ECM:

4-pin sensor
2-wire float sensor
The correct type of sensor must be programmed into
the monitoring system prior to use. If a coolant level
sensor is not installed or the coolant level sensor is
independent from the ECM, the parameter should be
programmed to None.
4-pin Sensor
The supply voltage for this sensor is connected to the
ECM through terminal P1-2 (+5 VDC) at the ECM
connector. The signals for the coolant level are wired
to terminal P1-54 (coolant level low) and terminal
P1-49 (coolant level normal) at the ECM connector.
The sensor return is connected to terminal location
P1-5 (AP sensor/switch sensor return).

Use this procedure to troubleshoot the system when


one of the following diagnostic codes is active or
easily repeated:

If coolant is present at the sensor probe, the terminal


for coolant level low provides an output that is near
zero volts to the ECM. If coolant is present at the
sensor probe, the terminal for coolant level normal
provides an output that is near +5 VDC. If coolant
is not present at the sensor probe, the terminal for
coolant level low provides an output that is near +5
VDC. If coolant is not present at the sensor probe,
the terminal for coolant level normal provides an
output that is near zero volts.

111-02 Coolant Level signal invalid

2-wire Float Sensor

111-03 Coolant Level voltage high

The supply voltage for this sensor is connected to


the ECM through terminal P1-26 (input No. 10). The
sensor return is connected to terminal location P1-5
(AP sensor/switch sensor return).

SMCS Code: 5574-038-CLT


System Operation Description:

111-04 Coolant Level voltage low


The coolant level sensor and the circuit for the sensor
are installed by the Original Equipment Manufacturer
(OEM). This sensor is the only optional sensor for
this engine. The sensor is selectable through the
Coolant Level Sensor parameter in the customer
programmable parameters. This parameter may be
protected by customer passwords.
Note: Some coolant level sensors that are OEM
installed do not require a connection to the Engine
Control Module (ECM). Prior to troubleshooting
the circuit for the coolant level sensor, be sure to
determine the configuration of the circuit.

Resistance through the sensor is varied by the level


of the coolant that is on the probe. The normal
operating range of the sensor is between 0.75 VDC
and 1.75 VDC.
The Coolant Level Sensor parameter in the
customer programmable parameters must be
programmed to the specific variable that defines the
correct type of coolant level sensor. If the parameter
is set to an incorrect sensor type, the following
diagnostic code will be logged:

111-02 Coolant Level signal invalid

SENR9698-09

The Coolant Level Sensor parameter must be


programmed in order for the warning lamp that will
indicate a low coolant level to operate correctly. The
Engine Monitoring Lamps parameter is used in
order to determine if a single warning lamp is used
for the engine monitoring system, or if discrete lamps
are used for each monitored condition. If the Engine
Monitoring Lamps parameter is programmed to
Warning Lamp, a single lamp is connected to
terminal P1-29 at the ECM connector. If the Engine
Monitoring Lamps parameter is programmed to
Option 1 and a coolant level sensor is installed, then
a discrete lamp for low coolant level is connected
to terminal P1-30 at the ECM connector. Refer to
Troubleshooting, Warning Lamp Circuit - Test for
details.

Test Step 1. Check for an Active


Diagnostic Code
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector.
B. Turn the keyswitch to the ON position.
C. Use Cat ET to check for active diagnostic codes
that are related to the circuit for the coolant level
sensor. Check for the following diagnostic codes:

111-02 Coolant Level signal invalid


111-03 Coolant Level voltage high
111-04 Coolant Level voltage low
Note: Wait at least 30 seconds for the activation of
the diagnostic code on Cat ET.
Expected Result:
None of the diagnostic codes that are listed above
are active.
Results:

OK None of the diagnostic codes that are

listed above are active. There does not appear


to be an electrical problem with the circuit for the
coolant level sensor at this time. If a problem is still
suspected with the coolant level sensor, proceed
to Test Step 2.

Not OK There is an active 111-02, 111-03, or

111-04 diagnostic code. The ECM is detecting an


electrical problem with the circuit for the coolant
level sensor. Proceed to Test Step 2.

Test Step 2. Determine the Type of


Coolant Level Sensor
A. Check the coolant level sensor in order to
determine the type of sensor that is installed on
the vehicle.

189
Troubleshooting Section

Determine if the sensor is a 4-pin sensor or a


2-wire float sensor.
Expected Result:
A 4-pin sensor or a 2-wire float sensor is installed in
the cooling system.
Results:

4-Pin Sensor A 4-pin sensor is installed in the


cooling system. Proceed to Test Step 3.

2-Wire Float A 2-wire float sensor is installed in


the cooling system. Proceed to Test Step 8.

None A coolant level sensor is not installed on


the application.

Repair: If a coolant level sensor is not installed,


change the configuration parameter for Coolant
Level Sensor to None. Verify that the repair
eliminates the problem.
STOP.

190
Troubleshooting Section

SENR9698-09

Test Step 3. Inspect the Electrical


Connectors and the Wiring for the 4-Pin
Sensor

g01255585

Illustration 54
Schematic for the 4-pin sensor

A. Turn the keyswitch to the OFF position.

Illustration 55

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

B. Thoroughly inspect the J1/P1 ECM connectors


and the vehicles firewall bulkhead connector.
Refer to Troubleshooting, Electrical Connectors Inspect for details.

Illustration 56

g01255606

Terminal locations at the P1 ECM connector for the 4-pin sensor


(P1-2) 5 V sensor supply
(P1-5) AP sensor/switch sensor return
(P1-49) Coolant level normal
(P1-54) Coolant level low

SENR9698-09

191
Troubleshooting Section

B. Turn the keyswitch to the ON position.


C. Measure the voltage at the harness connector
between terminal C (+5 V sensor supply) and
terminal B (AP sensor/switch sensor return).
D. Turn the keyswitch to the OFF position.
Expected Result:
The measured voltage is between 4.5 VDC and 5.5
VDC.
Results:
Illustration 57

g01255609

Terminal locations at the connector for the 4-pin sensor


(Terminal
(Terminal
(Terminal
(Terminal

A) Coolant level low


B) AP sensor/switch sensor return
C) 5 V sensor supply
D) Coolant level normal

C. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the sensor circuit.
D. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
E. Check the harness and wiring for abrasion and
pinch points from the sensor to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.
Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 9.

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem. Clear
all diagnostic codes.
STOP.

OK The measured voltage is between 4.5 VDC

and 5.5 VDC. The voltage is within the proper


range. Connect the connector for the coolant level
sensor. Proceed to Test Step 5.

Not OK The measured voltage is not between

4.5 VDC and 5.5 VDC. There is a problem with the


sensor supply. Leave the connector disconnected.
Proceed to Test Step 6.

Test Step 5. Create a Short at the Sensor


Connector
A. Fabricate a jumper wire that is long enough to
create a short circuit on the harness side of the
connector for the coolant level sensor.
B. Simulate a condition for a low coolant level at
the sensor connector:
a. Insert the jumper wire between terminal D
(coolant level normal) and terminal B (AP
sensor/switch sensor return) at the harness
connector.
b. Turn the keyswitch to the ON position.
c. Use Cat ET to check the status for Coolant
Level.
The correct status for Coolant Level on Cat
ET is LOW.
d. Turn the keyswitch to the OFF position.
e. Remove the jumper wire from the connector
terminals.
C. Simulate a condition for a normal coolant level
at the sensor connector:

Test Step 4. Check the Supply Voltage at


the Sensor

a. Insert the jumper wire between terminal


A (coolant level low) and terminal B (AP
sensor/switch sensor return) at the harness
connector.

A. Disconnect the coolant level sensor at the harness


connector.

b. Turn the keyswitch to the ON position.

192
Troubleshooting Section

c. Use Cat ET to check the status for Coolant


Level.
The correct status for Coolant Level on Cat
ET is OK.
d. Turn the keyswitch to the OFF position.
e.
Restore the wiring to the original configuration.
Expected Result:
Cat ET displays the correct status for Coolant Level
during the test procedure.
Results:

OK Cat ET displays the correct status for


Coolant Level.

Repair: The ECM and the wiring are OK. There is


a problem with the coolant level sensor. Replace
the sensor. Verify that the repair eliminates the
problem.
STOP.

Not OK Cat ET incorrectly displayed the status

for Coolant Level during the test. The problem is


in the harness between the ECM connector and
the harness connector. There may be a problem
with the ECM. Proceed to Test Step 7.

Test Step 6. Check the Sensor Supply at


the ECM
A. Disconnect the J1/P1 ECM connectors.
B. Fabricate two jumper wires that can be used as a
test circuit at the ECM connector. Crimp connector
sockets to one end of each of the jumper wires.
C. Remove the wire from terminal location P1-2
(5 V sensor supply) and terminal location P1-5
(AP sensor/switch sensor return) at the ECM
connector.
D. Install one of the jumper wires into each of these
terminal locations.
E. Connect the J1/P1 ECM connectors.
F. Turn the keyswitch to the ON position.
G. Measure the voltage between the loose ends of
the two jumper wires at the ECM connector.
The correct voltage measurement is between 4.5
VDC and 5.5 VDC.

SENR9698-09

H. Turn the keyswitch to the OFF position.


I. Restore all wiring to the original configuration.
Expected Result:
The measured voltage is between 4.5 VDC and 5.5
VDC.
Results:

OK The measured voltage is between 4.5 VDC


and 5.5 VDC.

Repair: The ECM is producing the correct voltage.


The problem is in the wiring harness between the
ECM connector and the sensor connector. Repair
the wiring harness or replace the wiring harness.
Verify that the repair eliminates the problem.
Send the vehicle to the OEM dealer for repair, if
necessary.
STOP.

Not OK The measured voltage is not between


4.5 VDC and 5.5 VDC.

Repair: There is a problem with the ECM. Perform


the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Recheck the circuit in order to ensure that the
original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.

Test Step 7. Check the ECM for Proper


Operation
A. Disconnect the J1/P1 ECM connectors.
B. Fabricate three jumper wires that are long enough
to create test circuits at the ECM connector. Crimp
a connector socket to one end of each of the
jumper wires.

SENR9698-09

C. Remove the wire from terminal location P1-49


(coolant level normal), terminal location P1-54
(coolant level low), and terminal location P1-5
(AP sensor/switch sensor return) at the ECM
connector.
D. Install one of the jumper wires into each of these
three terminal locations.
E. Connect the J1/P1 ECM connectors.
F. Simulate a condition for a low coolant level
at the ECM connector:
a. Short circuit the loose ends of the jumper wires
that are in terminal location P1-49 (coolant
level normal) and terminal location P1-5 (AP
sensor/switch sensor return) at the ECM
connector.
b. Turn the keyswitch to the ON position.
c. Use Cat ET to check the status for Coolant
Level.
The correct status for Coolant Level on Cat
ET is LOW.
d. Turn the keyswitch to the OFF position.
e. Disconnect the jumper wires that have been
shorted at the ECM connector.
G. Simulate a condition for a normal coolant level
at the ECM connector:
a. Short circuit the loose ends of the jumper wires
that are in terminal location P1-54 (coolant
level low) and terminal P1-5 (AP sensor/switch
sensor return) at the ECM connector.
b. Turn the keyswitch to the ON position.
c. Use Cat ET to check the status for Coolant
Level.
The correct status for Coolant Level on Cat
ET is OK.
d. Turn the keyswitch to the OFF position.
e. Restore the wiring to the original configuration.
Expected Result:
Cat ET reported the correct status for Coolant Level
during the test procedure.
Results:

OK Cat ET reported the correct status for


Coolant Level.

193
Troubleshooting Section

Repair: The ECM is functioning properly. The


problem is in the harness between the ECM
connectors and the harness connectors for the
coolant level switch. Repair the harness or replace
the harness, as required. Verify that the repair
eliminates the problem. Clear all diagnostic codes.
STOP.

Not OK Cat ET did not report the correct status


for Coolant Level.

Repair: There is a problem with the ECM. Perform


the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Recheck the circuit in order to ensure that the
original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.

194
Troubleshooting Section

SENR9698-09

Test Step 8. Inspect the Electrical


Connectors and the Wiring for the 2-Wire
Float Sensor

g01255755

Illustration 58
Schematic for the 2-wire float sensor

A. Turn the keyswitch to the OFF position.

Illustration 59

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

B. Thoroughly inspect the J1/P1 ECM connectors


and the vehicles firewall bulkhead connector.
Refer to Troubleshooting, Electrical Connectors Inspect for details.

Illustration 60

g01255763

Terminal locations at the P1 ECM connector for the 2-wire float


sensor
(P1-5) AP sensor/switch sensor return
(P1-26) Input No. 10

C. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the sensor circuit.

SENR9698-09

D. Check the allen head screw for each of the


ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
E. Check the harness and wiring for abrasion and
pinch points from the sensor to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.
Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 9.

Not OK There is a problem with the connectors


and/or wiring.

195
Troubleshooting Section

Test Step 10. Create a Short Circuit and


an Open Circuit at the Sensor Connector
A. Fabricate a jumper wire that is long enough to
create a short circuit across the harness connector
for the coolant level sensor.
B. Create an open circuit at the sensor connector:
a. Ensure that the sensor connectors for the
sensor are disconnected.
b. Turn the keyswitch to the ON position.
c. Use Cat ET and check for a 111-03 Coolant
Level voltage high that is active.
Note: Wait at least 30 seconds for the activation of
the diagnostic code on Cat ET.
The correct status for the sensor is a 111-03
diagnostic code that is active.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.

C. Create a short circuit at the sensor connector:

Verify that the repair eliminates the problem. Clear


all diagnostic codes.

a. Install the jumper wire across the terminals on


the harness side of the coolant level sensor.

STOP.

b. Turn the keyswitch to the ON position.

Test Step 9. Check for a Voltage at the


Sensor Connector
A. Disconnect the coolant level sensor at the harness
connector.
B. Turn the keyswitch to the ON position.
C. Measure the voltage at the connector between
terminal A (input No. 10) and terminal B (AP
sensor/switch sensor return).
D. Turn the keyswitch to the OFF position.

d. Turn the keyswitch to the OFF position.

c. Use Cat ET in order to check for a 111-04


Coolant Level voltage low that is active.
Note: Wait at least 30 seconds for the activation of
the diagnostic code on Cat ET.
The correct status for the sensor is an 111-04
diagnostic code that is active.
d. Turn the keyswitch to the OFF position.
e. Remove the jumper wire from the sensor
connector.

Expected Result:

D. Restore the wiring to the original configuration.

The measured voltage is between 4.5 VDC and 5.5


VDC.

Expected Result:

Results:

Cat ET reported that the correct diagnostic codes


were generated during the test procedure.

OK The measured voltage is between 4.5 VDC

Results:

and 5.5 VDC. The sensor is receiving the correct


voltage. Leave the sensor connector disconnected.
Proceed to Test Step 10.

Not OK The measured voltage is not between

4.5 VDC and 5.5 VDC. The sensor is not receiving


the correct voltage. Connect the sensor connector.
Proceed to Test Step 11.

OK Cat ET reported the diagnostic codes


correctly during the test.

196
Troubleshooting Section

Repair: The ECM and the harness are operating


correctly. There is a problem with the sensor.
Replace the sensor. Verify that the repair eliminates
the problem.
STOP.

Not OK Either of the following conditions exist:

There is not an active 111-03 while the sensor


connector is disconnected. There is not an active
111-04 while the jumper wire is installed at the
harness connector. Proceed to Test Step 12.

Test Step 11. Check for the Correct


Voltage at the ECM Connector

SENR9698-09

Repair: There is a problem with the ECM. Perform


the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Recheck the circuit in order to ensure that the
original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.

A. Disconnect the J1/P1 ECM connectors.

If the problem is not resolved with the test ECM,


install the original ECM. There is a problem in
the wiring.

B. Fabricate two jumper wires that can be used to


create a test circuit at the ECM connector. Crimp
a connector socket to one end of each of the
jumper wires.

Send the vehicle to the OEM dealer for repair,


if necessary.

C. Remove the wires from terminal location P1-26


(input No. 10) and terminal location P1-5
(AP sensor/switch sensor return) at the ECM
connector.
D. Install one of the jumper wires into each of these
terminal locations.
E. Connect the J1/P1 ECM connectors.
F. Turn the keyswitch to the ON position.
G. Measure the voltage at the loose ends of the
jumper wires.
H. Turn the keyswitch to the OFF position.

STOP.

Test Step 12. Check the ECM for Proper


Operation
A. Disconnect the J1/P1 ECM connectors.
B. Fabricate two jumper wires that can be used to
create a test circuit at the ECM connector. Crimp
a connector socket to one end of each of the
jumper wires.
C. Remove the wires from terminal location P1-26
(input No. 10) and terminal location P1-5
(AP sensor/switch sensor return) at the ECM
connector.

I. Restore the wiring to the original configuration.

D. Install one of the jumper wires into each of these


terminal locations.

Expected Result:

E. Connect the J1/P1 ECM connectors.

The measured voltage is between 4.5 VDC and 5.5


VDC.

F. Create an open circuit at the ECM connector:

Results:

OK The measured voltage is between 4.5 VDC

a. Hold the loose end of the jumper wires away


from any ground source in order to create an
open circuit condition.

and 5.5 VDC.

b. Turn the keyswitch to the ON position.

Repair: The problem is located in the harness


wiring. Repair the wiring or replace the wiring,
as required. Verify that the repair eliminates the
problem.

c. Use Cat ET to check for a 111-03 Coolant Level


voltage high that is active.

STOP.

Not OK The measured voltage is not between


4.5 VDC and 5.5 VDC.

Note: Wait at least 30 seconds for the activation of


the diagnostic code on Cat ET.
The correct status for the sensor is a 111-03
diagnostic code that is active.

SENR9698-09

d. Turn the keyswitch to the OFF position.


G. Create a short circuit at the ECM connector:
a. Connect the jumper wires in order to create a
short circuit at the ECM connector.
b. Turn the keyswitch to the ON position.
c. Use Cat ET to check for a 111-04 Coolant Level
voltage low that is active.
Note: Wait at least 30 seconds for the activation of
the diagnostic codes on Cat ET.
The correct status for the sensor is a 111-04
diagnostic code that is active.
d. Turn the keyswitch to the OFF position.
H. Restore the wiring to the original configuration.
Expected Result:
Cat ET reported that the correct diagnostic codes
were generated during the test procedure.
Results:

OK Cat ET reported that the correct diagnostic


codes were active during the test.

Repair: The ECM is operating correctly. There is


a problem in the wiring harness or in a connector
between the ECM connector and the sensor
connector. Repair the wiring harness or replace
the wiring harness and/or the connector. Verify that
the repair eliminates the problem.
STOP.

Not OK Either of the following conditions exist:

There is not an active 111-03 while the jumper


wires are held away from any ground source in
order to create an open circuit condition. There is
not an active 111-04 while the jumper wires are
shorted together at the ECM connector.
Repair: There is a problem with the ECM. Perform
the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Recheck the circuit in order to ensure that the
original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.

197
Troubleshooting Section

If the problem is not resolved with the test ECM,


install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.
i02049856

Cooling Fan Circuit and A/C


High Pressure Switch Circuit
- Test
SMCS Code: 1356-038; 1435-038-PX
System Operation Description:
Use this procedure under the following situation:
The cooling fan J1/P1:11(Output 5) or the A/C high
pressure switch J1/P1:41(Input 11) is suspected of
incorrect operation.
Note: Not all vehicle manufacturers, or all trucks for
a manufacturer use the Caterpillar cooling fan circuit.
Prior to troubleshooting, determine if the vehicle is
using the ECM cooling fan circuit.
Check the following items in order to determine if a
vehicle is using the ECM cooling fan circuit:

The Fan Control Type parameter must be

programmed to On/Off PWM, On/Off DC,


Three-Speed Fan PMW, or Three-Speed Fan
DC. The Caterpillar factory default is None.

A wire is present in the ECM connector J1/P1:11


(Output 5 (Cooling Fan Solenoid)). This occurs if
an On/Off type of fan is used.

A wire is present in the vehicle harness connector

J1/P1:11 (Output 5 (Slip Solenoid)). A wire is also


present in the vehicle harness connector J1/P1:13
(Output 4 (Brake Solenoid)). This occurs if a
three-speed fan is used.

Perform the special test for the On/Off Cooling

Fan or the special tests for the Three-Speed


Fan. Access each menu in the order that follows:
Diagnostics, Diagnostic Tests, and Special
Test. Activating and then deactivating the circuit
will cause the air solenoid to click if the circuit is
working properly.

The following background information is related


to this procedure:
Cooling Fan

198
Troubleshooting Section

SENR9698-09

The signal for the cooling fan is provided by the ECM


in order to control the cooling fan. An input from one
of the following items may cause the fan to turn on:

There is an active diagnostic code for the intake

Dyno mode

The intake manifold air temperature is greater than

Engine coolant temperature sensor


Intake manifold air temperature sensor
Engine retarder switches
PTO On/Off switch
OEM installed A/C high pressure switch
Manual fan override switch
The control unit for the A/C may be connected to the
A/C high pressure switch J1/P1:41(Input 11) instead
of a switch.
The output for the cooling fan is intended to connect
directly to the circuit for the cooling fan solenoid.
The solenoid and clutch configuration must be
selected in order for the ECM output to turn the fan
Off. The fan will remain on for a minimum of 30
seconds. The fan will not remain on for 30 seconds
during engine start-up. The fan will not remain on
for 30 seconds if the A/C Pressure Switch Fan
On Time is programmed to less than 30 seconds.
During engine start-up, the ECM will keep the fan
on for two seconds after the engine has reached
the programmed low idle (600 to 750 rpm). The fan
will be on continuously if the electrical circuit to the
cooling fan air solenoid valve has an open circuit or if
the ECM fan relay circuit is opened.
Cooling Fan On Conditions (On/Off Fan)
The ECM will turn on the cooling fan, if any of the
following conditions are met:

With software prior to DEC03, the engine speed


is less than 2250 rpm (2350 rpm on 2300 rpm
ratings).

With DEC03 software, the engine speed is less


than 2250 rpm.

The engine is not running.


The engine is cranking.
Dyno mode is active.
The engine coolant temperature is greater than
102 C (216 F).

There is an active diagnostic code for the coolant


temperature sensor.

manifold air temperature sensor and boost


pressure is greater than 70 kPa (10 psi).
87 C (189 F).

The intake manifold air temperature is greater than


72 C (162 F) while the boost pressure is greater
than 70 kPa (10 psi).

The Fan with Engine Retarder in High Mode is

programmed to YES and the retarder has been


on at least two seconds.

The A/C Switch Fan On-Time is programmed to

a value above 0 and the A/C high pressure switch


is Open.

The ECM is counting after the A/C high pressure


switch has closed.

The PTO Activates Cooling Fan parameter is

programmed to Continuous and the PTO On/Off


switch is on.

The manual fan override switch is on.


The last four items in the list are programmed by
the customer on the Configuration screen on the
Caterpillar Electronic Technician (Cat ET).
Note: The ECM will turn off the cooling fan for 10
seconds during an engine shutdown.
Cooling Fan OFF Conditions (On/Off Fan)
The cooling fan will be turned off by the ECM if
engine rpm exceeds 2250 rpm (2350 rpm for 2300
rpm ratings) or when all the following circumstances
are met:

The Intake Valve Actuator Test is active.


The engine coolant temperature is less than 98 C
(208 F).

The fan has been on for at least 30 seconds.


The intake manifold air temperature is less than
66 C (151 F).

The Fan with Engine Retarder in High Mode


strategy is not active.

The A/C High Pressure Switch Strategy is not


active.

The PTO Activates Cooling Fan strategy is not


active.

SENR9698-09

199
Troubleshooting Section

The manual fan override switch is off.

Illustration 61

g00675576

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.

Illustration 62

g00675579

This schematic represents the ON/OFF fan with a direct solenoid connection to the ECM and the A/C High Pressure Switch not connected to
the ECM input.

200
Troubleshooting Section

Illustration 63

SENR9698-09

g00675587

This schematic represents the ON/OFF fan with a direct solenoid connection to the ECM and the A/C Control Unit is connected to the ECM input.

Illustration 64

g00675591

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.

SENR9698-09

Illustration 65

201
Troubleshooting Section

g00675623

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.

Illustration 66

g00675640

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.

202
Troubleshooting Section

SENR9698-09

g00675642

Illustration 67
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.

Three-Speed Fan

Coolant temperature

The Three-Speed Fan operates in three modes:

Intake manifold air temperature

Brake

Engine operating conditions

Slip

Cooling Fan Trip Points (Three-Speed Fan)

Direct

The hysteresis can occur when different modes are


selected. The trip points are set at different values.
The values depend on increasing temperature and
decreasing temperature. The ECM will operate the
cooling fan under the conditions that are listed in the
following chart.

The fan is operating at full speed when the Direct


mode is used. The Slip mode is used most
often. The Fan Control Type parameter must be
programmed to Three-Speed Fan. Two outputs are
required for three-speed fan control. J1/P1:13(Output
4) is used for the brake solenoid. J1/P1:11(Output
5) is used for the slip solenoid. The function of
these outputs is automatically determined by the
ECM when the Fan Control Type parameter is
programmed to Three-Speed Fan. The fan is turned
on in the event of a failure in the output circuit. An
example would be an open circuit. The ECM provides
the power in order to turn off the fan. If the power
is interrupted due to an open circuit, the fan will run
continuously. This provides a fail safe operation. The
ECM turns off the output circuit power in order to turn
on the fan. Additional switching devices that are in
the circuit create an open circuit in order to turn the
fan On. Both of the output drivers are in the ON
position while the brake mode is active. However,
the fan is off. In slip mode, J1/P1:13(Output 4) is off
and J1/P1:11(Output 5) is on. During direct mode,
both output drivers are off. The fan is on at full speed.
The ECM controls the mode for the fan. The mode is
based on the following conditions:

SENR9698-09

203
Troubleshooting Section

Table 143

Trip Points for a Three-Speed Fan


Coolant Temperature

Intake Air
Temperature

Brake Mode to Slip


Mode

91 C (196 F)

54 C (129 F)

Slip Mode to Direct


Mode

102 C (216 F)

Direct Mode to Slip


Mode

96 C (205 F)

52 C (126 F)

Slip Mode to Brake


Mode

81 C (178 F)

0 C (32 F)

Mode

The following conditions will also cause the


three-speed fan to operate in direct mode:

Dyno mode is active.


The engine retarder is on and the engine retarder
selector switch is in the High position. The Fan
with Engine Retarder in High Mode parameter
must be programmed to Yes.

The PTO On/Off switch is on. The PTO Activates


Cooling Fan parameter is programmed to Yes.

The A/C high pressure switch is active. The A/C

Pressure Switch Fan On-Time is programmed to a


value that is greater than 0 seconds.

Note: There may be an initial delay before the fan is


in the direct mode. Activation of the fan is dependent
on the operating conditions.

Intake Air
Temperature with
Boost that is Less
Than 70 kPa (10 psi)

Intake Air
Temperature with
Boost that is Greater
Than 70 kPa (10 psi)

82 C (180 F)

66 C (151 F)

204
Troubleshooting Section

SENR9698-09

g00675646

Illustration 68
Three-Speed Fan with Direct Solenoid Connection

A/C High Pressure Switch Input Connected to


A/C Control Unit.
An OEM supplied air conditioning control may be
used. The air conditioning control determines when
the cooling fan should operate. This is based on the
following input information: A/C high pressure switch,
low pressure switch, and evaporator thermostat.
The fan output for the air conditioning control is
designed to interface with the ECM. The fan output
may be connected to the input for the A/C high
pressure switch. The input for the A/C high pressure
switch is J1/P1:41(Input 11). The fan is in the ON
position when the A/C high pressure switch is in
the OPEN position. This type of control has a time
delay. Typically, the A/C Switch Fan On-Time is
programmed to one second since the air conditioning
control provides an additional time delay.
The Cooling Fan Control can be Operated
Independently of the ECM.
Operation of the cooling fan control can be controlled
independently of the ECM. The OEM installed air
conditioning high pressure switch may be used for
independent cooling fan control. A cab mounted
override switch in the solenoid circuit can also
operate the cooling fan.
Troubleshooting

Before troubleshooting the cooling fan circuit,


determine the type of fan drive system that is used.
The fan drive can use the following controls in order
to control the fan:

Normally open with a pneumatic air solenoid


Normally closed with a pneumatic air solenoid
Normally open with an electrically controlled
solenoid

Normally closed with an electrically controlled


solenoid

The following OEM installed components may affect


the operation of the cooling fan in some applications:

OEM installed, normally open relay


The A/C high pressure switch is connected to
the ECM or the A/C high pressure switch is
independent of the ECM.

Cab mounted manual override switch


A timer that keeps the fan in the ON position
Cooling fan air solenoid valve

SENR9698-09

205
Troubleshooting Section

Test Step 1. Check the Electrical


Connectors and the Wiring

g00675876

Illustration 69
Terminal locations for the ECM

A. Thoroughly inspect the J1/P1 ECM connector,


the A/C high pressure switch connector, the
connections to the cooling fan solenoid, and
the firewall bulkhead connectors. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated
with the following connections:

Refer to Illustration 69 for terminal locations for


the ECM.
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion or of pinch points.
Results:

Cooling fan

OK Proceed to Test Step 2.

A/C high pressure switch

Not OK

C. Check the ECM connector (Allen head screw) for


the proper torque of 6.0 Nm (55 lb in).
D. Check the harness and the wiring for abrasion and
pinch points from the battery to the ECM. Then,
check from the key switch to the ECM.
E. Ensure that the ECM is wired to the cooling fan on
the vehicle and/or the A/C high pressure switch.
Check for wires that are connected to P1:11
(Output 5) and for wires that are connected to
P1:41 (Input 11). If a three-speed fan is used,
check for a wire that is connected to P1:13 (Output
4).

Repair: Repair the wiring or replace the wiring, if


necessary. Repair the connectors or replace the
connectors, if necessary. Ensure that all of the
seals are in the proper place. Ensure that all of the
connectors are connected properly.
Verify that the repair eliminates the problem.
STOP.

ECM Not Wired To Fan or Switch If the ECM is

not wired to the cooling fan on the vehicle and/or


the A/C high pressure switch, then the ECM is not
being used for fan control. STOP.

206
Troubleshooting Section

Test Step 2. Check the Programming of


the Fan Control Type Parameter
A. Connect Cat ET to the data link connector.
B. Turn the key switch to the ON position.
C. Check the Fan Control Type parameter. Ensure
that the parameter is programmed to either
On-Off or to Three-Speed Fan, if the ECM
is used to control the fan. If the parameter is
programmed to None and the ECM is connected
to the fan, then the fan will always be ON.
Expected Result:
The Fan Control Type parameter is programmed to
match the vehicle wiring. This is determined in the
previous step.
Results:

OK Proceed to Test Step 3.


Not OK Program the Fan Control Type to the

correct setting and then recheck the system. If


conditions are not resolved, then proceed to Test
Step 3.

Test Step 3. Check the A/C Pressure


Switch
A. Turn the key switch to the ON position.
B. View the following customer specified parameters.

SENR9698-09

Not OK The status of the A/C high pressure

switch is Unavailable. The ECM is not


programmed to use the A/C high pressure switch.
Proceed to Test Step 5.

Test Step 4. Check the Operation of the


A/C Pressure Switch
A. Turn the key switch to the ON position.
B. Access the status for the A/C High Pressure
Switch on Cat ET.
C. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wire.
D. Disconnect the A/C High Pressure Switch from
the vehicle harness at the switch and use the
jumper wire to short the two terminals in the
harness connector together.
E. Remove the jumper wire and then insert the
jumper wire. At the same time, view the status for
the A/C High Pressure Switch on Cat ET.
Expected Result:
Cat ET indicates that the A/C High Pressure Switch
turns to the ON position. Then, the A/C High
Pressure Switch turns to the OFF position.
Results:

OK The A/C high pressure switch harness is OK.


Proceed to Test Step 6.

Fan Control Type

Not OK Proceed to Test Step 7.

A/C Switch Fan On-Time

Test Step 5. Check Active Codes or


Logged Codes

Ensure that the A/C Switch Fan On-Time is


programmed to a greater value than 0. If the
A/C Switch Fan On-Time is programmed to 0,
then the A/C High Pressure Switch Input (Input
11) is not used.
Note: If the Fan Control Type parameter indicates
None, then the cooling fan driver is not used.
View the status for A/C High Pressure Switch
on Cat ET.

A. Turn the key switch to the ON position.


B. Access the Logged Diagnostic Codes and the
Active Diagnostic Codes on Cat ET.
C. Check for the following diagnostic codes.

110-00 High Coolant Temperature Warning


110-11 Very High Coolant Temperature

Expected Result:

110-03 Coolant Temperature voltage high

The status of the A/C high pressure switch indicates


On or Off.

110-04 Coolant Temperature voltage low

Results:

OK The status of the A/C high pressure switch is


On or Off. Proceed to Test Step 4.

Record any logged diagnostic codes. Record any


active diagnostic codes.

SENR9698-09

207
Troubleshooting Section

Expected Result:

Verify that the repair eliminates the problem.

Result 1 None of the diagnostic codes that are listed


are logged or active.

STOP.

Result 2 Diagnostic code 110-00, or 110-11 is logged


or active.
Result 3 Diagnostic code 110-03 or 110-04 is logged
or active.
Results:

Result 1 Proceed to Test Step 8.


Result 2 The cooling fan is on because of a high
coolant temperature.

Repair: Refer to the appropriate section in


Troubleshooting, Troubleshooting with a
Diagnostic Code.
STOP.

Result 3 The cooling fan is on because of a


coolant temperature sensor fault.

Repair: Perform the following diagnostic


procedure: Troubleshooting, Engine Temperature
Sensor Open or Short Circuit - Test
STOP.

Test Step 6. Check the A/C Pressure


Switch
A. Turn the key switch to the OFF position.
B. Disconnect the P1 ECM connector.
C. Measure the resistance between the two terminals
of the A/C high pressure switch at the P1 ECM
connector. The switch must be closed in order to
check the resistance.
Expected Result:
The resistance measures 10 Ohms or less.
Results:

OK The ECM, the A/C high pressure switch, and


the wiring are electrically OK.

Repair: Check the A/C pressure or send the


vehicle to the OEM dealer for repairs.
STOP.

Not OK
Repair: Replace the A/C high pressure switch.

208
Troubleshooting Section

SENR9698-09

Test Step 7. Check the ECM

g00676088

Illustration 70
Connector for the breakout T

A. Turn the key switch to the OFF position.


B. Disconnect the J1/P1 ECM connector.
C. Install a 140-2266 Cable (Seventy-Pin Breakout)
between the J1 and P1 ECM connectors .
D. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wire.
E. Connect the jumper wire to terminal 5 (AP
Sensor/Switch Common) and to terminal 41 (Input
11) of the breakout T.
Refer to Illustration 70.
F. Turn the key switch to the ON position.
G. Access the status for the A/C High Pressure
Switch on Cat ET.
H. Remove the jumper wire and then insert the
jumper wire. At the same time, watch the status of
the A/C High Pressure Switch on Cat ET.
Expected Result:
Cat ET indicates that the A/C High Pressure Switch
status is Off when the jumper wire is in place. Cat ET
indicates that the A/C High Pressure Switchstatus
is On when the jumper wire is removed.
Results:

OK The ECM is OK.


Repair: If a problem still exists, then the problem
is in the OEM wiring. Repair the problem or send
the vehicle to the OEM dealer for repair. Verify that
the repair eliminates the problem.
STOP.

Not OK
Repair: Temporarily connect a test ECM. Ensure
that the A/C Pressure Switch Fan On-Time
parameter is programmed in the same manner as
the suspect ECM. Use Cat ET to check the ECM. If
the problem is resolved with the test ECM, install
the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM.
Verify that the repair eliminates the problem.
STOP.

Test Step 8. Check Intake Manifold Air


Temperature and the Engine Coolant
Temperature
A. Turn the key switch to the ON position.
B. Access the status for the Coolant Temperature
and the Intake Manifold Air Temperature on Cat
ET.
C. Start the engine. Monitor the status screen for a
few minutes in order to verify that the temperatures
are changing as the engine warms up.
Expected Result:
The Coolant Temperature and the Intake Manifold
Air Temperature appear to have the correct reading.
Results:

OK Proceed to Test Step 9.


Not OK

SENR9698-09

209
Troubleshooting Section

Repair: Temporarily connect another sensor. Test


the new sensor by checking Intake Manifold Air
Temperature and Engine Coolant Temperature
again. If the problem is resolved with the new
sensor, then install the old sensor in order to verify
that the problem returns. If the problem returns,
then replace the old sensor.
Verify that the repair eliminates the problem.
STOP.

Test Step 9. Use the Special Test to


Check the Circuit for the Cooling Fan
Solenoid.

g00676097

Illustration 71
Connector for the breakout T

A. Turn the key switch to the ON position.


B. Access the On-Off Cooling Fan Special Test
for a fan that cycles Off and On. Access
the Three-Speed Fan Slip Output or the
Three-Speed Fan Brake Output Special Test for
a Three-Speed Fan. Access each menu in the
order that follows: Diagnostics, Diagnostic Tests,
and Special Test.
NOTE: If any override switches are installed, the
switch must be in the OFF position.
C. Cycle the Special Test to the ON position and to
the OFF position. Listen for the solenoid to click.
You may need to be near the engine in order to
hear the click of the solenoid.

Repair: If a problem still exists, then the problem is


in the OEM wiring. Repair the problem or send the
vehicle to the OEM dealer for repair.
Verify that the repair eliminates the problem.
STOP.

Not OK Proceed to Test Step 10.


Test Step 10. Use the Special Test in
Order to Check the ECM to the Cooling
Fan Circuit
A. Turn the key switch to the OFF position.
B. Disconnect the J1/P1 ECM connector.

Expected Result:

C. Remove the wire from P1:11 (Output 5).

An audible clicking is heard, and the solenoid


appears to be operating properly.

D. Connect a breakout T between the J1 and P1


ECM connector.

Results:

E. Connect a voltage test lamp between terminal 11


(Output 5) and terminal 67 (Negative Battery) of
the breakout T.

OK The cooling fan circuit from the ECM to the


solenoid is functioning properly at this time.

F. Turn the key switch to the ON position.

210
Troubleshooting Section

G. For a fan that cycles on and off, access the


On/Off Cooling Fan Special Test on Cat ET.
Cycle the On/Off Cooling Fan Special Test to the
ON position and to the OFF position. At the same
time, watch the voltage test lamp.
H. For a Three-Speed Fan, access the Three-Speed
Fan Slip Output and the Three-Speed Fan Bake
Output on Cat ET.
Cycle the Three-Speed Fan Slip Output to the
ON position and to the OFF position. At the same
time, watch the voltage test lamp.

SENR9698-09

i02508931

Cruise Control Switch Circuit


- Test
SMCS Code: 7332-038
System Operation Description:
Use this procedure if one of the following switches is
suspected of preventing normal operation of cruise
control, idle set speed, or PTO operation:

Cruise control on/off switch

Connect the voltage test lamp to terminal 13


(Output 4) and terminal 67 (-Battery) of the
breakout T.

Cruise control set/resume switch

Cycle the Three-Speed Fan Brake Output to the


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
or PTO operation:

Refer to Illustration 71 for the location of Output 4


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 tested.

Cruise control pause switch

Service brake pedal position (switch 2)


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
OFF position when the test is Not Active.

All of the following customer programmable


parameters can affect cruise control, idle set speed,
and PTO operation:

Results:

Adaptive Cruise Control Enable

OK The ECM cooling fan relay is functioning

Low Cruise Control Speed Set Limit

properly.

Repair: If a problem still exists, then the problem


is in the truck OEM wiring installation. Repair the
problem or send the vehicle to the OEM dealer for
repair.

High Cruise Control Speed Set Limit


Idle Vehicle Speed Limit
Cruise/Idle/PTO Switch Configuration

Verify that the repair eliminates the problem.

Idle/PTO Bump rpm

STOP.

Idle/PTO rpm Ramp Rate

Not OK

PTO Kickout Vehicle Speed Limit

Repair: Temporarily connect a test ECM. Use the


special test to check the ECM cooling fan circuit. If
the problem is resolved with the test ECM, install
the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM.

The vehicle speed calibration can also affect the


cruise control, the idle set speed, and the PTO if the
vehicle speed calibration is incorrectly programmed.
Refer to Troubleshooting, Customer Specified
Parameters.

Verify that the repair eliminates the problem.

Cruise Control On/Off Switch

STOP.

SENR9698-09

211
Troubleshooting Section

This switch must be on before cruise control or


controlled idle can be activated. This switch is on
when the switch is closed. When the switch is closed
the following terminals are connected:

If a problem is suspected with the adaptive cruise


control, the feature can be disabled. Toggle the
cruise control switch to the OFF position and to the
ON position twice within 10 seconds.

P1-59 (cruise control on/off switch)

The following background information is related


to this procedure:

P1-5 (AP sensor/switch sensor common)


Note: If the vehicle is programmed to use the
dedicated PTO, the PTO on/off switch overrides the
cruise control on/off switch. The PTO on/off switch
will override the cruise control on/off switch if the
vehicle speed is within the programmed range for the
PTO Kickout Vehicle Speed Limit parameter.
Set/Resume Switch
While the cruise control on/off switch is in the ON
position and the vehicle speed is within the range
of the programmed Low Cruise Control Speed Set
Limit and the High Cruise Control Speed Set Limit,
momentarily pressing the set switch will activate the
cruise or controlled idle, and the Engine Control
Module (ECM) will maintain the current speed.
Pressing the resume switch will cause the vehicle
speed to ramp to the last cruise control set speed.
This assumes that the vehicle speed is above the
Low Cruise Control Speed Set Limit for cruise
control or the vehicle speed is below the Idle/PTO
vehicle speed limit for the idle and the PTO.
After a speed has been set, pressing and holding the
set/resume switch in position will cause the engine
to establish a new set speed. The systems reaction
depends on the programming of the Cruise/Idle/PTO
Switch Configuration.
When the set/resume switch is momentarily pressed,
the current set point for the cruise will change
one mph. The rate of change is dependent on the
programmed Idle/PTO Bump RPM when an idle
speed is set.
Cruise Control Pause Switch
The cruise control pause switch is used to temporarily
disable cruise control. The cruise control cannot be
set while the cruise control pause switch is in the ON
position.
Adaptive Cruise Control
The adaptive cruise control is a J1939 based option.
A radar unit is used in order to detect vehicles. When
a vehicle is detected the cruise control set speed is
reduced in order to maintain a following distance.
This option must be enabled with the Caterpillar
Electronic Technician (ET). Customer passwords are
required to enable this option.

The kickout switch refers to the switch that is used to


exit the cruise control, the PTO, or the idle set speed.
The cruise controls control strategy for the Caterpillar
electronic engine is similar to the strategy of the
cruise controls that are installed in automobiles.
The operation of the cruise controls idle setting and
speed setting for the PTO is similar to the operation
of the cruise control except that the idle control and
the PTO control govern engine rpm instead of vehicle
speed.
Note: Idle in this procedure is an engine idle rpm
above the programmed low idle rpm. Idle is set
by using the cruise control on/off switch and the
set/resume switch. Refer to Troubleshooting, PTO
Switch Circuit - Test for additional information
regarding the programmable options for the
dedicated PTO.
Usage of Transmission Style Switches
The Transmission Style parameter defines the
configuration of the switches for the application. The
ECM can be configured to detect inputs from the
following switches:

Clutch pedal position


Neutral
Service brake pedal position (switch 1)
Service brake pedal position (switch 2)
Refer to Table 144 for additional information.

212
Troubleshooting Section

SENR9698-09

Table 144

Setting For
Transmission
Style
Parameter

Necessary Switches
Service
Brake
(Switch
1)

Service
Brake
(Switch
1)

Manual

Automatic
Option 1

Automatic
Option 2

Automatic
Option 3

Automatic
Option 4

Eaton Top 2

Clutch Neutral
X

X
X
X

If the Transmission Style parameter is programmed


to one of the following options, the input for the clutch
pedal position switch is not used:

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. The status of both of the service brake pedal
switches, the clutch pedal position switch, and the
transmission neutral switch can also be reported over
the J1939 data link.

SENR9698-09

213
Troubleshooting Section

g00643881

Illustration 72
Schematic for the cruise control switch, the service brake pedal position (switch 1), and clutch pedal position switch

Test Step 1. Check the Status of the


Cruise Control On/Off Switch

Test Step 2. Check the Status of the


Set/Resume Switch

A. Turn the keyswitch to the OFF position.

A. Place the cruise control on/off switch in the ON


position.

B. Connect Cat ET to the service tool connector.


C. Turn the keyswitch to the ON position.
D. Monitor the status for the Cruise/Idle On-Off
Switch while the cruise control on/off switch is
cycled.
The correct status for the Cruise/Idle On-Off
Switch is On when the cruise control on/off
switch is in the On position. The correct status for
the Cruise/Idle On-Off Switch is Off when the
cruise control on/off switch is in the Off position.
E. Turn the keyswitch to the OFF position.
Expected Result:
Cat ET displays the correct status for the switch
during the test procedure.
Results:

OK Cat ET displays the correct status for the

switch. The cruise control on/off switch is working


properly. Proceed to Test Step 2.

Not OK Cat ET does not display the correct

status for the switch. The cruise control on/off


switch is not working properly. Proceed to Test
Step 3.

B. Turn the keyswitch to the ON position.


C. Monitor the status for the Cruise Control
Set/Resume/Accel/Decel Switch P1-35 & 44
while the set/resume switch is cycled.
The correct status for the Cruise Control
Set/Resume/Accel/Decel Switch P1-35 & 44 is
Set Switch On when the set/resume switch is in
the Set position. The correct status for the Cruise
Control Set/Resume/Accel/Decel Switch P1-35 &
44 is Resume Switch On when the set/resume
switch is in the Resume position.
D. Turn the keyswitch to the OFF position.
Expected Result:
Cat ET displays the correct status for the switch
during the test procedure.
Results:

OK Cat ET displays the correct status for the


switch.

214
Troubleshooting Section

Repair: The cruise control set/resume switch


is working properly. There may have been an
intermittent electrical problem in the harness
or in a connector. If an intermittent problem is
suspected, refer to Troubleshooting, Electrical
Connectors - Inspect for information that is related
to troubleshooting intermittent electrical problems.

SENR9698-09

Test Step 4. Inspect the Electrical


Connectors and the Wiring

STOP.

Not OK Cat ET does not display the correct

status for the switch. The cruise control set/resume


switch is not working properly. Proceed to Test
Step 3.

Test Step 3. Determine the Configuration


of the Cruise Control Switches
A. Determine if the cruise control switches are wired
directly to the ECM, or if the switch position is
reported on the J1939 data link.
B. Verify that the Cruise Control On/Off Switch
and the Cruise Control Set/Resume/Accel/Decel
Switch parameters are programmed to reflect the
current wiring for the circuits.
Expected Result:
The cruise control switches are wired directly to the
ECM.
Results:

OK The cruise control switches are wired

directly to the ECM. Verify that the Cruise


Control On/Off Switch and the Cruise Control
Set/Resume/Accel/Decel Switch parameters are
programmed correctly. Proceed to Test Step 4.

Not OK The cruise control switches are not


wired to the ECM.

Repair: The switch position is reported to the ECM


via the J1939 data link. Verify that the Cruise
Control On/Off Switch and the Cruise Control
Set/Resume/Accel/Decel Switch parameters are
programmed to J1939 - Body Controller, J1939 Cab Controller, or J1939 - Instrument Cluster.
Refer to Troubleshooting, Powertrain Data Link
Circuit - Test for information that is related to
troubleshooting the J1939 data link.
STOP.

Illustration 73

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

A. Thoroughly inspect the J1/P1 ECM connector, the


connectors, and the firewall bulkhead connectors.
Refer to Troubleshooting, Electrical Connectors Inspect for details.

SENR9698-09

215
Troubleshooting Section

Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 5.

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.
STOP.

Illustration 74

g01255944

Terminals at the P1 ECM connector that are for the cruise control
(P1-5) AP sensor/switch sensor return
(P1-35) Set
(P1-44) Resume
(P1-59) Cruise control on/off switch

B. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the switches.
C. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
D. Check the harness and the wiring for abrasion and
pinch points from the battery to the ECM. Then,
check the wiring from the keyswitch to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.

216
Troubleshooting Section

SENR9698-09

Test Step 5. Check the Switch Circuit at


the ECM
Table 145

Status of the ECM Inputs for the Cruise Control Switch


Condition of Switch Circuit

Switch Status

Circuit

Off

Open

ECM terminal 59 is jumpered to terminal 5.

Cruise/idle on/off switch


On

Cruise/idle on/off switch


shorted

ECM terminal 35 is jumpered to terminal 5.

Set switch
On

Set switch
shorted

ECM terminal 44 is jumpered to terminal 5.

Resume switch
On

Resume switch
shorted

Jumper wire is not installed.

A. Turn the keyswitch to the OFF position.


B. Disconnect vehicle harness connector P1 from
the ECM.
C. Install a 208-0059 Adapter Cable As (70-PIN
BREAKOUT) at the J1/P1 ECM connectors.
D. Fabricate a jumper wire that is long enough to
create a short circuit across the terminals at the
breakout T. Crimp connector pins to each end of
the jumper wire.
E. Install the jumper into the suspect switch socket
of the breakout T. Connect the other end of the
jumper to ECM connector P1-5 (AP sensor/switch
sensor return) of the breakout T.
F. Turn the keyswitch to the ON position.
G. While the status for the suspect switch is being
monitored on the status screen of Cat ET, slowly
remove the jumper from terminal P1-5 (AP
sensor/switch sensor return). Reinstall the jumper
wire and check the status again.
H. Turn the keyswitch to the OFF position.
I. Restore the wiring to the original configuration.
Expected Result:
The switch status changes per the information in
Table 145.
Results:

OK The switch status changes correctly. The

ECM is functioning properly. Proceed to Test Step


6.

Not OK The switch status does not change


correctly.

Repair: The ECM is not functioning properly.


Perform the following repair:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Recheck the circuit in order to ensure that the
original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.

SENR9698-09

217
Troubleshooting Section

Test Step 6. Insert a Jumper at the


Suspect Switch
Table 146

Status of the ECM Inputs for the Cruise Control Switch


Condition of Switch Circuit

Switch Status

Circuit

No jumper wire is installed.

Off

Open

Jumper wire is installed at the harness connector for the


cruise/idle on/off switch.

On

Cruise/idle on/off switch


shorted

Jumper wire is installed at the harness connector for the


set switch.

On

Set switch
shorted

Jumper wire is installed at the harness connector for the


resume switch.

On

Resume switch
shorted

A. Find the suspect switch in the vehicle.

i02509246

B. Disconnect the wires from the suspect switch


terminals.

Diagnostic Enable Switch


Circuit - Test

C. Turn the keyswitch to the ON position.

SMCS Code: 7332-038-NQ

D. While the status for the suspect switch is being


monitored on the status screen of Cat ET, install
the jumper wire across the terminals of the
harness connector for the suspect switch. Remove
the jumper wire and check the status of the switch.

System Operation Description:

Refer to Table 146.


E. Turn the keyswitch to the OFF position.
Expected Result:
The switch status changes per the information that is
given in Table 146.
Results:

OK The switch status changes according to the


information that is given above.

Repair: The switch status for the suspect switch


changes correctly. There is a problem with the
switch. Replace the faulty switch. Verify that the
repair eliminates the problem.
STOP.

Not OK The switch status does not change

according to the information that is given above.


Repair: There is a problem in the harness or in a
connector between the ECM connector and the
switch. Repair the harness and/or the connector.
Replace parts, if necessary. Verify that the repair
eliminates the problem.
STOP.

Use this procedure under the following situation:


The circuit for the diagnostic enable switch is
suspected of incorrect operation.
Diagnostic Enable Switch
The diagnostic enable switch is used to prompt the
Engine Control Module (ECM) to display diagnostic
flash codes on the check engine lamp. For more
information, refer to the Flashing Out Diagnostic
Flash Codes section in Troubleshooting, Check
Engine Lamp Circuit - Test. The feature is disabled
if the Diagnostic Enable Switch parameter is
programmed to None (default). If the Diagnostic
Enable Switch parameter is programmed to
J1/P1:46, then the feature is available and the
switch circuit should be wired to P1-46 at the ECM
connector.

218
Troubleshooting Section

SENR9698-09

g01256017

Illustration 75
Schematic for the diagnostic enable switch

Test Step 1. Check the Status of the


Diagnostic Enable Switch

Test Step 2. Determine the Configuration


of the Diagnostic Enable Switch

A. Turn the keyswitch to the OFF position.

A. Determine if the diagnostic enable switch is wired


directly to the ECM, or if the switch position is
reported on the J1939 data link.

B. Connect Caterpillar Electronic Technician (ET) to


the data link connector.
C. Turn the keyswitch to the ON position.
D. Monitor the status for the Diagnostic Enable
while the diagnostic enable switch is toggled to
the ON position and the OFF position.
The correct status for the Diagnostic Enable is
On when the switch is in the ON position. The
correct status for the Diagnostic Enable is Off
when the switch is in the OFF position.
Note: If the status for the Diagnostic Enable
indicates Not Installed, then the Diagnostic Enable
parameter has not been programmed.
E. Turn the keyswitch to the OFF position.
Expected Result:
Cat ET correctly displayed the status for the
diagnostic enable switch.
Results:

OK Cat ET correctly displayed the status for


the switch.

Repair: The diagnostic enable switch appears


to operating correctly at this time. There may be
an intermittent electrical problem in the harness
or in a connector. If an intermittent problem is
suspected, refer to Troubleshooting, Electrical
Connectors - Inspect for information that is related
to troubleshooting intermittent electrical problems.
STOP.

Not OK Cat ET is not reporting the correct status


for the switch. The ECM is not reading the change
in switch status. Proceed to Test Step 2.

B. Verify that the Diagnostic Enable parameter is


programmed to reflect the current wiring for the
circuit.
Expected Result:
The diagnostic enable switch is wired directly to the
ECM.
Results:

OK The diagnostic enable switch is wired directly


to the ECM. Proceed to Test Step 3.

Not OK The diagnostic enable switch is wired


directly to the ECM.

Repair: The switch position is reported to the ECM


via the J1939 data link. Verify that the Diagnostic
Enable parameter is programmed to J1939 Body Controller, J1939 - Cab Controller, or
J1939 - Instrument Cluster.
Refer to Troubleshooting, Powertrain Data Link
Circuit - Test.
STOP.

SENR9698-09

219
Troubleshooting Section

Test Step 3. Check the Electrical


Connectors and the Wiring

Illustration 76

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

A. Thoroughly inspect the J1/P1 ECM connector


and the firewall bulkhead connectors. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.

Illustration 77

g01256021

Terminal locations at the ECM connector for the diagnostic enable


switch
(P1-5) AP sensor/switch sensor return
(P1-46) Input No. 7

B. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the suspect switch circuit.
C. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
D. Check the harness and the wiring for abrasion and
pinch points from the battery to the ECM. Then,
check the wiring from the keyswitch to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.
Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 4.

220
Troubleshooting Section

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.
STOP.

Test Step 4. Create a Short Circuit at the


Switch
A. Fabricate a jumper wire that is long enough to
create a short circuit across the terminals at the
harness connector for the diagnostic enable
switch.
B. Disconnect the switch from the harness.
C. Install the jumper wire across the two switch
terminals at the harness connector for the
diagnostic enable switch.
D. Turn the keyswitch to the ON position.
E. Use Cat ET to monitor the status of the Diagnostic
Enable. While the status for the Diagnostic
Enable is monitored, remove the jumper wire and
then insert the jumper wire.
The correct status for the Diagnostic Enable is
On when the jumper wire is inserted. The correct
status for the Diagnostic Enable is Off when
the jumper wire is removed.
F. Turn the keyswitch to the OFF position.
Expected Result:
Cat ET is reporting the correct status for the switch.
Results:

OK Cat ET is reporting the correct status.


Repair: The wiring harness and the ECM are OK.
There is a problem with the switch. Replace the
diagnostic enable switch. Verify that the repair
eliminates the problem.
STOP.

Not OK Cat ET does not report the correct status.


There is a problem in the wire harness between the
diagnostic enable switch and the ECM. There may
be a problem with the ECM. Restore the wiring to
the original configuration. Proceed to Test Step 5.

SENR9698-09

Test Step 5. Check for Proper Operation


of the ECM
A. Disconnect the J1/P1 ECM connectors.
B. Fabricate two jumper wires that are long enough
to create a test circuit at the ECM connector.
Crimp a connector socket to one end of each of
the jumper wires.
C. Remove the wire from terminal location P1-46
(input No. 7) at the ECM connector. Also,
remove the wire from terminal location P1-5 (AP
sensor/switch sensor return). Install one of the
jumper wires into each of these terminal locations.
D. Connect the J1/P1 ECM connectors.
E. Turn the keyswitch to the ON position.
F. Monitor the status of the Diagnostic Enable while
you short the loose ends of the jumper wires.
Provide an open circuit for the loose ends of the
jumper wires. Recheck the switch status.
The correct status for the Diagnostic Enable is
On when the jumper wires are shorted together.
The correct status for the Diagnostic Enable is
Off when the jumper wires are open.
G. Turn the keyswitch to the OFF position.
H. Restore all wiring to the original configuration.
Expected Result:
Cat ET is reporting the correct status for the switch.
Results:

OK Cat ET is reporting the correct status for


the switch.

Repair: The ECM is functioning properly at


this time. There is a problem in the OEM wiring
harness that is between the ECM connector and
the diagnostic enable switch. Repair the circuit or
send the vehicle to the OEM dealer for repairs.
STOP.

Not OK Cat ET does not report the correct status


for the switch.

Repair: The ECM is not reading the switch input


properly. There is a problem with the ECM. Perform
the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.

SENR9698-09

221
Troubleshooting Section

2. Recheck the circuit in order to ensure that the


original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.
i02509439

Eaton Top 2 Transmission


Circuit - Test
SMCS Code: 3174-038
System Operation Description:
Use this procedure under the following situation:
This procedure covers the following diagnostic codes:

54-05 Auxiliary Output #06 current low


54-06 Auxiliary Output #06 current high
55-05 Auxiliary Output #07 current low
55-06 Auxiliary Output #07 current high
191-07 Transmission Not Responding
Background Information
The Engine Control Module (ECM) controls shifts
between the top two gears of an Eaton Top 2
transmission. The shift points are based on engine
speed and load. When the transmission is in the Top
2 gears, the ECM will perform the following functions:

Shift the transmission between the top 2 gears


automatically.

Control the engine speed during a Top 2 shift.


Momentarily interrupt the cruise control or the

engine brake during the shift. Then, the cruise


control or the engine brake will resume.

Note: Top gear refers to tenth gear in a ten speed


transmission, and top gear refers to thirteenth gear in
a thirteen speed transmission. Top gear minus one
refers to ninth gear in a ten speed transmission, and
top gear minus one refers to twelfth gear in a thirteen
speed transmission. Top gear minus two refers to
eighth gear in a ten speed transmission, and top gear
minus two refers to eleventh gear in a thirteen speed
transmission.
When the engine has reached the upshift point the
ECM will automatically shift the transmission into
Top Gear. The ECM shifts the transmission into Top
Gear by turning on the shift solenoid and turning off
the lockout solenoid.
In order to downshift from Top Gear Minus One to Top
Gear Minus Two, make sure that the shift button is in
the forward position. Once the engine has reached
the shift point, move the gearshift lever to the next
lower lever position by double clutching.
When the engine has reached the shift point, the
ECM will automatically downshift the transmission
from Top Gear to Top Gear Minus One. The ECM
downshifts the transmission from Top Gear to Top
Gear Minus One by turning on the lockout solenoid
and turning off the shift solenoid.
If the Eaton Top 2 Override with Cruise Control
Switch parameter is programmed to YES the cruise
control on/off switch can be used to disable Top 2
mode. If the cruise control on/off switch is turned to
the OFF position and the transmission is not in Top 2
mode, the Top 2 mode will be disabled. This condition
is applicable to the manual mode of operation only.
If the cruise control on/off switch is turned to the ON
position, the Top 2 mode will be enabled and the
transmission will be allowed to shift automatically
in the Top 2 gears. When the vehicle is operating
in one of the Top 2 gears and the Top 2 mode is
enabled, switching the cruise control on/off switch to
the OFF position will place the transmission in hold
mode. When the transmission is in the hold mode,
the transmission will not shift out of the currently
selected gear. When the cruise control on/off switch
is returned to the ON position, the transmission will
return to Top 2 mode. When the clutch is depressed
and the transmission is in the hold mode, the manual
mode will be enabled and the Top 2 will be disabled.
System Problems

222
Troubleshooting Section

If the circuit malfunctions, the transmission will


typically default to manual operation. When the
system is in manual operation, Top 2 is inactive. For
some malfunctions, the system will detect a failure.
When the system detects a failure, the ECM begins a
nine second countdown. During the countdown, the
ECM will try to complete the shift. Once the ECM has
completed the countdown, the operator must place
the transmission in neutral in order to obtain manual
operation. The Top 2 function will be inactive until the
vehicle is stopped and power to the ECM is cycled.

SENR9698-09

Table 147

Top
Gear
Minus
Two
Ratio

Top
Gear
Minus
One
Ratio

Top
Gear
Ratio

RTLO-XX610B-T2
10 Over

1.352

1.000

0.741

RTL-XX710B-T2
10 Direct

1.825

1.351

1.000

Wiring Connections at the ECM

RTLO-XX713A-T2
13 Over

1.000

0.856

0.730

The Eaton Top 2 transmission is wired to the ECM


at the following outputs:

RTLO-XX718B-T2
18 Over

1.000

0.856

0.730

Output No. 6 (lockout solenoid)


Output No. 7 (shift solenoid )
The ECM will turn on the output No. 7 (shift solenoid)
when Top 2 is active in order to engage top gear.
The ECM will turn off output No. 7 (shift solenoid) at
all other times. The ECM will only provide control to
this output if the Transmission Style is programmed
to Eaton Top 2.
The ECM will turn on the output No. 6 (lockout
solenoid) when Top 2 is active in order to engage top
gear minus one. The ECM turns off the output No.
6 that is for the lockout solenoid at all other times.
The ECM will only provide control to this output if the
Transmission Style is programmed to Eaton Top 2.
Customer Specified Parameters
The following parameters must be programmed
per the following list in order for the Eaton Top 2
transmission to function properly:

Transmission Style Eaton Top 2


Top Gear Ratio Programmed range 0.000 to
3.750

Top Gear Minus One Ratio Programmed range


0.000 to 3.750

Top Gear Minus Two Ratio Programmed range


0.000 to 3.750

Eaton Top 2 Override with Cruise Switch Yes


or No

Note: Each gear ratio must be precisely programmed


to three decimal places per the following table for the
model of transmission that is installed:

Transmission
Model

Note: The XX that appears in the model number


of the transmission refers to the nominal torque
capacity. XX times 100 equals the nominal torque
capacity. For example, RTLO-14610B has a nominal
torque capacity of 14 times 100 or 1900 Nm
(1400 lb ft).
The model designation of the transmission and
other information are stamped on a tag on the
transmission. The tag is located on the lower left side
near the front of the transmission.

SENR9698-09

223
Troubleshooting Section

g01256175

Illustration 78
Schematic for the outputs to the Eaton Top 2 transmission

Test Step 1. Check for Active Diagnostic


Codes and Logged Diagnostic Codes
A. Turn the keyswitch to the OFF position.
B. Connect Cat ET to the service tool connector.
C. Turn the keyswitch to the ON position.
D. Monitor the active diagnostic code screen on Cat
ET.
E. Look for the following diagnostic codes:

191-07 Active or Logged Diagnostic code 191-07


is the only active diagnostic code or the only
logged diagnostic code that is present. Proceed
to Test Step 6.

54-05, 54-06, 55-05, or 55-06 Active or Logged


Any single diagnostic code or any combination of
these diagnostic codes are present. Proceed to
Test Step 2.

Test Step 2. Inspect the Electrical


Connectors and the Wiring

54-05 Auxiliary Output #06 current low


54-06 Auxiliary Output #06 current high
55-05 Auxiliary Output #07 current low
55-06 Auxiliary Output #07 current high
191-07 Transmission Not Responding
Note: If the Eaton Top 2 Override With Cruise
Switch parameter is programmed to YES and the
cruise control on/off switch is in the OFF position, the
operation of Top 2 is disabled.
F. Turn the keyswitch to the OFF position.
Expected Result:
None of the listed codes are active or logged.
Results:

OK None of the listed codes are active or logged.


Repair: If a transmission problem is still suspected,
send the vehicle to the OEM dealer for service of
the Eaton transmission.
STOP.

Illustration 79

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

A. Thoroughly inspect the J1/P1 ECM connector


and the firewall bulkhead connectors. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.

224
Troubleshooting Section

SENR9698-09

Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 3.

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.
STOP.

Test Step 3. Check the Solenoids


A. Turn the keyswitch to the ON position.
B. Access the customer specified parameters screen
on Cat ET.
C. Verify that the Transmission Style is programmed
to Eaton Top 2.
D. Access the special tests for the Shift Solenoid
and the Lockout Solenoid on Cat ET. Access the
following display screens in order:

Diagnostics
Diagnostic Tests
Illustration 80

g01256210

Terminal locations at the P1 ECM connector for the Eaton Top


2 transmission
(P1-19) Output No. 6 (lockout solenoid)
(P1-20) Output No. 7 (shift solenoid)

B. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the solenoid circuits.
C. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
D. Check the harness and wiring for abrasion and for
pinch points from the ECM connectors back to
the transmission.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.

Special Tests
Shift Solenoid and Lockout Solenoid
E. Use the following procedure for either of the
following active diagnostic codes or logged
diagnostic codes:

55-05 Auxiliary Output #07 current low


55-06 Auxiliary Output #07 current high
a. Move the splitter button to the rear position.
Note: Ensure that the air system pressure is equal to
or greater than 620 kPa (90 psi).
b. While you listen for the solenoid to shift, cycle
the special test for the Shift Solenoid from
the ON position to the OFF position back to
the ON position.
Note: You may need to be near the transmission in
order to hear the shift.

SENR9698-09

F. Use the following procedure for either of the


following active diagnostic codes or logged
diagnostic codes:

225
Troubleshooting Section

C. Use the following procedure for either of the


following active diagnostic codes or logged
diagnostic codes:

54-05 Auxiliary Output #06 current low

55-05 Auxiliary Output #07 current low

54-06 Auxiliary Output #06 current high

55-06 Auxiliary Output #07 current high

a. Move the splitter button to the forward position.

a. Connect a voltage test lamp between terminal


B (chassis ground) and terminal C (output
No. 7) on the harness side of the solenoid
connector at the transmission.

Note: Ensure that the air system pressure is equal to


or greater than 620 kPa (90 psi).
b. While you listen for the solenoid to shift, cycle
the special test for the Lockout Solenoid from
the ON position to the OFF position back to
the ON position.
Note: You may need to be near the transmission in
order to hear the shift.
Note: 191-07 Transmission Not Responding may
occur when one of the following diagnostic codes
occurs during vehicle operation:

54-05 Auxiliary Output #06 current low


54-06 Auxiliary Output #06 current high
55-05 Auxiliary Output #07 current low
55-06 Auxiliary Output #07 current high
Expected Result:
The solenoid is operating correctly when the test is
activated.
Results:

OK
Repair: The ECM, the relay, and the solenoid
appear to be operating correctly at this time. There
may be an intermittent electrical problem in the
harness or in a connector. If an intermittent problem
is suspected, refer to Troubleshooting, Electrical
Connectors - Inspect for information that is related
to troubleshooting intermittent electrical problems.
STOP.

D. Turn the keyswitch to the ON position.


E. Access the special test for the Shift Solenoid
on Cat ET. Access the following display screens
in order:

Diagnostics
Diagnostic Tests
Special Test
Shift Solenoid
F. While you monitor the voltage test lamp, cycle the
special test for the Shift Solenoid from the ON
position to the OFF position and back to the ON
position.
G. Stop the special test for the Shift Solenoid.
Note: When the keyswitch is turned on and the
solenoid connector is disconnected, the following
diagnostic code will occur during performance of the
special test for the Lockout Solenoid:

54-05 Auxiliary Output #06 current low


Clear this logged code when this step is
completed.
H. Turn the keyswitch to the OFF position.
I. Use the following procedure for either of the
following active diagnostic codes or logged
diagnostic codes:

54-05 Auxiliary Output #06 current low

Not OK The solenoid did not operate correctly

54-06 Auxiliary Output #06 current high

Test Step 4. Use the Special Test at the


Solenoid Connector

a. Connect a voltage test lamp between terminal


B (chassis ground) and terminal A (output
No. 6) on the harness side of the solenoid
connector at the transmission.

when the test was activated. The solenoid is not


operating correctly. Proceed to Test Step 4.

A. Turn the keyswitch to the OFF position.


B. Disconnect the Eaton Top 2 solenoid connector.

J. Turn the keyswitch to the ON position.

226
Troubleshooting Section

K. Access the special test for the Shift Solenoid


and the Lockout Solenoid on Cat ET. Access the
following display screens in order:

Diagnostics
Diagnostic Tests
Special Test
Lockout Solenoid
L. While you monitor the voltage test lamp, cycle the
special test for the Lockout Solenoid from the
ON position to the OFF position and back to the
ON position.

SENR9698-09

Not OK The voltage test lamp did not agree with


the results that are listed above. The problem is
in the harness wiring or the ECM. Remove the
voltage test lamp. Proceed to Test Step 5.

Test Step 5. Use Cat ET to Check the ECM


A. Disconnect the J1/P1 ECM connector.
B. Connect a 208-0059 Adapter Cable As (70-PIN
BREAKOUT)at the J1/P1 ECM connector.
C. Use the following procedure for either of the
following diagnostic codes:

55-05 Auxiliary Output #07 current low

M. Stop the special test for the Lockout Solenoid.

55-06 Auxiliary Output #07 current high

Note: When the keyswitch is turned on and the


solenoid connector is disconnected, the following
diagnostic code will occur during performance of the
special test for the Lockout Solenoid:

a. Remove the wire from terminal location P1-20


at the ECM connector.

55-05 Auxiliary Output #07 current low


Clear this logged code when this step is
completed.

b. Connect a voltage test lamp between terminal


67 (Battery) and terminal 20 (output No. 7)
of the breakout T.
Note: The output No. 7 is the terminal location of the
ECM solenoid driver for the shift solenoid.

N. Turn the keyswitch to the OFF position.

c. Turn the keyswitch to the ON position.

Expected Result:

d. Access the special test for the Shift Solenoid


on Cat ET. Access the following display
screens in order:

The voltage test lamp behaves in the following


manner:

The voltage test lamp turns on when the test is


active.

The voltage test lamp turns off when the test is


not active.

Results:

OK The voltage test lamp agreed with the results


that are listed above.

Repair: The engine harness and the ECM are


OK. Temporarily connect the suspect solenoids.
Clear all logged diagnostic codes. Complete a test
drive of the truck. If the diagnostic code is logged
after attempting to use the Top 2 feature, replace
the solenoids. Repeat the test drive in order to
ensure that the problem has been corrected. Clear
all logged diagnostic codes. Verify that the repair
eliminates the problem.
STOP.

Diagnostics
Diagnostic Tests
Special Test
Shift Solenoid
e. While you monitor the voltage test lamp, cycle
the special test for the Shift Solenoid from the
ON position to the OFF position and back to
the ON position.
f. Stop the special test for the Shift Solenoid.
g. Turn the keyswitch to the OFF position.
D. Use the following procedure for either of the
following diagnostic codes:

54-05 Auxiliary Output #06 current low


54-06 Auxiliary Output #06 current high
a. Remove the wire from terminal location P1-19
at the ECM connector.

SENR9698-09

b. Connect a voltage test lamp between terminal


67 (Battery) and terminal 19 (output No. 6)
of the breakout T.
Note: The output No. 6 is the terminal location of the
ECM solenoid driver for the lockout solenoid.
c. Turn the keyswitch to the ON position.
d. Access the special test for the Lockout
Solenoid on Cat ET. Access the following
display screens in order:

227
Troubleshooting Section

Repair: There is a problem in the wiring harness


or in a connector between the solenoid connector
and the ECM connector. Repair the harness and/or
the connector. Replace parts, if necessary. Clear
any diagnostic codes that were caused during this
step. Verify that the repair eliminates the problem.
STOP.

Not OK The voltage test lamp did not respond


correctly.

Diagnostics

Repair: There is a problem with the ECM. Perform


the following procedure:

Diagnostic Tests

1. Temporarily connect a test ECM.

Special Test
Lockout Solenoid
e. While you monitor the voltage test lamp, cycle
the special test for the Lockout Solenoid from
the ON position to the OFF position and back
to the ON position.
f. Stop the special test for the Lockout Solenoid.
g. Turn the keyswitch to the OFF position.
h. Restore the wiring to the original configuration.
Expected Result:
The voltage test lamp behaves in the following
manner:

The voltage test lamp turns on when the test is


active.

Refer to Troubleshooting, Replacing the ECM.


2. Recheck the circuit in order to ensure that the
original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.

Test Step 6. Check the Gear Ratios


A. Turn the keyswitch to the ON position.

The voltage test lamp turns off when the test is

B. Access the customer specified parameters screen


in Cat ET.

Note: When all of the following conditions exist a


54-05 and 55-05 diagnostic code will occur:

C. Verify that the three parameters for gear ratios are


correctly programmed.

not active.

The keyswitch is turned on.

Refer to Table 147.

The ECM connector J1/P1 is disconnected.

Expected Result:

The Transmission Style is programmed to Eaton

The parameters for the gear ratios are programmed


correctly.

This is normal. Clear these diagnostic codes after


this test step is completed.

Results:

Top 2.

Results:

OK The voltage test lamp responded correctly.

OK The parameters for the gear ratios were


programmed correctly.

Repair: If a transmission problem is still suspected,


send the vehicle to the OEM dealer for service to
the transmission.
STOP.

228
Troubleshooting Section

SENR9698-09

Not OK The parameters for the gear ratios were


not programmed correctly.

Repair: Consult the OEM dealer in order to


determine the proper values for the gear ratios and
program the proper values for the gear ratios.
STOP.

The ECM uses a microprocessor to perform the


computing that is required for controlling the following
functions:

Engine speed governing


Engine timing control
Engine diagnostic capability

i02503713

ECM Memory - Test


SMCS Code: 1901-038
System Operation Description:
Use this procedure under the following situation:
One of the following diagnostic codes is present:

252-11 Engine Software Incorrect

ECM communications
Programmable Parameters
Programmable parameters are stored in permanent
memory. This includes both customer specified
parameters and system configuration parameters.
Refer to Troubleshooting, Customer Specified
Parameters for details on customer specified
parameters. Refer to Troubleshooting, System
Configuration Parameters for details on system
configuration parameters.

253-02 Check Customer or System Parameters

Logged Diagnostics

Also, use this procedure if the integrity of the


customer parameters or the system parameters in
the Engine Control Module (ECM) is questionable.
Also, use this procedure if the data for the engine
lifetime totals is questionable.

Logged diagnostics are stored by the ECM into


memory so a permanent record of the diagnostic
code is retained. Logged faults that are not critical
are automatically cleared after 100 hours.

The following background information is related


to this procedure:
The ECM is the computer that controls the Caterpillar
electronic engine. The personality module contains
the software that controls the operation of the ECM.

Input Circuits
Input circuits filter electrical noise for sensor signals.
Also, input circuits protect internal circuits from
potentially damaging voltage levels.
Output Circuits

The personality module software is used by the


ECM to control the engine. For this reason, updating
the personality module to a different version may
cause some engine functions to behave in a different
manner.

Output circuits provide the voltage or current that is


required to energize components that are connected
to the ECM.

Performance Maps

Power circuits provide clean stable electrical power


to internal circuits and external sensors.

Performance maps define characteristics for various


operating conditions. These characteristics are used
to achieve optimum performance while emissions
requirements are being met. Examples of these
characteristics include the engines fuel rate and the
engine timing.
These characteristics are programmed into the
personality module at the factory.
Microprocessor

Power Circuits

SENR9698-09

229
Troubleshooting Section

Test Step 1. Inspect the Electrical


Connectors and the Wiring

Illustration 81

g01252833

Location of the ECM and the harness connectors (typical left side
engine view)
(1) J2/P2 ECM connectors
(2) J1/P1 ECM connectors
(3) ECM

A. Thoroughly inspect connectors (1) and (2) that are


for ECM (3). Refer to Troubleshooting, Electrical
Connectors - Inspect for details.
Illustration 82

g01252845

Terminal locations at the J1/P1 ECM connectors that are


associated with the ECM memory
(J1-8) ATA Data Link (+)
(J1-9) ATA Data Link ()
(J1-48) unswitched +Battery
(J1-52) unswitched +Battery
(J1-53) unswitched +Battery
(J1-61) Battery
(J1-63) Battery
(J1-65) Battery
(J1-70) Keyswitch input

B. Perform a 45 N (10 lb) pull test on each of the


wires at the ECM connectors that are associated
with the circuit.
C. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
D. Check the harness and the wiring for abrasion
and pinch points from the data link connectors,
the batteries, and the keyswitch back to the ECM.

230
Troubleshooting Section

Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion or of pinch points.
Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 2.

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that
all of the seals for each of the connectors are
properly in place and ensure that the connectors
are completely coupled. Verify that the repair
eliminates the problem.
STOP.

Test Step 2. Check for Active Diagnostic


Codes
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
B. Turn the keyswitch to the ON position.
C. Monitor the active diagnostic code screen on Cat
ET. Check for an active 252-11 or 253-02 code.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
D. Turn the keyswitch to the OFF position.
Expected Result:
There are no active diagnostic codes and the ECM
parameters and data appear to be correct.
Results:

OK There are no active diagnostic codes and the


ECM parameters and data appear to be correct.

Repair: There does not appear to be a problem


with the ECM memory at this time. There may
have been an intermittent electrical problem
in the vehicle harness or in a connector. If an
intermittent electrical problem is suspected, refer to
Troubleshooting, Electrical Connectors - Inspect
for information that is related to troubleshooting
intermittent electrical problems.
STOP.

SENR9698-09

Active 252-11 There is an active 252-11 at this

time. There appears to be engine software that is


installed into the ECM that is incorrect. Proceed
to Test Step 3.

Active 253-02 There is an active 253-02 at this

time. There may be engine parameters that have


not yet been programmed into the ECM. Proceed
to Test Step 4.

Scrambled parameters or corrupt data There are


scrambled parameters or incorrect data. There
are scrambled parameters or incorrect data that is
being displayed. Proceed to Test Step 5.

Test Step 3. Check the Part Number for


the ECM Flash File
A. Turn the keyswitch to the ON position.
B. Use Cat ET to check that the most current version
of the flash files have been installed in the ECM.
C. Turn the keyswitch to the OFF position.
Expected Result:
The flash file that is installed in the ECM is the latest
version.
Results:

OK The flash files are the latest version.


Repair: Clear the 252-11 code. Clearing this
diagnostic code requires factory passwords. Verify
that the code does not recur.
STOP.

Not OK The flash files are not the latest version.


Repair: Perform the following procedure:
1. Obtain the latest version of the flash files
for both the engine ECM and the Caterpillar
Monitoring System.
Note: The Flash File Search tool on the Service
Technician Workbench (STW) can be used to obtain
flash files. SIS Web can also be used to obtain the
flash files by clicking the Service Software Files
feature that is on the SIS Web web site.
2. Use Cat ET to install the flash files. Verify that
the original problem has been resolved.
STOP.

SENR9698-09

Test Step 4. Determine Parameters that


Require Programming
A. Turn the keyswitch to the ON position.
B. Use Cat ET to check the list of parameters that
are not programmed. Record the parameters that
are not programmed.
C. Program these parameters to the correct values.
D. Turn the keyswitch to the OFF position.

231
Troubleshooting Section

Results:

OK The parameters and engine lifetime totals


are OK.

Repair: The parameters and totals are not


scrambled. Attempt to reprogram any suspect
parameters. If the ECM does not retain the
information, there may be a problem with the
unswitched battery circuit that is part of the vehicle
wiring. There may be a problem with the ECM.

The ECM allows the parameters that are listed to be


programmed.

Check that the ECM is receiving the correct battery


power during all of the operating conditions. If
the ECM is receiving the correct power, there is
a problem with the ECM. Perform the following
procedure:

Results:

1. Temporarily connect a test ECM.

Expected Result:

OK The ECM allows the parameters to be


programmed to the correct values.

Repair: Clear the 253-02 code. Verify that the


code does not recur.
STOP.

Not OK The parameters could not be


programmed.

Repair: There is a problem with the ECM. Perform


the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Recheck the circuit in order to ensure that the
original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
STOP.

Test Step 5. Review Parameters and Data


A. Turn the keyswitch to the ON position.
B. Review the customer and system parameters.
C. Review the engine lifetime totals.
Expected Result:
The parameters and engine lifetime totals are OK.

Refer to Troubleshooting, Replacing the ECM.


2. Reprogram the ECM. Recheck the ECM in
order to ensure that the memory is retaining the
new data.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
STOP.

Not OK The parameters and/or engine lifetime


totals are scrambled.

Repair: The parameters and totals are scrambled.


Attempt to reprogram any suspect parameters. If
the ECM does not retain the information, there is a
problem with the unswitched battery circuit that is
part of the vehicle wiring. There may be a problem
with the ECM.
Check that the ECM is receiving the correct battery
power during all of the operating conditions. If
the ECM is receiving the correct power, there is
a problem with the ECM. Perform the following
procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Reprogram the ECM. Recheck the ECM in
order to ensure that the memory is retaining the
new data.

232
Troubleshooting Section

SENR9698-09

If the problem is resolved with the test ECM,


install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.
If the problem is not resolved with the test ECM,
install the original ECM. There is a problem in
the wiring.
STOP.
i02378207

The connection of any electrical equipment and


the disconnection of any electrical equipment may
cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an
explosive atmosphere.

Test Step 1. Check Connectors for


Moisture and Corrosion

Electrical Connectors - Inspect


SMCS Code: 7553-040-WW
System Operation Description:
Most electrical problems are caused by poor
connections. The following procedure will assist in
detecting problems with connectors and with wiring.
If a problem is found correct the condition and verify
that the problem is resolved.
Intermittent electrical problems are sometimes
resolved by disconnecting and reconnecting
connectors. It is very important to check for diagnostic
codes immediately before disconnecting a connector.
Also check for diagnostic codes after reconnecting
the connector. If the status of a diagnostic code is
changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
likely reasons are loose terminals, improperly crimped
terminals, moisture, corrosion, and inadequate
mating of a connection.
Follow these guidelines:

Always use a 1U-5804 Crimp Tool to service

Deutsch HD and DT connectors. Never solder the


terminals onto the wires. Refer to SEHS9615,
Servicing Deutsch HD and DT Style Connectors.

Always use a 147-6456 Wedge Removal Tool to

remove wedges from DT connectors. Never use a


screwdriver to pry a wedge from a connector.

Always use a breakout harness for a voltmeter

probe or a test light. Never break the insulation


of a wire in order to access to a circuit for
measurements.

If a wire is cut, always install a new terminal for


the repair.

Illustration 83

g01131211

Leaky seal at the connector (typical example)

A. Inspect all wiring harnesses. Ensure that the


routing of the wiring harness allows the wires to
enter the face of each connector at a perpendicular
angle. Otherwise, the wire will deform the seal
bore. Refer to Illustration 83. This will create a
path for the entrance of moisture. Verify that the
seals for the wires are sealing correctly.

SENR9698-09

Illustration 84

233
Troubleshooting Section

g01131276

Diagram for the installation of a connector plug (typical example)


(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug

B. Ensure that the sealing plugs are in place. If any


of the plugs are missing, replace the plug. Ensure
that the plugs are inserted correctly into the
connector. Refer to Illustration 84.

Illustration 86

g01131165

Seal for ECM connector (typical example)

C. Disconnect the suspect connector and inspect the


connector seal. Ensure that the seals are in good
condition. If necessary, replace the connector.
D. Thoroughly inspect the connectors for evidence
of moisture entry.
Note: It is normal to see some minor seal abrasion
on connector seals. Minor seal abrasion will not allow
the entry of moisture.
If moisture or corrosion is evident in the connector,
the source of the moisture entry must be found and
the source of the moisture entry must be repaired.
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
Illustration 85
Seal for a three-pin connector (typical example)

g01131019

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
connector, thoroughly check the connectors
harness for damage. Also check other connectors
that share the harness for moisture.
Note: The ECM is a sealed unit. If moisture is found
in an ECM connector, the ECM is not the source of
the moisture. Do not replace the ECM.

234
Troubleshooting Section

SENR9698-09

Expected Result:

Expected Result:

The harness wiring, connectors, and seals are in


good condition. There is no evidence of moisture in
the connectors.

The wires are free of abrasion, of nicks, and of cuts


and the harness is properly clamped.

Results:

OK The harness wiring, connectors, and seals


are in good condition. Proceed to Test Step 2.

Not OK A problem has been found with the


harness or the connectors.

Repair: Repair the connectors or the wiring, as


required. Ensure that all of the seals are properly
in place. Ensure that the connectors have been
reattached.
If corrosion is evident on the pins, sockets or the
connector, use only denatured alcohol to remove
the corrosion. Use a cotton swab or a soft brush
to remove the corrosion.
If moisture was found in the connectors, run the
engine for several minutes and check again for
moisture. If moisture reappears, the moisture is
wicking into the connector. Even if the moisture
entry path is repaired, it may be necessary to
replace the wires.

Results:

OK The harness is OK. Proceed to Test Step 3.


Not OK There is damage to the harness.
Repair: Repair the wires or replace the wires,
as required. Verify that the repair eliminates the
problem.
STOP.

Test Step 3. Inspect the Connector


Terminals
A. Visually inspect each terminal in the connector.
Verify that the terminals are not damaged.
Verify that the terminals are properly aligned in
the connector and verify that the terminals are
properly located in the connector.
Expected Result:
The terminals are properly aligned and the terminals
appear undamaged.

Verify that the repair eliminates the problem.

Results:

STOP.

OK The terminals are OK. Proceed to Test Step

Test Step 2. Check the Wires for Damage


to the Insulation
A. Carefully inspect each wire for signs of abrasion,
of nicks, and of cuts.
Inspect the wires for the following conditions:

Exposed insulation
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.

4.

Not OK The terminals of the connector are


damaged.

Repair: Repair the terminals and/or replace the


terminals, as required.
Verify that the repair eliminates the problem.
STOP.

SENR9698-09

235
Troubleshooting Section

Test Step 4. Perform a Pull Test on Each


Wire Terminal Connection

Illustration 87

g01131435

Test Step 5. Check Individual Pin


Retention into the Socket

Illustration 88

g01131604

Receptacle lock wedge (typical example)

Diagram for testing pin retention (typical example)

A. Ensure that the locking wedge for the connector


is installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not
installed properly.

A. Verify that the sockets provide good retention for


the pins. Insert a new pin into each socket one
at a time in order to check for a good grip on the
pin by the socket.

B. Perform the 45 N (10 lb) pull test on each wire.


Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire
should remain in the connector body. This test
checks whether the wire was properly crimped
in the terminal and whether the terminal was
properly inserted into the connector.

Expected Result:

Expected Result:
Each terminal and each connector easily withstands
45 N (10 lb) of pull and each wire remains in the
connector body.
Results:

OK All terminals pass the pull test. Proceed to


Test Step 5.

Not OK A wire has been pulled from a terminal


or a terminal has been pulled from the connector.

Repair: Use the 1U-5804 Crimp Tool to replace


the terminal. Replace damaged connectors, as
required. Verify that the repair eliminates the
problem.
STOP.

The sockets provide good retention for the new pin.


Results:

OK The terminals are OK. Proceed to Test Step


6.

Not OK Terminals are damaged.


Repair: Use the 1U-5804 Crimp Tool to replace
the damaged terminals. Verify that the repair
eliminates the problem.
STOP.

Test Step 6. Check the Locking


Mechanism of the Connectors
A. Ensure that the connectors lock properly. After
locking the connectors, ensure that the two halves
cannot be pulled apart.
B. Verify that the latch tab of the connector is
properly latched. Also verify that the latch tab of
the connector returns to the locked position.
Expected Result:
The connector will securely lock. The connector and
the locking mechanism are without cracks or breaks.
Results:

OK The connectors are in good repair. Proceed


to Test Step 7.

236
Troubleshooting Section

SENR9698-09

Not OK The connectors locking mechanism is


damaged or missing.

Repair: Repair the connector or replace the


connector, as required. Verify that the repair
eliminates the problem.
STOP.

Test Step 7. Check the Allen Head Screws


on the Connectors
Visually inspect the allen head screws for the ECM
connectors. Ensure that the threads on each allen
head screw are not damaged.
A. Connect the ECM connectors.

Illustration 91

g01132863

Allen head screw for the 40 pin ECM connector (typical example)

c. Torque the allen head screw for the 40 pin ECM


connector to 2.25 0.25 Nm (20 2 lb in).

Illustration 89

g01132827

Allen head screw for the 120 pin ECM connector (typical example)

a. Torque the allen head bolt for the 120 pin ECM
connector to 7.0 0.5 Nm (60 4 lb in).

Illustration 92

g01133047

Allen head screw for the 40 pin customer connector and the 70 pin
customer connector (typical example)

B. Connect the customer connector.


Torque the allen head screw for the 40 pin
customer connector and the 70 pin customer
connector to 2.25 0.25 Nm (20 2 lb in).
Expected Result:
The ECM connector is secure and the allen head
screws are properly torqued.
Results:
Illustration 90

g01132849

Allen head screw for the 70 pin ECM connector (typical example)

b. Torque the allen head screw for the 70


pin ECM connector to 6.0 + 1.5 - 0.5 Nm
(55 + 13 - 4 lb in).

OK The ECM connectors and the customer

connector is properly connected. Proceed to Test


Step 8.

Not OK The allen head screws for the ECM

connector or the customer connector is damaged.

SENR9698-09

Repair: Repair the connector or replace the


connector, as required. Verify that the repair
eliminates the problem.
STOP.

Test Step 8. Perform the Wiggle Test on


the Caterpillar Electronic Technician (ET)
A. Select the Wiggle Test from the diagnostic tests
on Cat ET.

237
Troubleshooting Section

i01921850

Engine Coolant Diverter Circuit


- Test
SMCS Code: 5479-038-CLT
System Operation Description:

If an intermittent problem exists, the status will be


highlighted and an audible beep will be heard.

During normal operation, coolant is sent to the


air intake system in order to cool the intake air. A
jacket water aftercooler in the air lines after the
turbochargers cools the air before the air enters
the air-to-air aftercooler. When the vehicle is at idle
in cold climates, the aftercooler may overcool the
engine. The engine coolant diverter stops the flow
of coolant to the aftercooler in order to prevent the
coolant temperature from becoming too low. Diverting
the coolant will also prevent the temperature in the
cab from becoming too low.

Expected Result:

Coolant Diverter Valve Test

No intermittent problems were indicated during the


Wiggle Test.

The Coolant Diverter Valve Test is available to help


diagnose problems with the engine coolant diverter
solenoid. A small current is applied to the circuit at
all times. This allows the Engine Control Module
(ECM) to detect open circuits when the valve is not
actuated. A short circuit will only be detected when
the valve is actuated.

B. Choose the appropriate group of parameters to


monitor.
C. Press the Start button. Wiggle the wiring harness
in order to reproduce intermittent problems.

Results:

OK No intermittent problems were found. The

harness and connectors appear to be OK. If you


were sent from another procedure, return to the
procedure and continue testing. If this test has
resolved the problem, return the engine to service.
STOP.

Not OK At least one intermittent problem was

The following conditions must be met before the


Coolant Diverter Valve Test will function:

Engine speed is 0.

indicated.

Vehicle speed is 0.

Repair: Repair the harness or the connector. Verify


that the repair eliminates the problem.

The neutral switch is in the Neutral position.

STOP.

238
Troubleshooting Section

SENR9698-09

g01012736

Illustration 93
Schematic

g01012737

Illustration 94
P2 ECM connector

Test Step 1. Inspect Electrical Connectors


and Wiring
A. Turn the key switch to the OFF position.
B. Thoroughly inspect the J2/P2 ECM connector and
the solenoid connector. Refer to Troubleshooting,
Electrical Connectors - Inspect for details.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and the solenoid
connector.
D. Check the ECM connector (allen head screw) for
the proper torque of 6 Nm (55.0 lb in).
E. Check the harness and wiring for abrasion and for
pinch points.
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted and the harness and the
wiring are free of corrosion, of abrasion, or of pinch
points.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.

Test Step 2. Determine the Condition that


is Present
A. Connect the Caterpillar Electronic Technician (Cat
ET) to the data link connector.
B. Turn the key switch to the ON position.
C. Check for active diagnostic codes that are related
to the engine coolant diverter solenoid.
D. Start the Coolant Diverter Valve Test in the
Special Tests under the Diagnostics menu on
Cat ET.

Results:

E. Once Cat ET displays the status of the engine


coolant diverter, stop the Coolant Diverter Valve
Test.

OK The electrical connectors and wiring are OK.

Expected Result:

Not OK There is a problem with the electrical

The test indicated Not Active: Device Open or Not


Active: Device Short.

Proceed to Test Step 2.

connectors and/or the wiring.

SENR9698-09

239
Troubleshooting Section

Results:

Results:

Open The test indicated Not Active: Device

OK The resistance is within the specifications.

Open. Proceed to Test Step 3.

Short The test indicated Not Active: Device


Short. Proceed to Test Step 7.

Test Step 3. Short the Wires at the


Solenoid
A. Turn the key switch to the OFF position.
B. Disconnect the engine coolant diverter solenoid at
the solenoid connector.
C. Fabricate a jumper wire to short terminal 1 and
terminal 2 of the connector for the solenoid on the
engine harness.
D. Turn the key switch to the ON position.
E. Access the Special Tests under the Diagnostics
menu.
F. Start the Coolant Diverter Valve Test on Cat ET.
G. Once Cat ET displays the status of the engine
coolant diverter, stop the Coolant Diverter Valve
Test.
Expected Result:
The test indicated Not Active: Device Short with the
jumper wire in place.
Results:

OK The test indicated Not Active: Device Short.


Proceed to Test Step 4.

Not OK The test indicated Not Active: Device


Open.

Repair: Reconnect the solenoid to the solenoid


connector.
Proceed to Test Step 5.

Test Step 4. Check the Resistance of the


Solenoid
A. Turn the key switch to the OFF position.
B. Use a multimeter to measure the resistance
between terminal 1 and terminal 2 of the engine
coolant diverter solenoid.
Expected Result:
The resistance is less than 13 Ohms for 12 volt
systems and the resistance is less than 50 Ohms for
24 volt systems.

Repair: Inspect the solenoid connector, terminals,


and wiring.
Verify that all of the connectors, terminals, and
wiring are OK.
If the problem is intermittent refer to
Troubleshooting, Electrical Connectors - Inspect.
STOP.

Not OK The resistance is not within the


specifications.

Repair: Temporarily connect a new solenoid.


If the new solenoid fixes the problem, reconnect
the suspect solenoid.
If the problem returns, permanently replace the
solenoid.
Verify that the repair eliminates the problem.
STOP.

Test Step 5. Short the Circuit at the ECM


A. Turn the key switch to the OFF position.
B. Disconnect the P2 ECM connector.
C. Remove the wires from P2:8 (Engine coolant
diverter solenoid) and P2:53 (Solenoid common).
D. Fabricate a jumper wire to short P2:8 (Engine
coolant diverter solenoid) and P2:53 (Solenoid
common).
E. Reconnect the P2 ECM connector.
F. Turn the key switch to the ON position.
G. Access the Special Tests under the Diagnostics
menu.
H. Start the Coolant Diverter Valve Test on Cat ET.
I. Once Cat ET displays the status of the engine
coolant diverter, stop the Coolant Diverter Valve
Test.
Expected Result:
The test indicated Not Active: Device Short with the
jumper wire in place.

240
Troubleshooting Section

Results:

OK The test indicated Not Active: Device Short

with the jumper wire in place. Proceed to Test Step


6.

SENR9698-09

O. Access the Special Tests under the Diagnostics


menu.
P. Start the Coolant Diverter Valve Test on Cat ET.

Open with the jumper wire in place.

Q. Once Cat ET displays the status of the engine


coolant diverter, stop the Coolant Diverter Valve
Test.

Repair: Temporarily connect a test ECM.

Expected Result:

If the test ECM fixes the problem, reconnect the


suspect ECM.

The test indicates Active with one or both of the


jumper wires in place.

If the problem returns, permanently replace the


ECM.

Results:

Not OK The test indicated Not Active: Device

Verify that the repair eliminates the problem.


STOP.

OK The bypass harness repaired the problem.


Repair: Repair the suspect wires or replace the
suspect wires.

Test Step 6. Bypass the Harness

Verify that the repair eliminates the problem.

A. Turn the key switch to the OFF position.

STOP.

B. Disconnect the P2 ECM connector and the P702


engine coolant diverter solenoid connector.
C. Remove the wire from P2:8 (engine coolant
diverter solenoid) and P702:1 (engine coolant
diverter solenoid).
D. Fabricate two jumper wires that can reach from
the ECM to the engine coolant diverter solenoid.
E. Insert one of the jumper wires into P2:8 and
P702:1.
F. Turn the key switch to the ON position.
G. Access the Special Tests under the Diagnostics
menu.
H. Start the Coolant Diverter Valve Test on Cat ET.
I. Once Cat ET displays the status of the engine
coolant diverter, stop the Coolant Diverter Valve
Test.
J. Turn the key switch to the OFF position.
K. Disconnect the P2 ECM connector and the P702
Engine coolant diverter solenoid connector.
L. Remove the wire from P2:53 (solenoid common)
and P702:2 (solenoid common).
M. Insert the other jumper wire into P2:53 and
P702:2.
N. Turn the key switch to the ON position.

Not OK The bypass harness did not repair the


problem.

Repair: Verify that the bypass harness is properly


connected.
Check the ECM connector and the solenoid
connector for damage and/or moisture.
If the problem is intermittent, refer to
Troubleshooting, Electrical Connectors - Inspect.
STOP.

Test Step 7. Create an Open at the


Solenoid
A. Turn the key switch to the OFF position.
B. Disconnect the engine coolant diverter solenoid at
the solenoid connector.
C. Turn the key switch to the ON position.
D. Access the Special Tests under the Diagnostics
menu.
E. Start the Coolant Diverter Valve Test on Cat ET.
F. Once Cat ET displays the status of the engine
coolant diverter, stop the Coolant Diverter Valve
Test.
Expected Result:
The test indicates Not Active: Device Open.

SENR9698-09

241
Troubleshooting Section

Results:

F. Turn the key switch to the ON position.

OK The test indicates Not Active: Device Open.

G. Access the Special Tests under the Diagnostics


menu.

Not OK The test indicates Not Active: Device

H. Start the Coolant Diverter Valve Test on Cat ET.

Test Step 8. Check the Resistance of the


Solenoid

I. Once Cat ET displays the status of the engine


coolant diverter, stop the Coolant Diverter Valve
Test.

A. Turn the key switch to the OFF position.

Expected Result:

B. Use a multimeter to measure the resistance


between terminal 1 and terminal 2 of the engine
coolant diverter solenoid.

The test indicates Not Active: Device Open.

Expected Result:

OK The test indicates Not Active: Device Open.

The resistance is greater than 5 Ohms for 12 volt


systems and the resistance is greater than 23 Ohms
for 24 volt systems.

Not OK The test indicates Not Active: Device

Proceed to Test Step 8.

Short. Proceed to Test Step 9.

Results:
Proceed to Test Step 10.
Short.

Results:

Repair: Temporarily connect a test ECM.

OK The resistance is within the specifications.

If the test ECM fixes the problem, reconnect the


suspect ECM.

Repair: Check the solenoid connector for corrosion


and for moisture.

If the problem returns, permanently replace the


ECM.

If the problem is intermittent, refer to


Troubleshooting, Electrical Connectors - Inspect.

Verify that the repair eliminates the problem.

STOP.

STOP.

Not OK There is a short circuit in the solenoid.

Test Step 10. Bypass the Harness

Repair: Temporarily connect a new solenoid.

A. Turn the key switch to the OFF position.

If the new solenoid fixes the problem, reconnect


the suspect solenoid.

B. Disconnect the P2 ECM connector and the P702


Engine coolant diverter solenoid connector.

If the problem returns, permanently replace the


solenoid.

C. Remove the wire from P2:8 (engine coolant


diverter solenoid) and P702:1 (engine coolant
diverter solenoid).

Verify that the repair eliminates the problem.


STOP.

Test Step 9. Create an Open at the ECM


A. Turn the key switch to the OFF position.
B. Disconnect the P2 ECM connector.
C. Check the ECM connector for corrosion and for
moisture.
D. Remove the wires from P2:8 (engine coolant
diverter solenoid) and P2:53 (solenoid common).
E. Reconnect the P2 ECM connector.

D. Fabricate two jumper wires that can reach from


the ECM to the engine coolant diverter solenoid.
E. Insert one of the jumper wires into P2:8 and
P702:1.
F. Turn the key switch to the ON position.
G. Access the Special Tests under the Diagnostics
menu.
H. Start the Coolant Diverter Valve Test on Cat ET.
I. Once Cat ET displays the status of the engine
coolant diverter, stop the Coolant Diverter Valve
Test.

242
Troubleshooting Section

SENR9698-09

J. Turn the key switch to the OFF position.

i01939052

K. Disconnect the P2 ECM connector and the P702


Engine coolant diverter solenoid connector.

Engine Pressure Sensor Open


or Short Circuit - Test

L. Remove the wire from P2:53 (solenoid common)


and P702:2 (solenoid common).

SMCS Code: 1917-038; 1923-038; 1924-038

M. Insert the other jumper wire into P2:53 and


P702:2.
N. Turn the key switch to the ON position.
O. Access the Special Tests under the Diagnostics
menu.
P. Start the Coolant Diverter Valve Test on Cat ET.
Q. Once Cat ET displays the status of the engine
coolant diverter, stop the Coolant Diverter Valve
Test.
Expected Result:
The test indicates Active with one or both of the
jumper wires in place.
Results:

OK The bypass harness repaired the problem.


Repair: Repair the suspect wires or replace the
suspect wires.
Verify that the repair eliminates the problem.
STOP.

Not OK The bypass harness did not repair the


problem.

Repair: Verify that the bypass harness is properly


connected.
Check the ECM connector and the solenoid
connector for damage and for moisture.
If the problem is intermittent, refer to
Troubleshooting, Electrical Connectors - Inspect.
STOP.

System Operation Description:


The troubleshooting procedures for the diagnostic
codes of each pressure sensor are identical. The
Engine Control Module (ECM) sends a 5 Volt supply
to terminal A of each sensor. The sensor common
connection is connected to terminal B of each sensor.
The signal voltage from terminal C of each sensor is
sent to the appropriate terminal at the J2/P2 ECM
connector.

SENR9698-09

Illustration 95

243
Troubleshooting Section

g00970385

Schematic for engine pressure sensors

Illustration 96
P2 ECM connector

g00970387

244
Troubleshooting Section

SENR9698-09

Test Step 2. Inspect Electrical Connectors


And Wiring
A. Thoroughly inspect the J2/P2 ECM connector and
the connectors for any suspect sensors. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and the sensor
connectors that are associated with the active
diagnostic code.
Refer to Illustration 96.
C. Check the ECM connector (Allen Head Screw) for
the proper torque of 6.0 Nm (55 lb in).
D. Check the harness and wiring for abrasion and
pinch points from the sensors back to the ECM.
Illustration 97

g00810608

Sensor connector

Test Step 1. Check for Active +5 V Sensor


Supply Diagnostic Codes
A. Connect the electronic service tool to the data link
connector.
B. Turn the key switch to the ON position. Wait at
least 15 seconds for activation of the diagnostic
codes.
C. Verify if any of the following diagnostic codes are
active:

Expected Result:
All connectors, pins and sockets should be completely
coupled and/or inserted and the harness and wiring
should be free of corrosion, abrasion or pinch points.
Results:

OK Proceed to Test Step 3.


Not OK
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.

232-03 5 Volt Supply voltage high

Verify that the repair eliminates the problem.

232-04 5 Volt Supply voltage low

Clear all logged diagnostic codes.

Expected Result:
None of the preceding diagnostic codes are active.
Results:

OK Proceed to Test Step 2.


Not OK
Repair: Perform the following diagnostic
procedure: Troubleshooting, 5 Volt Engine
Pressure Sensor Supply Circuit - Test.
STOP.

STOP.

Test Step 3. Determine the Condition that


is Present
A. Turn the key switch to the ON position. Wait at
least 15 seconds for activation of the diagnostic
codes.
B. Monitor the active diagnostic code screen on the
electronic service tool.
C. Determine if the problem is related to a voltage
high diagnostic code (open circuit) or a voltage
low diagnostic code (short circuit).

SENR9698-09

Expected Result:
Either a voltage low diagnostic code (short circuit)
is active or a voltage high diagnostic code (open
circuit) is active.

245
Troubleshooting Section

Test Step 5. Create an Open Circuit at the


ECM
A. Turn the key switch to the OFF position.

Results:

B. Remove the signal wire of the suspect sensor


from the P2 ECM connector.

Voltage Low (Short) A voltage low diagnostic

C. Turn the key switch to the ON position.

code (short circuit) is active at this time. Proceed


to Test Step 4.

Voltage High (Open) A voltage high diagnostic


code (open circuit) is active at this time. Proceed
to Test Step 7.

Test Step 4. Disconnect the Suspect


Sensor
A. Turn the key switch to the OFF position.
B. Disconnect the sensor with the voltage low
diagnostic code (short circuit).
C. Turn the key switch to the ON position. Wait at
least 15 seconds for activation of the diagnostic
codes.
D. Check for an active voltage high diagnostic code
(open circuit) for the disconnected sensor.

D. Check for active diagnostic codes.


Expected Result:
A voltage high diagnostic code (open circuit)
became active after disconnecting the signal wire.
Results:

OK A voltage low diagnostic code (short

circuit) was active before disconnecting the sensor.


A voltage high diagnostic code (open circuit)
became active after disconnecting the sensor.
Proceed to Test Step 6.

Not OK There is still a voltage low diagnostic


code (short circuit).

Repair: Connect a test ECM.

Expected Result:

If the test ECM fixes the problem, reconnect the


suspect ECM.

A voltage high diagnostic code (open circuit) for the


disconnected sensor is now active.

If the problem returns, permanently replace the


suspect ECM.

Results:

Verify that the repair eliminates the problem.

OK A voltage low diagnostic code (short

STOP.

circuit) was active before disconnecting the sensor.


A voltage high diagnostic code (open circuit)
became active after disconnecting the sensor.

Test Step 6. Check the Resistance of the


Harness

Repair: Temporarily connect a new sensor.

A. Turn the key switch to the OFF position.

Check for active diagnostic codes.

B. Verify that the suspect sensor is disconnected.

If the new sensor fixes the problem, reconnect the


suspect sensor.

C. Measure the resistance between terminal B


(Pressure Sensor Common) and terminal C
(Signal) of the connector for the suspect sensor
on the engine harness.

If the problem returns, permanently install the new


sensor.
Verify that the repair eliminates the problem.
STOP.

Not OK There is a short circuit between the


sensor and the ECM.

Repair: Leave the suspect sensor disconnected.


Proceed to Test Step 5.

Expected Result:
The resistance is greater than 20,000 ohms, or OL
is displayed on the multimeter.
Results:

OK The resistance is greater than 20,000 ohms,


or OL is displayed on the multimeter.

Repair: Check the signal wire for a short to ground.

246
Troubleshooting Section

Repair the faulty wiring or replace the faulty wiring.


Verify that the repair eliminates the problem.
STOP.

Not OK There is a short between the pressure


sensor common and the signal wire.

Repair: Locate the short between the pressure


sensor common and the signal wire.
Repair the faulty wiring or replace the faulty wiring.
Verify that the repair eliminates the problem.
STOP.

Test Step 7. Measure the Sensor Supply


Voltage
A. Turn the key switch to the OFF position.

SENR9698-09

C. Install a jumper wire between terminal C (Signal)


and terminal B (Pressure Sensor Common) of
the sensor connector. Wait at least 15 seconds
for activation of the voltage low diagnostic code
(short circuit).
Expected Result:
A voltage low diagnostic code (short circuit) is
active when the jumper wire is installed. A voltage
high diagnostic code (open circuit) is active when
the jumper wire is removed.
Results:

OK The engine harness and the ECM are OK.


Repair: Temporarily connect a new sensor.
If the new sensor fixes the problem, reconnect the
suspect sensor.

B. Disconnect the suspect sensor.

If the problem returns, permanently replace the


suspect sensor.

C. Turn the key switch to the ON position.

Verify that the repair eliminates the problem.

D. Measure the voltage from terminal A (Pressure


Sensor +5V) to terminal B (Pressure Sensor
Common).

STOP.

Not OK The voltage high diagnostic code

Expected Result:

(open circuit) remains active when the jumper wire


is installed.

The voltage is 5.0 0.16 VDC.

Repair: Remove the jumper wire.

Results:

Proceed to Test Step 9.

OK The sensor supply voltage is correct.


Repair: Leave the sensor disconnected.
Proceed to Test Step 8.

Not OK The sensor supply voltage is out of the


range.

Repair: Check the 5 volt supply wire for an open


circuit.
Repair the faulty wiring or replace the faulty wiring.
Verify that the repair eliminates the problem.
STOP.

Test Step 8. Create a Short Circuit at the


Sensor
A. Turn the key switch to the ON position.
B. Monitor the active diagnostic code screen.

Test Step 9. Create a Short Circuit at the


ECM
A. Turn the key switch to the OFF position.
B. Disconnect the J2/P2 ECM connector.
C. Turn the key switch to the ON position.
A voltage high diagnostic code (open circuit)
should be active for the suspect sensor.
D. Monitor the active diagnostic code screen. Wait at
least 15 seconds for activation of the code.
Note: When the P2 ECM connector is disconnected,
all of the voltage high diagnostic codes (open
circuit) for the pressure sensors will be active. This
is normal.

SENR9698-09

E. Install a jumper wire between the terminal for the


signal of the suspect sensor and the pressure
sensor common on the ECM. Wait at least
15 seconds for activation of the voltage low
diagnostic code (short circuit).
Expected Result:
A voltage low diagnostic code (short circuit) is
active for the suspect sensor.
Results:

OK The ECM is operating properly.


Repair: Leave the P2 ECM connector
disconnected.
Proceed to Test Step 10.

Not OK The voltage high diagnostic code

(open circuit) is still active when the jumper wire


is installed.

247
Troubleshooting Section

Verify that the repair eliminates the problem.


STOP.

Not OK There is a short between the 5 volt


supply and the signal wire.

Repair: Locate the short between the 5 volt supply


and the signal wire.
Repair the faulty wiring or replace the faulty wiring.
Verify that the repair eliminates the problem.
STOP.
i02509549

Engine Running Output Circuit


- Test
SMCS Code: 1901-038

Repair: Temporarily connect a test ECM.

System Operation Description:

If the test ECM fixes the problem, reconnect the


suspect ECM.

This procedure checks the circuit for the engine


running output for proper operation. There are no
diagnostic codes for this output.

If the problem returns, permanently replace the


ECM.

Background Information

Verify that the repair eliminates the problem.


STOP.

Test Step 10. Check the Resistance of


the Harness
A. Turn the key switch to the OFF position.
B. Verify that the suspect sensor is disconnected.
C. Check the resistance between terminal A
(Pressure Sensor +5V) and terminal C (Signal)
of the connector for the suspect sensor on the
engine harness.
Expected Result:
The resistance is greater than 20,000 ohms or OL
is displayed on the multimeter.
Results:

OK There is an open circuit in the signal wire.


Repair: Locate the open in the signal wire.
Repair the faulty wiring or replace the faulty wiring.

The Engine Running Output activates when the


engine is running. This can be used to prevent the
engagement of the starting motor while the engine is
running. The Engine Control Module (ECM) can be
connected to a relay that disables the starter. The
relay is normally closed so cranking can be achieved
immediately at powerup. During cranking, the ECM
energizes the output for the Engine Running Output
once engine rpm reaches 50 rpm below low idle. The
output is de-energized when the engine speed falls
by 100 rpm below the programmed low idle. The low
idle rpm is programmable. The range for low idle is
between 600 rpm and 750 rpm.
The Engine Running Output parameter can be
programmed to J1/P1:10, J1/P1:12, or J1/P1:13.

248
Troubleshooting Section

SENR9698-09

g00656153

Illustration 98
Schematic for the engine running output

Test Step 1. Inspect the Electrical


Connectors and the Wiring

Illustration 99

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

A. Thoroughly inspect the J1/P1 ECM connector


and the firewall bulkhead connectors. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.

SENR9698-09

249
Troubleshooting Section

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.

Test Step 2. Determine the Configuration


of the Engine Running Output
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
B. Turn the keyswitch to the ON position.
C. Use Cat ET to check the configuration parameter
for Engine Running Output. Record the
parameter setting.
D. Verify that the Engine Running Output parameter
is programmed to reflect the current wiring for
the circuit.
E. Turn the keyswitch to the OFF position.
Expected Result:
The parameter is programmed to reflect the current
wiring for the circuit.
Illustration 100

g01256249

Terminal locations at the P1 ECM connector for the engine running


output
(P1-10) Output No. 2
(P1-12) Output No. 3
(P1-13) Output No. 4

B. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the relay circuit.
C. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
D. Check the harness and wiring for abrasion and for
pinch points from the relay to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.
Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 2.

Results:

OK The parameter is programmed to reflect

the current wiring for the circuit. The relay for the
engine running output is wired correctly. Proceed
to Test Step 3.

Not OK The parameter is not programmed to


reflect the current wiring for the circuit.

Repair: The parameter is not programmed


correctly. Update the customer specified parameter
in order to match the correct wiring for the circuit.
STOP.

Test Step 3. Use Caterpillar ET to Check


the Relay
A. Turn the keyswitch to the ON position.
B. Access the Engine Running Output Special Test
on ET. The Engine Running Output Special Test
will power the output for the Engine Running
Output when the test is active.

250
Troubleshooting Section

C. Begin the Engine Running Output Special Test


and listen for the relay to click. You may need to
be near the relay in order to hear the click.
D. Turn the keyswitch to the OFF position.
Expected Result:
An audible click is heard at the relay when the test
is activated.

SENR9698-09

H. Activate the Engine Running Output Special Test


while you watch the voltage test lamp. For correct
operation of the ECM, the test lamp will illuminate
during the test. Deactivate the test and observe
the voltage test lamp again. The test lamp will turn
off as the test deactivates.
I. Stop the special test.

Results:

Note: A multimeter can not be used in place of the


voltage test lamp when the ECM outputs are being
tested.

OK An audible click is heard at the relay.

J. Turn the keyswitch to the OFF position.

Repair: The relay appears to be operating


correctly at this time. There may be an intermittent
electrical problem in the harness or in a connector.
If an intermittent problem is suspected, refer to
Troubleshooting, Electrical Connectors - Inspect
for information that is related to troubleshooting
intermittent electrical problems.
STOP.

Not OK An audible click is not heard at the

relay when the test is activated. The relay is not


energizing. Proceed to Test Step 4.

Test Step 4. Check for Proper Operation


of the ECM
A. Disconnect the J1/P1 ECM connector .
B. Install a 208-0059 Adapter Cable As (70-PIN
BREAKOUT) at the J1/P1 ECM connector .
C. If the Engine Running Output is programmed to
J1/P1:10, remove the wire from terminal location
P1-10 at the ECM connector. Connect a voltage
test lamp between terminal 10 (output No. 2) and
terminal 65 (Battery) of the breakout T.
D. If the Engine Running Output is programmed to
J1/P1:12, remove the wire from terminal location
P1-12 at the ECM connector. Connect a voltage
test lamp between terminal 12 (output No. 3) and
terminal 65 (Battery) of the breakout T.
E. If the Engine Running Output is programmed to
J1/P1:13, remove the wire from terminal location
P1-13 at the ECM connector. Connect a voltage
test lamp between terminal 13 (output No. 4) and
terminal 65 (Battery) of the breakout T.
F. Turn the keyswitch to the ON position.
G. Access the appropriate Engine Running Output
Special Test on Cat ET.

K. Restore the wiring to the original configuration.


Expected Result:
The voltage test lamp turns on when the Engine
Running Output Special Test is active. The voltage
test lamp also turns off when the Engine Running
Output Special Test is not active.
Results:

OK The voltage test lamp turns on when the

Engine Running Output Special Test is active.


The voltage test lamp also turns off when the
Engine Running Output Special Test is not active.

Repair: The ECM is OK. The problem is in the


wiring harness or in a connector between the ECM
connector and the relay. Check for a problem
with the relay. Repair the wiring harness and/or
replace the wiring harness. Send the vehicle to the
OEM dealer for repair, if necessary. Verify that the
original condition is resolved.
STOP.

Not OK The voltage test lamp did not turn on


according to the above requirements.

Repair: There is a problem with the ECM. Perform


the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Recheck the circuit in order to ensure that the
original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.

SENR9698-09

251
Troubleshooting Section

If the problem is not resolved with the test ECM,


install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.
i02509610

Engine Shutdown Output


Circuit - Test
SMCS Code: 1901-038
System Operation Description:
This procedure checks the circuit for the engine
shutdown output for proper operation. There are no
diagnostic codes for this output.
Background Information
The Engine Shutdown Output allows the Engine
Control Module (ECM) to shut down portions of the
vehicles electrical system at shutdown. This reduces
the consumption of electrical power (battery drain)
after the shutdown. The system activates a relay
(engine shutdown relay) when the engine begins
running. This permits the driver to turn the keyswitch
to the OFF position without causing the engine
to shutdown. When the shutdown delay time has
expired for the idle shutdown timer feature, the ECM
initiates the shutdown by removing power from the
relay for the engine shutdown output. This interrupts
the power to the ECM and the engine shuts down.
The current draw on the batteries is then dependent
on the items that are not powered through the relay
circuit for the shutdown output.
The Engine Shutdown Output parameter can be
programmed to J1/P1:10, J1/P1:12, or J1/P1:13.

252
Troubleshooting Section

SENR9698-09

g00656155

Illustration 101
Schematic for the engine shutdown output

Test Step 1. Inspect the Electrical


Connectors and the Wiring

Illustration 102

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

A. Thoroughly inspect the J1/P1 ECM connector


and the firewall bulkhead connectors. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.

SENR9698-09

253
Troubleshooting Section

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.

Test Step 2. Determine the Configuration


of the Engine Shutdown Output
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector.
B. Turn the keyswitch to the ON position.
C. Use Cat ET to check the configuration parameter
for Engine Shutdown Output. Record the
parameter setting.
D. Verify that the Engine Shutdown Output
parameter is programmed to reflect the current
wiring for the circuit.
E. Turn the keyswitch to the OFF position.
Expected Result:
The parameter is programmed to reflect the current
wiring for the circuit.
Illustration 103

g01256249

Terminal locations at the P1 ECM connector for the engine


shutdown output
(P1-10) Output No. 2
(P1-12) Output No. 3
(P1-13) Output No. 4

B. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the relay circuit.
C. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
D. Check the harness and wiring for abrasion and for
pinch points from the relay to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.
Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 2.

Results:

OK The parameter is programmed to reflect

the current wiring for the circuit. The relay for the
engine shutdown output is wired correctly. Proceed
to Test Step 3.

Not OK The parameter is not programmed to


reflect the current wiring for the circuit.

Repair: The parameter is not programmed


correctly. Update the customer specified parameter
in order to match the correct wiring for the circuit.
STOP.

Test Step 3. Use Caterpillar ET to Check


the Relay
A. Turn the keyswitch to the ON position.
B. Access the Engine Shutdown Output Special
Test on Cat ET. The Engine Shutdown Output
Special Test will enable the Engine Shutdown
Output when the test is active.

254
Troubleshooting Section

C. Begin the Engine Shutdown Output Special Test


and listen for the relay to click. You may need to
be near the relay in order to hear the click.
D. Turn the keyswitch to the OFF position.
Expected Result:
An audible click is heard at the relay when the test
is activated.

SENR9698-09

H. Activate the Engine Shutdown Output Special


Test while you watch the voltage test lamp. For
correct operation of the ECM, the test lamp will
illuminate during the test. Deactivate the test and
observe the voltage test lamp again. The test lamp
will turn off as the test deactivates.
I. Stop the special test.

Results:

Note: A multimeter can not be used in place of the


voltage test lamp when the ECM outputs are being
tested.

OK An audible click is heard at the relay.

J. Turn the keyswitch to the OFF position.

Repair: The relay appears to be operating


correctly at this time. There may be an intermittent
electrical problem in the harness or in a connector.
If an intermittent problem is suspected, refer to
Troubleshooting, Electrical Connectors - Inspect
for information that is related to troubleshooting
intermittent electrical problems.
STOP.

Not OK An audible click is not heard at the relay


when the test is activated. Proceed to Test Step 4.

Test Step 4. Check for Proper Operation


of the ECM
A. Disconnect the J1/P1 ECM connector .
B. Install a 208-0059 Adapter Cable As (70-PIN
BREAKOUT) at the J1/P1 ECM connector .
C. If the Engine Shutdown Output is programmed to
J1/P1:10, remove the wire from terminal location
P1-10 at the ECM connector. Connect a voltage
test lamp between terminal 10 (output No. 2) and
terminal 65 (Battery) of the breakout T.
D. If the Engine Shutdown Output is programmed to
J1/P1:12, remove the wire from terminal location
P1-12 at the ECM connector. Connect a voltage
test lamp between terminal 12 (output No. 3) and
terminal 65 (Battery) of the breakout T.
E. If the Engine Shutdown Output is programmed to
J1/P1:13, remove the wire from terminal location
P1-13 at the ECM connector. Connect a voltage
test lamp between terminal 13 (output No. 4) and
terminal 65 (Battery) of the breakout T.
F. Turn the keyswitch to the ON position.
G. Access the appropriate Engine Shutdown Output
Special Test on Cat ET.

K. Restore the wiring to the original configuration.


Expected Result:
The voltage test lamp turns on when the Engine
Shutdown Output Special Test is active. The voltage
test lamp turns off when the Engine Shutdown
Output Special Test is not active.
Results:

OK The voltage test lamp turns on when the

Engine Shutdown Output Special Test is active.


The voltage test lamp turns off when the Engine
Shutdown Output Special Test is not active.

Repair: The ECM is OK. The problem is in the


wiring harness or in a connector between the ECM
connector and the relay. Check for a problem
with the relay. Repair the wiring harness and/or
replace the wiring harness. Send the vehicle to the
OEM dealer for repair, if necessary. Verify that the
original condition is resolved.
STOP.

Not OK The voltage test lamp did not turn on


according to the above requirements.

Repair: There is a problem with the ECM. Perform


the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Recheck the circuit in order to ensure that the
original problem has been resolved.
If the problem is resolved with the test ECM,
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.

SENR9698-09

255
Troubleshooting Section

If the problem is not resolved with the test ECM,


install the original ECM. There is a problem in
the wiring.
Send the vehicle to the OEM dealer for repair,
if necessary.
STOP.
i02506902

Engine Speed/Timing Sensor


Circuit - Test
SMCS Code: 1912-038
System Operation Description:
Use this procedure to troubleshoot any suspect
problems with the following sensors:

Primary engine speed/timing sensor


Secondary engine speed/timing sensor
This procedure covers the following diagnostic codes:

22-11 Primary to Secondary Engine Speed Signal


Calibration

64-08 Secondary Engine Speed loss of signal


190-08 Primary Engine Speed Loss of Signal
The engine uses two engine speed/timing sensors.
The secondary engine speed/timing sensor
monitors the camshaft gear and the primary engine
speed/timing sensor monitors the crankshaft gear.
Both of the engine speed/timing sensors detect the
reference for engine speed and timing from a unique
pattern on the respective gears as the gears rotate.
Under normal operation, the secondary engine
speed/timing sensor is used to determine timing
for starting purposes. The secondary engine
speed/timing sensor is used to determine when
the piston in the No. 1 cylinder is at the top of the
compression stroke. When the timing has been
established, the primary engine speed/timing sensor
is then used to determine engine speed and the
signal from the secondary engine speed/timing
sensor is ignored.

After locating the No. 1 cylinder, the ECM triggers


each injector in the correct firing order and at the
correct unit injector timing. The actual timing and
duration of each injection is based on engine rpm
and on load. If the engine is running and the signal
from the primary engine speed/timing sensor is
lost, a slight change in engine performance will be
noticed when the ECM performs the changeover to
the secondary engine speed/timing sensor. Loss of
the signal from the secondary engine speed/timing
sensor during engine operation will not result in any
noticeable change in engine performance. However,
if the signal from the secondary engine speed/timing
sensor is not present during start-up the following
conditions may exist:

The engine may require a slightly longer period


of time to start-up.

The engine may run rough for a few seconds until

the ECM determines the proper firing order by


using the primary engine speed/timing sensor only.

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 of the
engine by the ECM. The loss of the signal from both
of the sensors during start-up will prevent the engine
from starting.
Both sensors are magnetic sensors with an integral
connector. The two sensors are not interchangeable.
Do not switch the positions of the sensor. If the
sensors are replaced, a timing calibration is not
necessary for the engine.
Note: When the sensors are being installed,
complete all of the following tasks:

Lubricate the O-ring with oil.


Ensure that the sensor is fully seated into the
engine before tightening the bracket bolt.

Ensure that the connector is properly latched.


Ensure that the harness is properly secured, and

ensure that the tie-wraps are placed in the correct


location.

256
Troubleshooting Section

SENR9698-09

g01255093

Illustration 104
C-15 schematic for engine speed/timing

g01255097

Illustration 105
C-11 and C-13 schematic for engine speed/timing

Test Step 1. Inspect Electrical Connectors


and Wiring
A. Turn the keyswitch to the OFF position.

Illustration 106

g01146562

Typical C-11 and C-13 sensor locations (left side engine view)
(1) J2/P2 ECM connector
(2) Secondary engine speed/timing sensor
(3) Primary engine speed/timing sensor

SENR9698-09

257
Troubleshooting Section

Illustration 108
Typical C-15 sensor locations (left side engine view)
(4) J2/P2 ECM connector
(5) Secondary engine speed/timing sensor
(6) Primary engine speed/timing sensor

Illustration 107
ECM connector for the C-11 and C-13
(P2-48)
(P2-49)
(P2-58)
(P2-59)

Secondary engine speed/timing signal (+)


Secondary engine speed/timing signal ()
Primary engine speed/timing signal (+)
Primary engine speed/timing signal ()

g01146574

g01255124

258
Troubleshooting Section

SENR9698-09

Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
Results:

OK The harness and wiring are OK. Proceed


to Test Step 2.

Not OK There is a problem in the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.

Test Step 2. Check for Active Diagnostic


Codes
A. Connect the Caterpillar Electronic Technician (
ET) to the service tool connector.
B. Turn the keyswitch to the ON position.
C. Verify whether any of the following diagnostic
codes are active or logged:
Illustration 109

g01146574

ECM connector for the C-15


(P2-48)
(P2-49)
(P2-58)
(P2-59)

Primary engine speed/timing signal (+)


Primary engine speed/timing signal ()
Secondary engine speed/timing signal (+)
Secondary engine speed/timing signal ()

B. Thoroughly inspect ECM connector (1). Also,


thoroughly inspect the connectors for sensors (2)
and (3).
Refer to the diagnostic functional test
Troubleshooting, Electrical Connectors - Inspect
for details.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and the sensor
connectors that are associated with the circuit.
D. Check the ECM connector (allen head screw)
for the proper torque. Refer to the diagnostic
functional test Troubleshooting, Electrical
Connectors - Inspect for details.
E. Check the harness and wiring for abrasions and
for pinch points from the sensors back to the ECM.

22-11 Primary to Secondary Engine Speed


Signal Calibration

64-08 Secondary Engine Speed loss of signal


190-08 Primary Engine Speed Loss of Signal
D. If the diagnostic code is logged but not active, run
the engine until the engine is at normal operating
temperature. The problem may only occur when
the engine is at the normal operating temperature.
E. If the engine will not start, monitor the engine
speed on Cat ET while the engine is being
cranked. Cat ET may need to be powered from
another battery while the engine is being cranked
in order to ensure that Cat ET does not reset.
Note: Upon initial cranking, the status for engine
speed may indicate that the engine speed signal is
abnormal. This message will be replaced with an
engine speed once the ECM is able to calculate a
speed from the signal.

SENR9698-09

259
Troubleshooting Section

Expected Result:
One or more of the diagnostic codes that are listed
above are logged or active.
Results:

Active Code There is an active diagnostic code

or a logged diagnostic code. Proceed to Test Step


4.

No Engine rpm Engine rpm is not indicated on


Cat ET. Proceed to Test Step 3.

Test Step 3. Inspect the Sensor Assembly

B. Inspect the bracket in order to ensure that the


installation allows the flange of the sensor to be
flush against the engine.
Verify that the bracket is not bent.
Note: The bracket cannot be replaced separately.
C. Ensure that the O-ring has been installed on
the sensor, and ensure that the O-ring is free of
damage.
D. If the following diagnostic code is active, there
may be a problem with the assembly of the
camshaft gear or the crankshaft gear:

22-11
Expected Result:
The sensors and the bracket are properly installed.
Results:

OK The sensors and the bracket are properly


installed. Proceed to Test Step 4.

Not OK
Repair: Perform the following procedure in order
to properly install the sensors and the bracket:
1. Loosen the bolt that holds the sensor mounting
bracket to the engine.
2. Seat the sensor and tighten the bolt.
If the sensor will not seat, repair the sensor or
replace the sensor, as required.
Note: The sensor must not be removed from the
bracket.
3. Ensure that the sensor is properly oriented
and that the harness is secured in the proper
location.
4. Verify that the repair eliminates the problem.
Illustration 110

g01255131

Engine speed/timing sensors


(7) Bracket
(8) Secondary speed/timing sensor
(9) Mounting plate
(10) O-ring seals
(11) Bracket
(12) Primary speed/timing sensor

A. The flange of the sensor should be flush against


the engine in order to ensure proper operation.

STOP.

Test Step 4. Measure the Sensor


Resistance through the Engine Harness
A. Turn the keyswitch to the OFF position.
B. Use the following procedure to measure the circuit
resistance for the primary engine speed/timing
sensor:

260
Troubleshooting Section

a. Measure the resistance between the primary


engine speed/timing + terminal and the
primary engine speed/timing terminal on
the P2 connector.
Note: Check for an intermittent problem (open or
short) by moving the harness while you measure the
resistance. Pull the wires that are directly behind the
sensors and shake the wires that are directly behind
the sensors.
Resistance ............................. 75 to 230 Ohms
C. Use the following procedure to measure the circuit
resistance for the secondary engine speed/timing
sensor:
a. Measure the resistance between the
secondary engine speed/timing + terminal
and the secondary engine speed/timing
terminal on the P2 connector.
Note: Check for an intermittent problem (open or
short) by moving the harness while you measure the
resistance. Pull the wires that are directly behind the
sensors and shake the wires that are directly behind
the sensors.
Resistance ........................ 600 to 1800 Ohms
Expected Result:
The readings agree with the values that are listed
above.
Results:

OK Neither a short circuit nor an open circuit is


indicated. Proceed to Test Step 6.

Not OK The resistance is not within the

acceptable range when the circuit resistance is


measured through the engine harness. Proceed
to Test Step 5.

Test Step 5. Measure the Resistance of


the Sensor
A. Turn the keyswitch to the OFF position.
B. Check the harness and the wiring for abrasion and
pinch points from the sensor back to the ECM.
C. Disconnect the suspect sensor from the engine
harness.
D. Thoroughly inspect the connector for the
suspect engine speed/timing sensor. Refer to
the diagnostic functional test Troubleshooting,
Electrical Connectors - Inspect for details.

SENR9698-09

E. Use the following procedure to measure the


resistance of the primary engine speed/timing
sensor:
a. Disconnect the primary engine speed/timing
sensor connector.
b. Measure the resistance between terminal 1
and terminal 2 of the sensor.
Resistance ............................. 75 to 230 Ohms
F. Use the following procedure to measure the
resistance of the secondary engine speed/timing
sensor:
a. Disconnect the secondary engine speed/timing
sensor connector .
b. Measure the resistance between terminal 1
and terminal 2 of the sensor.
Resistance ........................ 600 to 1800 Ohms
Expected Result:
The resistance measurement for the suspect sensor
is within the specification.
Results:

OK The resistance measurement for the suspect


sensor is within the specification. The sensors
resistance measurement at the P2 connector was
incorrect. There is a problem with the harness.

Repair: Repair the harness or replace the harness.


Verify that the problem is resolved.
STOP.

Not OK The resistance measurement for the


suspect sensor is not within the specification.
There is a problem with the sensor.
Repair: Replace the sensor assembly.
Do not switch the positions of the sensors.
The sensors are not interchangeable. A timing
calibration is not required when the sensors are
replaced. Perform the following procedure in order
to replace the sensor assembly:
1. Lubricate the O-ring seal with oil.
2. Fully seat the sensor into the housing.
3. Tighten the bracket bolt.

SENR9698-09

4. Connect the connector and verify that the latch


tab of the connector is latched on both sides.
5. Ensure that the harness is properly secured,
and ensure that the harness is attached to the
harness clip.
Verify that the problem is resolved.
STOP.

Test Step 6. Check the ECM


A. Turn the keyswitch to the OFF position.
B. Temporarily connect a test ECM.
C. Start the engine. Run the engine in order to repeat
the conditions when the problem occurs.
D. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
E. If the problem returns with the suspect ECM,
replace the ECM.
Verify that the repair eliminates the problem.
Expected Result:
The problem remains with the suspect ECM.
Results:

OK
Repair: If the problem is resolved with the test
ECM and the problem returns with the suspect
ECM, replace the ECM.
Verify that the repair eliminates the problem.
STOP.

261
Troubleshooting Section

i01942352

Engine Temperature Sensor


Open or Short Circuit - Test
SMCS Code: 1906-038; 1921-038; 1922-038;
1928-038
System Operation Description:
The troubleshooting procedures for the diagnostic
codes of each temperature sensor are identical.
The temperature sensors are sensors that have
two terminals. Terminal 2 is the common wire that
is shared between all temperature sensors. The
common wire provides a path to ground. Terminal
1 connects to a unique terminal on the J2/P2 ECM
connector for each temperature sensor. 5 volts are
supplied to the temperature sensor through terminal
1.

262
Troubleshooting Section

Illustration 111

SENR9698-09

g00970545

Schematic for engine temperature sensors

Test Step 1. Inspect Electrical Connectors


and Wiring

Illustration 112
P1 and P2 ECM connectors

g00970546

SENR9698-09

A. Thoroughly inspect the J2/P2 ECM connector


and the suspect sensor connector. Refer to
Troubleshooting, Electrical Connections - Inspect
for details.
B. Perform a 45 N (10 lb) pull test on each of the
wires in the sensor connector and in the ECM
connector that are associated with the active
diagnostic code.
Refer to Illustration 112.
C. Verify that the latch tab of the connector is properly
latched.

263
Troubleshooting Section

Results:

Voltage High (Open) A voltage high diagnostic


code (open circuit) is active at this time. Proceed
to Test Step 6.

Voltage Low (Short) A voltage low diagnostic

code (short circuit) is active at this time. Proceed


to Test Step 3.

Test Step 3. Disconnect the Suspect


Sensor
A. Turn the key switch to the OFF position.

D. Check the ECM Connector (allen head screw) for


the proper torque of 6.0 Nm (55 lb in).

B. Disconnect the sensor with the voltage low


diagnostic code (short circuit).

E. Check the harness and wiring for abrasion and for


pinch points from the sensor to the ECM.

C. Turn the key switch to the ON position. Wait at


least 15 seconds for activation of the diagnostic
codes.

Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, or of pinch points.
Results:

OK Proceed to Test Step 2.


Not OK
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.

Test Step 2. Determine the Condition that


is Present
A. Connect the Caterpillar Electronic Technician (Cat
ET) to the data link connector.
B. Turn the key switch to the ON position. Wait at
least 15 seconds for activation of the diagnostic
codes.
C. Check for active diagnostic codes on Cat ET.
D. Determine if the problem is related to a voltage
high diagnostic code (open circuit) or a voltage
low diagnostic code (short circuit).
Expected Result:
A voltage high diagnostic code (open circuit) or a
voltage low diagnostic code (short circuit) is active.

D. Check for an active voltage high diagnostic code


(open circuit) on Cat ET.
Expected Result:
A voltage high diagnostic code (open circuit) for the
suspect sensor is now active.
Results:

OK A voltage high diagnostic code (open


circuit) for the suspect sensor is now active.
Repair: Temporarily connect a new sensor.
If the new sensor fixes the problem, reconnect the
suspect sensor.
If the problem returns, permanently replace the
sensor.
Verify that the repair eliminates the problem.
STOP.

Not OK There is a short circuit between the


sensor harness connector and the ECM.
Repair: Leave the sensor disconnected.
Proceed to Test Step 4.

Test Step 4. Disconnect the ECM


Connector
A. Turn the key switch to the OFF position.
B. Disconnect the J2/P2 ECM connector. Thoroughly
inspect both halves of the connector for signs of
corrosion or of moisture.

264
Troubleshooting Section

Note: If the Ambient Air Temperature Sensor is being


tested, a 140-2266 Cable (Seventy-Pin Breakout) is
required in order to maintain the battery connections.
C. Turn the key switch to the ON position. Wait at
least 15 seconds for activation of the code.
D. Check for active diagnostic codes on Cat ET.
Note: When the J2/P2 ECM connector is
disconnected, all of the voltage high diagnostic
codes (open circuit) for the temperature sensors will
be active. This is normal.
Expected Result:
Voltage high diagnostic codes (open circuit)
are active when the J2/P2 ECM connector is
disconnected.
Results:

OK The ECM is working properly.


Repair: Leave the ECM connector disconnected.
Proceed to Test Step 5.

Not OK A voltage low diagnostic code (short


circuit) is still active for the suspect sensor.
Repair: Temporarily connect a test ECM.
If the test ECM fixes the problem, reconnect the
suspect ECM.
If the problem returns, permanently replace the
suspect ECM.
Verify that the repair eliminates the problem.
STOP.

Test Step 5. Check the Resistance

SENR9698-09

Repair: Check the supply wire of the suspect


sensor for a short to ground.
Repair the faulty wiring or replace the faulty wiring.
Verify that the repair eliminates the problem.
STOP.

Not OK There is a short between the supply wire


and the common wire.

Repair: Locate the short between the supply wire


and the common wire.
Repair the faulty wiring or replace the faulty wiring.
Verify that the repair eliminates the problem.
STOP.

Test Step 6. Create a Short at the Sensor


A. Fabricate a jumper wire 150 mm (6 inch) long.
B. Install the jumper wire between terminal 1 and
terminal 2 of the sensor connector.
C. Turn the key switch to the ON position.
D. Monitor the active diagnostic code screen.
Expected Result:
A voltage low diagnostic code (short circuit) is
active when the jumper wire is installed.
Results:

OK A voltage low diagnostic code (short circuit)


is active.

Repair: Temporarily connect a new sensor.

A. Turn the key switch to the OFF position.

If the new sensor fixes the problem, reconnect the


suspect sensor.

B. Verify that the suspect sensor and the ECM


connector are disconnected.

If the problem returns, permanently replace the


suspect sensor.

C. Measure the resistance between terminal 1 and


terminal 2 of the sensor connector.

Verify that the repair eliminates the problem.

Expected Result:
The resistance is greater than 20,000 Ohms or OL
is displayed on the multimeter.
Results:

OK There is a problem with the supply wire.

STOP.

Not OK A voltage high diagnostic code (open


circuit) is still active.

Repair: Remove the jumper wire.


Proceed to Test Step 7.

SENR9698-09

265
Troubleshooting Section

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.


D. Install the jumper wire between the terminal for
the sensor supply of the suspect sensor and the
terminal for the sensor common.

Not OK The voltage is not within the range.


Repair: If the voltage is above 5.5 VDC, check the
supply wire for a short to a voltage source.

E. Turn the key switch to the ON position.

If the voltage is below 4.5 VDC, check the supply


wire for an open circuit.

F. Monitor the active diagnostic code screen.

Repair the faulty wiring or replace the faulty wiring.

Expected Result:

Verify that the repair eliminates the problem.

A voltage low diagnostic code (short circuit) is


active when the jumper wire is installed.

STOP.

Results:

i02504775

is active when the jumper wire is installed.

Fan Override Switch Circuit Test

Repair: Reconnect the P2 ECM connector.

SMCS Code: 7332-038

OK A voltage low diagnostic code (short circuit)

Not OK A voltage high diagnostic code (open


circuit) is still active.

Repair: Temporarily connect a test ECM.


If the test ECM fixes the problem, reconnect the
suspect ECM.
If the problem returns, permanently replace the
suspect ECM.
Verify that the repair eliminates the problem.
STOP.

Test Step 8. Check the Voltage at the


Sensor
A. Verify that the sensor is disconnected.
B. Turn the key switch to the ON position.
C. Measure the voltage between terminal 1 of the
sensor harness and chassis ground.

System Operation Description:


Use this procedure under the following situation:
The circuit for the fan override switch is suspected of
incorrect operation.
Note: This procedure is intended for troubleshooting
a fan override switch that is connected to an input
circuit on the Engine Control Module (ECM). This
procedure is not intended for a fan override switch
that is installed in the output circuit for the cooling fan.
The following background information is related
to this procedure:
The ECM can use various inputs in a number of ways.
The inputs depend on the parameter programming.
Certain features are available on several different
inputs. The configuration for the fan override switch
must match the actual switch installation in order for
the fan override switch to function properly.
Fan Override Switch

The voltage is 5.0 0.5 volts.

The fan override switch is used to turn on the cooling


fan. Using a fan override switch can provide the
following benefits:

Results:

Helpful for troubleshooting problems with the

Expected Result:

OK The voltage is within the range.


Repair: Check for an open circuit in the common
wire.

cooling fan

Additional engine cooling

266
Troubleshooting Section

SENR9698-09

Additional braking horsepower under certain


operating conditions

The circuit for the fan override switch can be installed


on one of four different inputs. The desired input for
the fan circuit is selected by setting the Fan Override
Switch parameter. If this parameter is set to None
(default), the feature is disabled. If the feature is
enabled, the switch circuit should be connected to
the input that is specified. The programmable options
for the fan override switch are J1/P1:7, J1/P1:47,
J1/P1:6, and J1/P1:46.
Note: The wiring for your particular application
may be slightly different. The circuits for the sensor
return are used interchangeably by the OEM of the
vehicle. The following circuits for the sensor return
are common internally to the ECM:

The Input Sensor Common 1 outputs at terminal


location J1-18

The Input Sensor Common 2 outputs at terminal


location J1-3

The AP Sensor/Switch Sensor Common outputs


at terminal location J1-5

g01253914

Illustration 113
Schematic for the fan override switch

Test Step 1. Check the Status of the Fan


Override Switch

Note: If the status for the Fan Override Switch


indicates Not Installed, then the Fan Override
Switch parameter has not been programmed.

A. Connect Caterpillar Electronic Technician (ET) to


the service tool connector.

D. Turn the keyswitch to the OFF position.

B. Turn the keyswitch to the ON position.

Expected Result:

C. Monitor the status for the Fan Override Switch


while the fan override switch is toggled to the ON
position and the OFF position.

Cat ET is reporting the correct status for the switch.

The correct status for the Fan Override Switch


is On when the switch is in the ON position. The
correct status for the Fan Override Switch is Off
when the switch is in the OFF position.

Results:

OK Cat ET is reporting the correct status for


the switch.

SENR9698-09

Repair: The fan override switch appears to


operating correctly at this time. There may be
an intermittent electrical problem in the harness
or in a connector. If an intermittent problem is
suspected, refer to Troubleshooting, Electrical
Connectors - Inspect for information that is related
to troubleshooting intermittent electrical problems.

267
Troubleshooting Section

Test Step 3. Check the Electrical


Connectors and the Wiring

STOP.

Not OK Cat ET is not reporting the correct status


for the switch. The ECM is not reading the change
in switch status. Proceed to Test Step 2.

Test Step 2. Determine the Configuration


of the Fan Override Switch
A. Determine if the fan override switch is wired
directly to the ECM, or if the switch position is
reported on the J1939 data link.
B. Verify that the Fan Override Switch parameter
is programmed to reflect the current wiring for
the circuit.
Expected Result:
The fan override switch is wired directly to the ECM.
Results:

OK The fan override switch is wired directly to


the ECM. Proceed to Test Step 3.

Not OK The fan override switch is not wired


directly to the ECM.

Repair: The switch position is reported to the


ECM via the J1939 data link. Verify that the
Fan Override Switch parameter is programmed
to J1939 - Body Controller, to J1939 - Cab
Controller, or to J1939 - Instrument Cluster.
Refer to Troubleshooting, Powertrain Data Link
Circuit - Test.
STOP.

Illustration 114

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

A. Thoroughly inspect the J1/P1 ECM connector, the


connectors, and the firewall bulkhead connectors.
Refer to Troubleshooting, Electrical Connectors Inspect for details.

268
Troubleshooting Section

SENR9698-09

Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 4.

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.
STOP.

Test Step 4. Create a Short Circuit at the


Switch
A. Fabricate a jumper wire that is long enough to
create a short circuit across the terminals at the
harness connector for the fan override switch.
B. Disconnect the switch from the harness.
C. Install the jumper wire across the two switch
terminals at the harness connector for the fan
override switch.
D. Turn the keyswitch to the ON position.

Illustration 115

g01253945

Terminal locations at the P1 ECM connector for the fan override


switch
(P1-5) AP sensor/switch sensor return
(P1-6) Input No. 6
(P1-7) Input No. 4
(P1-46) Input No. 7
(P1-47) Input No. 5

E. Use Cat ET to monitor the status of the Fan


Override Switch. While the status for the Fan
Override Switch is monitored, remove the jumper
wire and then insert the jumper wire.
The correct status for the Fan Override Switch is
On when the jumper wire is inserted. The correct
status for the Fan Override Switch is Off when
the jumper wire is removed.
F. Turn the keyswitch to the OFF position.

B. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the suspect switch circuit.

Expected Result:

C. Check the allen head screw for each of the


ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.

Results:

Cat ET is reporting the correct status for the switch.

OK Cat ET is reporting the correct status.

D. Check the harness and the wiring for abrasion and


pinch points from the battery to the ECM. Then,
check the wiring from the keyswitch to the ECM.

Repair: The wiring harness and the ECM are OK.


There is a problem with the switch. Replace the fan
override switch. Verify that the repair eliminates
the problem.

Expected Result:

STOP.

All connectors, pins and sockets are completely


coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.

SENR9698-09

Not OK Cat ET does not report the correct status.


There is a problem in the wire harness between
the fan override switch and the ECM. There may
be a problem with the ECM. Restore the wiring to
the original configuration. Proceed to Test Step 5.

Test Step 5. Check for Proper Operation


of the ECM
A. Disconnect the J1/P1 ECM connectors.

269
Troubleshooting Section

Repair: The ECM is not reading the switch input


properly. There is a problem with the ECM. Perform
the following procedure:
1. Temporarily connect a test ECM.
Refer to Troubleshooting, Replacing the ECM.
2. Recheck the circuit in order to ensure that the
original problem has been resolved.

B. Fabricate two jumper wires that are long enough


to create a test circuit at the ECM connector.
Crimp a connector socket to one end of each of
the jumper wires.

If the problem is resolved with the test ECM,


install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify
that the problem is resolved.

C. Remove the wire from the terminal location at


the P1 ECM connector that is the input for the
fan override switch. Also, remove the wire from
terminal location P1-5 (AP sensor/switch sensor
return). Install one of the jumper wires into each of
these terminal locations.

If the problem is not resolved with the test ECM,


install the original ECM. There is a problem in
the wiring.

D. Connect the J1/P1 ECM connectors.

Send the vehicle to the OEM dealer for repair,


if necessary.
STOP.

E. Turn the keyswitch to the ON position.


F. Monitor the status of the Fan Override Switch
while you short the loose ends of the jumper wires.
Provide an open circuit for the loose ends of the
jumper wires. Recheck the switch status.
The correct status for the Fan Override Switch is
On when the jumper wires are shorted together.
The correct status for the Fan Override Switch is
Off when the jumper wires are open.
G. Turn the keyswitch to the OFF position.
H. Restore all wiring to the original configuration.
Expected Result:
Cat ET is reporting the correct status for the switch.
Results:

OK Cat ET is reporting the correct status for


the switch.

Repair: The ECM is functioning properly at this


time. There is a problem in the OEM wiring harness
that is between the ECM connector and the fan
override switch. Repair the circuit or send the
vehicle to the OEM dealer for repairs.
STOP.

Not OK Cat ET does not report the correct status


for the switch.

i02186010

Idle Shutdown Timer - Test


SMCS Code: 1901-038
System Operation Description:
Idle Shutdown Timer
The Idle Shutdown Timer is intended to improve
fuel economy by limiting idling time.
The Idle Shutdown Timer is a Customer Specified
Parameter that may be programmed for any period
from 3 to 1440 minutes.
The timer is activated when all of the following
conditions are met regardless of the position of the
parking brake:

The vehicle speed is 0.


The engine is not in Cold Mode or Dedicated
PTO Mode.

The engine is not under load.


The timer can be reset by moving the vehicle or
the timer can be reset by quickly depressing the
accelerator pedal and releasing the accelerator
pedal.
The check engine lamp will begin to rapidly flash 90
seconds before the programmed time expires. During
this 90 second time period, the following conditions
can disable the timer:

270
Troubleshooting Section

The driver moves the clutch pedal.


The driver moves the service brake pedal.
The following event code will be logged when the
driver overrides the timer by the use of the clutch
pedal or the brake pedal during the 90 second period:

71-00 Idle Shutdown Override


If the parameter for the Allow Idle Shutdown
Override is programmed to NO, the timer can not
be overridden by the use of the clutch pedal or the
brake pedal during the final 90 second period. YES
is the factory default that is programmed for the
parameter for the Allow Idle Shutdown Override.
The allowance of the override is the default.
An additional parameter can be programmed to
allow the timer to be reset above a specified engine
speed. When the Idle Shutdown Timer Maximum
RPM parameter is programmed to a value below
the Top Engine Limit, the timer can be reset by
increasing engine rpm above the programmed limit.
The timer will be reset until engine rpm drops below
the programmed value. The timer will begin counting
again. The factory default of 2120 rpm disables this
feature. The Top Engine Limit is 2120 rpm.
If the timer is activated and the timer is allowed to
shut down the engine the following event code will
be generated:

71-01 Idle Shutdown


Code 71-01 records the event and the code does
not indicate an electrical system malfunction or an
electronic system malfunction. Disable the timer by
programming Idle Shutdown Timer to 0 (Caterpillar
Factory Default).

SENR9698-09

Note: If the following diagnostic code is active, the


Idle Shutdown Timer will not operate.

84-08 Vehicle Speed signal out of range


Note: The timer will be overridden if the following
conditions exist.

The Allow Idle Shutdown Timer Override is

programmed to Outside Temperature Based or


J1587 Outside Temperature Based.

The temperature that is being sensed by the ECM


is below the minimum air temperature that is
programmed or the air temperature is above the
maximum air temperature that is programmed.

Test Step 1. Verify Activation of the Idle


Shutdown Timer
A. Connect Cat ET to the data link connector.
B. Access the Configuration screen on Cat ET.
a. Access the following display screens in order:

Service
Configuration
b. Record the programmed time for the Idle
Shutdown Timer. The Idle Shutdown Timer
must be between 3 and 1440 minutes. If the
Idle Shutdown Timer is programmed to 0,
then the timer is disabled.
c. Record the programmed status of the
parameter for the Allow Idle Shutdown
Override and the Idle Shutdown Timer
Maximum RPM.

The Engine Control Module (ECM) will shut down


the engine but not the vehicle electrical system when
the Idle Shutdown 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.

C. Start the engine. Allow the engine to warm up until


the coolant temperature is 38 C (100 F). Allow
the engine to operate at the programmed low idle
and turn off any unnecessary accessory devices.

The Idle Shutdown Timer feature can be temporarily


disabled by the use of Caterpillar Electronic
Technician (ET). The Idle Shutdown Timer feature
can be temporarily disabled through the System
Troubleshooting Settings screen in order to help
troubleshoot other problems. Temporarily disabling
this feature avoids engine shutdowns when you
are troubleshooting other systems. The use of this
method eliminates the need to temporarily alter the
customer specified parameter of Idle Shutdown
Timer.

The Idle Shutdown Timer Maximum RPM can


be programmed to allow the timer to be reset by
increasing the engine rpm above the programmed
limit. Ensure that the accelerator is not being
depressed so that the rpm increases beyond the
programmed limit.

D. Ensure that all unnecessary loads are turned off.

a. Park the vehicle.


b. Ensure that the status for Vehicle Speed on
Cat ET is 0 km/h (0 mph).

SENR9698-09

c. Ensure that the engine speed on the status


screen is at Low Idle.
d. Ensure that the clutch pedal is not depressed.
Ensure that the brake pedal is not depressed.
e. Ensure that the status of the PTO On/Off switch
is Off.
f. Observe the Idle Shutdown Status.
Expected Result:
Result 1 The Idle Shutdown Status indicates
Counting.
Result 2 The Idle Shutdown Status indicates Not
Active.
Results:

Result 1 The ECM is reading the proper

conditions for the activation of the Idle Shutdown


Timer. Proceed to Test Step 2.

Result 2 The ECM is not reading the proper


conditions for activation of the Idle Shutdown
Timer. Proceed to Test Step 3.

Test Step 2. Verify the Driver Alert


Function for Idle Shutdown and the
Override Function for Idle Shutdown

271
Troubleshooting Section

Press the clutch pedal.


Press the service brake pedal.
Note: This action must be accomplished while the
check engine lamp is flashing. The check engine
lamp flashes during the 90 second period before the
programmed shutdown time.
E. Reprogram the Idle Shutdown Timer to the value
that was recorded earlier for this test.
Expected Result:
During the 90 second period before the scheduled
shutdown, the status changes from Counting to
Driver Alert and the check engine lamp flashes
rapidly. If the Allow Idle Shutdown Override is
programmed to YES, the Idle Shutdown Status
changes to Override after the pedals are depressed.
Result 1 The Idle Shutdown Timer behaves in the
manner that is described above.
Result 2 The check engine lamp did not flash during
the alert.
Result 3 The ECM did not sense a change in the
status of the service brake.
Result 4 The ECM did not sense a change in the
status of the clutch.

A. Connect Cat ET to the data link connector.

Results:

B. Access the Configuration screen on Cat ET.

Result 1 The Idle Shutdown Timer behaves in

a. Access the following display screens in order:

the manner that is described above.

Service

Repair: The Idle Shutdown Timer is operating


properly.

Configuration

STOP.

b. Record the programmed time for the Idle


Shutdown Timer. The Idle Shutdown Timer
must be between 3 and 1440 minutes. If the
Idle Shutdown Timer is programmed to 0, the
timer is disabled.
c. Reprogram the Idle Shutdown Timer to 3
minutes for this test.
C. Observe the following items during the 90 second
period before the programmed shutdown time:

Check engine lamp


Idle shutdown status
D. If the customer parameter of Allow Idle Shutdown
Override is programmed to YES, perform either
of the following actions in order to override the
shutdown:

Result 2 The check engine lamp did not flash


during the alert.

Repair: Perform the following diagnostic


procedure: Troubleshooting, Check Engine Lamp
Circuit - Test
STOP.

Result 3 The ECM did not sense a change in the


status of the service brake.

Repair: Perform the following diagnostic


procedure: Troubleshooting, Service Brake Pedal
Position (Switch 1) Circuit - Test
STOP.

Result 4 The ECM did not sense a change in


the status of the clutch.

272
Troubleshooting Section

Repair: Perform the following diagnostic


procedure: Troubleshooting, Clutch Pedal Position
Switch Circuit - Test
STOP.

Test Step 3. Check the State of the


Related Conditions when the Vehicle is
Parked
A. Check the state of the following related conditions
when the vehicle is parked:

Ensure that the vehicle speed is 0 km/h (0 mph)


on Cat ET or the dash display.

SENR9698-09

Result 3 The status of the PTO On/Off switch is


not OFF.

Repair: Perform the following diagnostic


procedure: Troubleshooting, PTO Switch Circuit Test
STOP.

Result 4 The engine is not at low idle.


Repair: Return the engine to low idle. Perform the
test procedure again.
STOP.

Ensure that the engine is not in cold mode. (The


status screen on Cat ET will indicate that Cold
Mode is Active in the corner of the display
screen.)

Ensure that the PTO On/Off switch is in the


OFF position.

Ensure that the engine is at low idle.


Expected Result:
Result 1 Vehicle speed is not indicated as 0 km/h
(0 mph).
Result 2 The status screen on Cat ET indicates that
the engine is in cold mode.
Result 3 The status of the PTO On/Off switch is not
OFF.
Result 4 The engine is not at low idle.
Results:

Result 1 Vehicle speed is not indicated as 0 km/h


(0 mph).

Repair: Perform the following diagnostic


procedure: Troubleshooting, Vehicle Speed and
Speedometer Circuit - Test
STOP.

Result 2 The status screen on Cat ET indicates


that the engine is in cold mode.

Repair: The engine must not be in Cold Mode


operation while this test procedure is being
performed. Allow the engine to run until the coolant
temperature exceeds 20 C (68 F). Troubleshoot
and repair any related conditions.
STOP.

i02509722

Ignition Keyswitch Circuit and


Battery Supply Circuit - Test
SMCS Code: 1401-038; 1553-038
System Operation Description:
This procedure tests whether proper voltage is being
supplied to the Engine Control Module (ECM).
Use this procedure to troubleshoot the system when
one of the following diagnostic codes is active or
easily repeated:

43-02 Key Switch Fault


168-01 Low ECM Battery Power
The ECM receives electrical power (battery voltage)
through the wiring that is supplied by the vehicle
manufacturer. Unswitched battery voltage is supplied
to terminals P1-48, P1-52, and P1-53 at the J1/P1
ECM connectors. The negative battery is supplied
to terminals P1-63, P1-65, and P1-67 at the J1/P1
ECM connectors. The ECM receives the input from
the keyswitch at terminal P1-70 while the keyswitch
is in the ON position or the START position. When
the ECM detects battery voltage at the keyswitch
input, the ECM powers up. When battery voltage is
removed from this input, the ECM powers down.
The cause of an intermittent power supply to the
ECM can occur on either the positive side or on
the negative side of the battery circuit. The three
connections for the unswitched +Battery must be
routed through a dedicated protection device (circuit
breaker).

SENR9698-09

Some vehicles may be equipped with an engine


protection shutdown system or an idle timer
shutdown system that interrupts electrical power
to the keyswitch. The engine protection shutdown
system can be an aftermarket device and the idle
timer shutdown system can be external to the ECM.
Some of these systems will not supply power to the
ECM until one of the following conditions is met:

The engine is cranked.


The engine oil pressure achieves acceptable limits.
An override button is pressed.
Keep in mind that these devices may be the cause of
intermittent power to the ECM. These devices may
unexpectedly shut down the engine.
Usually, battery power to the service tool connector
is available and the battery power to the service
tool connector is independent of the keyswitch.
Therefore, you will be able to power up Caterpillar
Electronic Technician (ET), but you may not be able
to communicate with the ECM. The ECM requires
the keyswitch to be in the ON position in order to
maintain communications. The ECM may power
down a short time after connecting Cat ET if the
keyswitch is in the OFF position. This is normal.
For intermittent problems such as intermittent
shutdowns that could be caused by vehicle wiring,
temporarily bypassing the vehicle wiring may be
an effective means of determining the root cause.
If the symptoms disappear with the bypass wiring,
the vehicle wiring is the cause of the problem. A
means of bypassing vehicle wiring is explained in
this test procedure. This is especially important for
vehicles that do not provide dedicated circuits for
the unswitched battery and the connections for the
keyswitch.

273
Troubleshooting Section

274
Troubleshooting Section

Illustration 116
Schematic for ECM battery circuit

SENR9698-09

g01104227

SENR9698-09

275
Troubleshooting Section

Test Step 1. Inspect Electrical Connectors


and Wiring

Illustration 117

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

A. Thoroughly inspect the J1/P1 ECM connector


and the firewall bulkhead connectors. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.

Illustration 118

g01256390

Terminal locations at the P1 ECM connector for the keyswitch and


battery supply circuit
(48)
(52)
(53)
(63)
(65)
(67)
(70)

Unswitched +Battery
Unswitched +Battery
Unswitched +Battery
Battery
Battery
Battery
Keyswitch

B. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the circuit for the keyswitch and the battery.
C. Check the allen head screw for each of the
ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
D. Check the harness and wiring for abrasion and
for pinch points from the battery to the ECM, and
from the keyswitch to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.

276
Troubleshooting Section

Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 2.

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.
STOP.

SENR9698-09

Test Step 3. Check the Battery Voltage at


the ECM Connector
A. Disconnect the J1/P1 ECM connectors.
B. Turn the keyswitch to the ON position.
C. Measure the voltage between P1-48 (Unswitched
+Battery) and P1-63 (-Battery).
D. Measure the voltage between P1-52 (Unswitched
+Battery) and P1-65 (-Battery).
E. Measure the voltage between P1-53 (Unswitched
+Battery) and P1-67 (-Battery).

Test Step 2. Check for Active Diagnostic


Codes or Logged Diagnostic Codes

F. Measure the voltage between P1-70 (keyswitch)


and P1-67 (-Battery).

A. Connect Cat ET to the service tool connector.

G. Turn the keyswitch to the OFF position.

B. Turn the keyswitch to the ON position.

Expected Result:

C. Monitor the active diagnostic code screen on Cat


ET. Check and record any active diagnostic codes
or logged diagnostic codes.

For 12 Volt Systems, the measured voltage is


a constant 11.0 to 13.5 VDC with no suspected
intermittent problems at this time.

Note: Wait at least 30 seconds in order for the


diagnostic codes to become active.

For 24 Volt Systems, the measured voltage is


a constant 22.0 to 27.0 VDC with no suspected
intermittent problems at this time.

Expected Result:
One of the following diagnostic codes is active or
logged:

43-02 Key Switch Fault


168-01 Low ECM Battery Power
Note: A 43-02 code can be generated by rapidly
cycling the keyswitch. If the 43-02 Key Switch Fault
is logged but not active, this may be the cause.
Results:

OK A 43-02 diagnostic code or a 168-01

diagnostic code is active or logged. Proceed to


Test Step 3.

Not OK No diagnostic code is active.


Repair: The problem is no longer present. There
may be an intermittent electrical problem in the
harness or in a connector. If an intermittent problem
is suspected, refer to Troubleshooting, Electrical
Connectors - Inspect for information that is related
to troubleshooting intermittent electrical problems.
STOP.

Results:

OK The ECM is receiving the correct voltage.


Repair: If an intermittent condition is suspected,
refer to Troubleshooting, Electrical Connectors
- Inspect.
STOP.

Not OK - Keyswitch No voltage was present on


P1-70.

Repair: Check for continuity in the wiring for the


keyswitch from P1-70 through the keyswitch circuit
to the batteries. Check the circuit protection for
the circuit. Refer to the vehicle service manual for
instructions on troubleshooting the circuit for the
keyswitch.
For intermittent problems such as intermittent
shutdowns that could be caused by vehicle wiring,
temporarily bypassing the vehicle wiring may be an
effective means of determining the root cause.
Proceed to Test Step 5.

Not OK - Unswitched +Battery No voltage was


present on P1-48, P1-52, or P1-53.

SENR9698-09

Repair: Check for continuity in the wiring for the


unswitched +Battery from the ECM to the batteries.
Check the circuit protection for the circuit. Check
for continuity in the wiring for the Battery from the
ECM to the batteries.
For intermittent problems such as intermittent
shutdowns that could be caused by vehicle wiring,
temporarily bypassing the vehicle wiring may be an
effective means of determining the root cause.
Proceed to Test Step 5.

Not OK - Battery Voltage is out of range Proceed


to Test Step 4.

Test Step 4. Check the Batteries


A. Measure no-load battery voltage at the battery
posts.
B. Load test the batteries. Use the 4C-4911
Battery Load Tester. Refer to Special Instruction,
SEHS9249, Use of 4C-4911 Battery Load Tester
for 6, 8 and 12 Volt Lead Acid Batteries and
Special Instruction, SEHS7633, Battery Test
Procedure.
Expected Result:
The batteries pass the load test. For 12 Volt systems,
the measured voltage is at least 11.0. For 24 Volt
systems, the measured voltage is at least 22.0.
Results:

OK The batteries pass the load test. For 12 Volt

systems, the measured voltage is at least 11.0. For


24 Volt systems, the measured voltage is at least
22.0.
Repair: Refer to the vehicle service manual for
instructions on troubleshooting the vehicle wiring
harness. Troubleshoot the vehicle wiring harness
and repair the vehicle wiring harness, as required.
Verify that the repairs eliminate the problem.
STOP.

Not OK The batteries do not pass the load test.

For 12 Volt systems, the measured voltage is less


than 11.0. For 24 Volt systems, the measured
voltage is less than 22.0.
Repair: Recharge or replace the faulty batteries.
Verify that the repair eliminates the problem.
STOP.

277
Troubleshooting Section

Test Step 5. Bypass the Vehicle Harness

Batteries give off flammable fumes which can explode.


To avoid injury or death, do not strike a match,
cause a spark, or smoke in the vicinity of a battery.
NOTICE
Do Not connect the Bypass Harness to the battery
until all three of the 10 Amp in-line fuses have been
removed from the +Battery line. If the fuses are not
removed before connection to the battery a spark may
result.

278
Troubleshooting Section

SENR9698-09

g01017846

Illustration 119
Schematic of the bypass harness

Note: This bypass harness is only for test


applications. This bypass harness must be removed
before the vehicle is released to the customer. The
bypass harness can be used in order to determine if
the cause of the intermittent problem is interruptions
in battery power to the ECM or to the keyswitch
circuit.

Expected Result:

A. Turn the keyswitch to the OFF position.

Results:

B. Disconnect the J1/P1 ECM connector.

OK The symptoms disappear when the bypass

C. Connect a bypass harness to the ECM.


D. Remove the three 10 Amp in-line fuses from the
+Battery wire of the bypass harness and connect
the +Battery and the Battery wires directly to the
battery posts.
Note: This bypass directly connects the circuit for the
keyswitch to the ECM. The ECM will remain powered
until the connection to the unswitched battery line +
is disconnected. Remove the three 10 Amp fuses
from the in-line fuse holder to power down the ECM.
Do not connect the bypass to the battery posts or do
not remove the bypass from the battery posts without
first removing the 10 Amp in-line fuses.
E. Connect Cat ET to the data link connector of the
bypass harness and verify that communication
can be established.
Note: Remove the bypass harness and restore all
wiring to the original condition after testing.

Installing the bypass eliminates the problem.


Note: The status of the Ignition keyswitch will
always indicate On while the bypass harness is
installed.

harness is installed. Also, the symptoms return


when the bypass harness is removed. The problem
is in the vehicle wiring that supplies power to the
ECM. Check for aftermarket engine protection
switches that interrupt power. Send the vehicle to
the OEM dealer to repair. STOP.

Not OK
Repair: Connect the bypass to another battery and
verify if the problem is resolved. If the problem is
resolved, the problem is with the vehicle batteries.
If the problem still exists, temporarily connect
a test ECM. Remove all jumpers and replace
all connectors. Recheck the system for active
diagnostic codes and repeat the Test Step. If the
problem is resolved with the test ECM, reconnect
the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM.
Verify that the repair eliminates the problem.
STOP.

SENR9698-09

279
Troubleshooting Section

i02504880

Ignore Brake/Clutch Switch


Circuit - Test
SMCS Code: 7332-038-CL
System Operation Description:
Use this procedure under the following situation:
The circuit for the ignore brake/clutch switch is
suspected of incorrect operation.
The following background information is related
to this procedure:
The Engine Control Module (ECM) can use various
inputs in a number of ways. The inputs depend
on the parameter programming. Certain features
are available on several different inputs. The
configuration for the switch must match the actual
switch installation in order for the switch to function
properly.
Ignore Brake/Clutch Switch
The ignore brake/clutch switch is typically used with
a Cab Switches PTO Configuration which requires
mobile use of the vehicle during PTO operation. When
the ignore brake/clutch switch is on, depressing the
brake or the clutch will not disengage PTO operation
or a set engine speed. If the Ignore/Brake Clutch
Switch parameter is programmed to None (default),
this feature is not used. If the Ignore/Brake Clutch
Switch parameter is programmed to J1/P1:47, then
the feature is available and the switch circuit should
be connected to P1-47 of the ECM connector.
Note: The wiring for your particular application
may be slightly different. The circuits for the sensor
return are used interchangeably by the OEM of the
vehicle. The following circuits for the sensor return
are common internally to the ECM:

The Input Sensor Common 1 outputs at terminal


location J1-18

The Input Sensor Common 2 outputs at terminal


location J1-3

The AP Sensor/Switch Sensor Common outputs


at terminal location J1-5

280
Troubleshooting Section

SENR9698-09

g01254014

Illustration 120
Schematic for the ignore brake/clutch switch

Test Step 1. Check the Status of the


Ignore Brake/Clutch Switch

Test Step 2. Check the Electrical


Connectors and the Wiring

A. Connect Caterpillar Electronic Technician (ET) to


the service tool connector.
B. Turn the keyswitch to the ON position.
C. Monitor the status for the Ignore Brake/Clutch
Switch while the ignore brake/clutch switch is
toggled to the ON position and the OFF position.
The correct status for the Ignore Brake/Clutch
Switch is On when the switch is turned on. The
correct status for the Ignore Brake/Clutch Switch
is Off if the switch is turned off.
Note: If the Ignore Brake/Clutch Switch
status indicates Not Installed, then the Ignore
Brake/Clutch Switch parameter has not been
programmed.
Expected Result:
Cat ET is reporting the correct status for the switch.
Results:

OK Cat ET is reporting the correct status for


the switch.

Repair: The ignore brake/clutch switch appears


to operating correctly at this time. There may be
an intermittent electrical problem in the harness
or in a connector. If an intermittent problem is
suspected, refer to Troubleshooting, Electrical
Connectors - Inspect for information that is related
to troubleshooting intermittent electrical problems.
STOP.

Not OK Cat ET is not reporting the correct status


for the switch. The ECM is not reading the change
in switch status. Proceed to Test Step 2.

Illustration 121

g01186024

Location of the J1/P1 ECM connectors (typical left side engine


view)

A. Thoroughly inspect the J1/P1 ECM connectors


and the firewall bulkhead connectors. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.

SENR9698-09

281
Troubleshooting Section

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.

Test Step 3. Create a Short Circuit at the


Switch
A. Fabricate a jumper wire that is long enough to
create a short circuit across the terminals at the
harness connector for the ignore brake/clutch
switch.
B. Disconnect the switch from the harness.
C. Install the jumper wire across the two switch
terminals at the harness connector for the ignore
brake/clutch switch.
D. Turn the keyswitch to the ON position.
E. Use Cat ET to monitor the status of the Ignore
Brake/Clutch Switch. While the status for the
Ignore Brake/Clutch Switch is monitored, remove
the jumper wire and then insert the jumper wire.
F. Turn the keyswitch to the OFF position.
Illustration 122

g01254023

Terminal locations at the P1 ECM connector for the ignore


brake/clutch switch
(18) Input No. 1 sensor return
(47) Input No. 5 (ignore brake/clutch switch)

The correct status for the Ignore Brake/Clutch


Switch is On when the jumper wire is installed.
The correct status for the Ignore Brake/Clutch
Switch is Off when the jumper wire is removed.

B. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector that are associated
with the suspect switch circuit.

Expected Result:

C. Check the allen head screw for each of the


ECM connectors for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.

Results:

Cat ET is reporting the correct status for the switch.

OK Cat ET is reporting the correct status.

D. Check the harness and the wiring for abrasion and


pinch points from the battery to the ECM. Then,
check the wiring from the keyswitch to the ECM.

Repair: The wiring harness and the ECM are OK.


There is a problem with the switch. Replace the
ignore brake/clutch switch. Verify that the repair
eliminates the problem.

Expected Result:

STOP.

All connectors, pins and sockets are completely


coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion or of pinch points.
Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 3.

Not OK Cat ET does not report the correct

status. There is a problem in the wire harness


between the ignore brake/clutch switch and the
ECM. There may be a problem with the ECM.
Restore the wiring to the original configuration.
Proceed to Test Step 4.

282
Troubleshooting Section

Test Step 4. Check for Proper Operation


of the ECM
A. Disconnect the J1/P1 ECM connectors.
B. Fabricate two jumper wires that are long enough
to create a test circuit at the ECM connector.
Crimp a connector socket to one end of each of
the jumper wires.
C. Remove the wires from terminal location P1-18
(input sensor return No. 1) and terminal location
P1-47 (input No. 5 (ignore brake/clutch switch)).
Install one of the jumper wires into each of these
terminal locations.

SENR9698-09

Repair: The ECM is not reading the switch input


properly. There is a problem with the ECM. Replace
the ECM. Refer to Troubleshooting, Replacing the
ECM. Verify that the original problem is resolved.
STOP.
i02199370

Injector Solenoid Circuit - Test


SMCS Code: 1290-038
System Operation Description:

D. Connect the J1/P1 ECM connectors.

Use this procedure to troubleshoot any suspect


problems with the injector solenoids.

E. Turn the keyswitch to the ON position.

Use this procedure for the following diagnostic codes:

F. Monitor the status of the Ignore Brake/Clutch


Switch while you short the loose ends of the
jumper wires. Provide an open circuit for the loose
ends of the jumper wires. Recheck the switch
status.

1-05 Cylinder #1 Injector current low

The correct status for the Ignore Brake/Clutch


Switch is On when the jumper wires are shorted
together. The correct status for the Ignore
Brake/Clutch Switch is Off when the jumper
wires are open.

1-06 Cylinder #1 Injector current high


2-05 Cylinder #2 Injector current low
2-06 Cylinder #2 Injector current high
3-05 Cylinder #3 Injector current low
3-06 Cylinder #3 Injector current high

G. Turn the keyswitch to the OFF position.

4-05 Cylinder #4 Injector current low

H. Restore all wiring to the original configuration.

4-06 Cylinder #4 Injector current high

Expected Result:

5-05 Cylinder #5 Injector current low

Cat ET is reporting the correct status for the switch.

5-06 Cylinder #5 Injector current high

Results:

6-05 Cylinder #6 Injector current low

OK Cat ET is reporting the correct status for

6-06 Cylinder #6 Injector current high

the switch.

Repair: The ECM is functioning properly at this


time. There is a problem in the OEM wiring harness
that is between the ECM connector and the ignore
brake/clutch switch. Repair the circuit or send the
vehicle to the OEM dealer for repairs.
STOP.

Not OK Cat ET does not report the correct status


for the switch.

You have been directed to this procedure from


Troubleshooting, Troubleshooting without a
Diagnostic Code.

Perform this procedure under conditions that are


identical to the conditions that exist when the problem
occurs. Typically, problems with the injector solenoid
occur when the engine is warmed up and/or when
the engine is under vibration (heavy loads).

SENR9698-09

283
Troubleshooting Section

These engines have Electronic Unit Injectors (EUI)


that are mechanically actuated and electronically
controlled. The Engine Control Module (ECM) sends
a 105 volt pulse to each injector solenoid. The pulse
is sent at the proper time and at the correct duration
for a given engine load and speed. The solenoid
is mounted on top of the fuel injector body. The
105 volt pulse can be individually cut out to aid in
troubleshooting misfire problems.
If an open is detected in the solenoid circuit, a
diagnostic code is generated. The ECM continues
to try to fire the injector. If a short is detected, a
diagnostic code is generated. The ECM will disable
the solenoid circuit. The ECM will periodically try
to fire the injector. If the short circuit remains this
sequence of events will be repeated until the problem
is corrected.
The injector codes must be programmed into the
ECM. Injector codes allow each individual injector to
be fine tuned for optimum performance. The ECM will
generate the following diagnostic code if the injector
codes are not programmed:

253-02 Check Customer or System Parameters


When an injector is replaced, program the injector
code into the ECM. If the ECM is replaced, all six
injector codes must be programmed into the new
ECM. Refer to Troubleshooting, Injector Code Calibrate for more information.
Cylinder Cutout Test
Use the Cylinder Cutout Test on the Caterpillar
Electronic Technician (ET) to diagnose a
malfunctioning injector while the engine is running.
All active diagnostic codes must be repaired before
running the Cylinder Cutout Test. When a good
injector is cut out, the Fuel Position should change.
The change in the fuel position is caused by the
other injectors that are compensating for the cut out
injector. If a malfunctioning injector is cut out, the
Fuel Position will not change. The Cylinder Cutout
Test is used to isolate the malfunctioning injector in
order to avoid replacement of good injectors.
Injector Solenoid Test
Use the Injector Solenoid Test on Cat ET to aid in
diagnosing an open circuit or a short circuit diagnostic
code while the engine is not running. The Injector
Solenoid Test will send a signal to each solenoid.
Cat ET will indicate the status of the solenoid as
OK, Open, or Short. Due to the use of a shared
supply, an open circuit or a short circuit in the wire
that is used as a supply for the injector solenoid will
cause two cylinders to have diagnostic codes.

Illustration 123
Electronic unit injector

g01109300

284
Troubleshooting Section

Illustration 124

SENR9698-09

g01098254

Schematic for C11 and C13 engines

Illustration 125
Schematic for C15 engines

g01098255

SENR9698-09

285
Troubleshooting Section

g01110868

Illustration 126
P2 ECM connector
(P2-36) Injector 1 & 2 supply
(P2-37) Injector 3 & 4 supply
(P2-38) Injector 5 & 6 supply

(P2-44) Injector 1 return


(P2-45) Injector 2 return
(P2-46) Injector 3 return

g01107778

Illustration 127
Valve cover connectors for C11 and C13 engines
(P681-4)
(P681-5)
(P681-6)
(P681-7)
(P681-8)

Injector 1
Injector 2
Injector 3
Injector 3
Injector 1

(P2-47) Injector 4 return


(P2-67) Injector 6 return
(P2-68) Injector 5 return

return
return
return
& 4 supply
& 2 supply

(P682-3)
(P682-4)
(P682-5)
(P682-6)
(P682-7)

Injector 4
Injector 5
Injector 6
Injector 3
Injector 5

return
return
return
& 4 supply
& 6 supply

286
Troubleshooting Section

SENR9698-09

g01107792

Illustration 128
Valve cover connectors for C15 engines
(P681-1) Injector 1 return
(P681-2) Injector 2 return
(P681-3) Injector 3 return

(P681-4) Injector 4 return


(P681-5) Injector 1 & 2 supply
(P681-6) Injector 3 & 4 supply

(P682-3) Injector 5 return


(P682-4) Injector 6 return
(P682-5) Injector 5 & 6 supply

D. Check the ECM connector (allen head screw) for


the proper torque of 6.0 Nm (55 lb in).
E. Check the harness and wiring for abrasion and for
pinch points from the injectors to the ECM.
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, and of pinch points.
Results:
Illustration 129

g01109586

OK The harness and wiring are OK. Proceed


to Test Step 2.

Harness connector for the injectors

Test Step 1. Inspect Electrical Connectors


and Wiring

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Thoroughly inspect the J2/P2 ECM connector.
Thoroughly inspect the front and rear valve cover
connectors at the valve cover base. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated
with injector solenoids.

Not OK There is a problem in the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.

Test Step 2. Check for Logged Diagnostic


Codes That Are Related to the Injector
Solenoids
A. Connect Cat ET to the data link connector.
B. Turn the key switch to the ON position.
C. Check for logged diagnostic codes that are related
to the injector solenoids on Cat ET.

SENR9698-09

Expected Result:
One or more diagnostic codes that are related to the
injector solenoids have been logged:

1-05
1-06
2-05
2-06
3-05
3-06
4-05
4-06
5-05
5-06
6-05

287
Troubleshooting Section

F. Shut off all parasitic loads such as the air


conditioning and the air compressors which could
affect the results of the test.
G. Set the engine speed to 1000 20 rpm.
H. Select the start button at the bottom of the screen
for the cylinder cutout test on Cat ET.
I. Select the 4 Cylinder Cutout Test which is the
default test.
J. Follow the instructions that are provided in the
cylinder cutout test. The cylinder cutout tests are
interactive so the procedure is guided to the finish.
Note: The Manual Cylinder Cutout Test is also
available. Access the manual test by selecting the
Change button on the screen for the cylinder
cutout test. The 4 Cylinder Cutout Test is the
recommended starting procedure. The automated
tests run twice collecting data. The two sets of data
are analyzed and an OK or Not OK result is
displayed.

6-06

K. Check for active diagnostic codes and for logged


diagnostic codes that are related to the injector
solenoids.

Results:

Expected Result:

OK One or more diagnostic codes have been

All cylinders indicate OK on Cat ET.

logged. Proceed to Test Step 4.

Not OK No diagnostic codes have been logged.


Proceed to Test Step 3.

Test Step 3. Check the Variation of the


Injectors Between Cylinders
A. When possible, put the truck on a dynamometer.
B. Start the engine.
C. Allow the engine to warm up to normal operating
temperature (77 C (171 F)).
D. After the engine is warmed to operating
temperature, access the Cylinder Cutout Test by
accessing the following display screens in order:

Diagnostics
Diagnostic Tests
Cylinder Cutout Test
E. Enable the cooling fan, if the fan is not controlled
by the ECM. If the ECM controls the cooling fan,
the cooling fan will start automatically when the
test begins.

Results:

OK All cylinders indicate 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.
If a diagnostic code results from running the
cylinder cutout test, proceed to Test Step 4.

Not OK One or more cylinders displayed Not


OK during the test. Proceed to Test Step 4.

Test Step 4. Use the Injector Solenoid


Test
A. Start the engine.
B. Allow the engine to warm up to the normal
operating temperature 77 C (171 F).
C. Stop the engine.
D. Turn the key switch to the ON position.
E. Access the Injector Solenoid Test by accessing
the following display screens in order:

288
Troubleshooting Section

SENR9698-09

Diagnostics

C. Turn the key switch to the ON position.

Diagnostic Tests

D. Fabricate a jumper wire 100 mm (4 inch) long with


Deutsch terminals on both ends of the wire.

Injector Solenoid Test


F. Activate the test.
Note: Do not confuse the Injector Solenoid Test
with the Cylinder Cutout Test. The Cylinder Cutout
Test is used to shut off fuel to a specific cylinder
while the engine is running. The Injector Solenoid
Test is used to actuate the injector solenoids while
the engine is not running. This allows the click of the
injector solenoids to be heard while the engine is off
in order to determine that the circuit is functioning
properly.
G. As each solenoid is energized by the ECM, an
audible click can be heard at the valve cover.
H. Perform the Injector Solenoid Test at least two
times.
Expected Result:
All cylinders indicate OK.
Results:

OK There is not an electronic problem with the


injectors at this time.

Repair: If the Cylinder Cutout Test returned a


Not OK for any injector, refer to Troubleshooting,
Engine Misfires, Runs Rough or Is Unstable.
STOP.

Open Note the cylinders that indicate Open.


Proceed to Test Step 5.

Short Note the cylinders that indicate Short.


Proceed to Test Step 8.

Test Step 5. Check the Harness Between


the ECM and the Valve Cover Base for an
Open Circuit

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Disconnect the connectors from the valve cover
base.

E. Insert one end of the jumper wire into the terminal


for the suspect injectors supply. Insert the other
end of the jumper wire into the terminal for the
suspect injectors return circuit.
F. Perform the Injector Solenoid Test at least two
times.
G. Repeat this test for each suspect injector. Stop
the Injector Solenoid Test before handling the
jumper wires.
Expected Result:
Cat ET displays Short for the cylinder with the
jumper wire.
Results:

OK The harness between the ECM and the

valve cover base is OK. Proceed to Test Step 6.

Not OK There is a problem between the ECM

and the valve cover base. Proceed to Test Step 7.

Test Step 6. Check the Injector Harness


Under the Valve Cover

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Remove the valve cover.
C. Disconnect the harness from the suspect injector.
Disconnect the harness from the injector that
shares the same supply circuit as the suspect
injector.
Note: If both injectors that share a common supply
indicate Open, inspect the supply wire under the
valve cover for problems. The open circuit is probably
caused by an open in the supply wire.
D. Thoroughly clean the terminals on both injectors
and on the harness connectors.
E. Exchange the harness between the two injectors
that share the common supply.

SENR9698-09

289
Troubleshooting Section

F. Turn the key switch to the ON position.

Expected Result:

G. Perform the Injector Solenoid Test at least two


times.

Cat ET displays Short for the cylinder with the


jumper wire.

Expected Result:

Note: Shorting a shared supply will affect the status


of two injectors. Ignore the status of the other injector
that is on the shared shared supply.

Exchanging the harness between the two injectors


caused the problem to move to the other injector.
Results:

OK There is a problem with the injector harness


under the valve cover.

Repair: Repair the injector harness or replace the


injector harness under the valve cover.
Verify that the repair eliminates the problem.
STOP.

Not OK The injector may be faulty.


Repair: Replace the faulty injector.
Restore the wiring to the proper injectors.

Results:

OK The ECM is OK.


Repair: If two injectors that share a supply indicate
Open, inspect the supply wire that is in the
engine harness for problems. The open circuit is
probably caused by an open in the supply circuit
of the harness.
Repair the engine harness or replace the engine
harness, as required.
Verify that the repair eliminates the problem.
STOP.

Not OK There may be a problem with the ECM.

Perform the Injector Solenoid Test.

Repair: Temporarily connect a test ECM.

Verify that the repair eliminates the problem.

Remove the jumper wire from the P2 ECM


connector and reinstall the injector wires.

STOP.

Test Step 7. Check the ECM for an Open


Circuit

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Disconnect the P2 ECM connector from the ECM.
C. Remove the supply wire and the return wire for
the suspect injector from the P2 ECM connector.
Install a jumper wire into the P2 ECM connector in
order to provide a short between the supply and
the return of the suspect injector.
D. Reinstall the P2 ECM connector to the ECM.

Perform the Injector Solenoid Test.


If the test ECM fixes the problem, reconnect the
suspect ECM.
If the problem returns with the suspect ECM,
replace the ECM.
Verify that the repair eliminates the problem.
STOP.

Test Step 8. Check the Harness Between


the ECM and the Valve Cover Base for a
Short Circuit

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.

E. Turn the key switch to the ON position.

A. Turn the key switch to the OFF position. A strong


electrical shock hazard is present if the key switch
is not turned off.

F. Perform the Injector Solenoid Test at least two


times.

B. Disconnect the connectors from the valve cover


base.
C. Turn the key switch to the ON position.

290
Troubleshooting Section

D. Perform the Injector Solenoid Test at least two


times.
Expected Result:
All cylinders indicate Open.
Results:

OK All cylinders indicate Open. Proceed to


Test Step 10.

Not OK One or more cylinders indicate Short.


Note the cylinders that indicate Short. Proceed
to Test Step 9.

Test Step 9. Check the ECM for a Short


Circuit

SENR9698-09

Verify that the repair eliminates the problem.


STOP.

Not OK There may be a problem with the ECM.


Repair: Temporarily connect a test ECM.
Reconnect the P2 ECM connector.
Perform the Injector Solenoid Test.
If the test ECM fixes the problem, reconnect the
suspect ECM.
If the problem returns with the suspect ECM,
replace the ECM.
Verify that the repair eliminates the problem.
STOP.

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Disconnect the P2 ECM connector from the ECM
and check for evidence of moisture entry.
C. Turn the key switch to the ON position.
D. Perform the Injector Solenoid Test at least two
times.
Expected Result:
All cylinders indicate Open when the P2 ECM
connector is disconnected from the ECM.

Test Step 10. Check the Engine Harness


Under the Valve Cover for a Short Circuit

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Remove the valve cover.
C. Disconnect each of the injectors that indicate a
Short from the wiring harness. Ensure that each
of the connectors from the disconnected injector
harness does not touch any other components.

Note: When the engine harness is disconnected,


all of the diagnostic codes for supply voltage to the
sensors will be active. This is normal. Clear all of
these diagnostic codes after completing this test step.

D. Turn the key switch to the ON position.

Results:

Expected Result:

OK The short circuit is in the engine harness.

All of the injectors that were disconnected indicate


Open.

Repair: The problem is most likely in one of the


wires to the injector. Inspect the connectors for
moisture and for corrosion. Also, check the wire
insulation for damage and for strands that are
exposed.
Repair the engine harness or replace the engine
harness, as required. Clear all diagnostic codes
after completing this test step.

E. Perform the Injector Solenoid Test at least two


times.

Results:

OK All of the injectors that were disconnected


indicate Open.

Repair: Leave the injector wires disconnected.


The supply wire is not shorted to the engine.
Proceed to Test Step 11.

SENR9698-09

Not OK One or more of the injectors that were


disconnected indicate Short.

Repair: The problem is most likely in the supply to


the injector. Inspect the connectors for moisture
and for corrosion. Also, check the supply wires
insulation for damage and for strands that are
exposed.
Repair the injector harness or replace the injector
harness under the valve cover.
Verify that the repair eliminates the problem.
STOP.

Test Step 11. Check for a Short Circuit in


the Return Wire

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Disconnect the P2 ECM connector from the ECM.
C. Locate the terminal for the supply of the problem
injector in the P2 connector. Measure the
resistance from the terminal to the engine ground
stud.
Expected Result:
The resistance is greater than 10 Ohms.
Results:

OK The resistance is greater than 10 Ohms.


Repair: Reconnect the J2/P2 ECM connector.
Replace the faulty injector.
Perform the Injector Solenoid Test.
Verify that the repair eliminates the problem.
STOP.

Not OK There is a short in the return line.


Repair: Disconnect the connectors from the valve
cover base.
Measure the resistance of the return wire between
the P2 ECM connector and the engine ground stud.

291
Troubleshooting Section

If the resistance is less than 10 Ohms, the problem


is in the return wire between the ECM and the
valve cover base.
If the resistance is greater than 10 Ohms, the
problem is in the return wire under the valve cover.
Repair the injector harness or replace the injector
harness.
Perform the Injector Solenoid Test in order to
verify that the repair eliminates the problem.
STOP.
i01921773

Intake Valve Actuation System


Oil Pressure Circuit - Test
SMCS Code: 5479-038-IL
System Operation Description:
Intake Valve Actuator Pressure Solenoid Test
The Intake Valve Actuator Pressure Solenoid Test
is available to help diagnose problems with the intake
valve actuator pressure solenoid. A small current
is applied to the circuit at all times. This allows the
Engine Control Module (ECM) to detect open circuits
when the valve is not actuated. A short circuit will
only be detected when the valve is actuated.
The following conditions must be met before the
Intake Valve Actuator Pressure Solenoid Test will
function:

Engine speed is 0.
Vehicle speed is 0.
The neutral switch is in the Neutral position.

292
Troubleshooting Section

SENR9698-09

g01012666

Illustration 130
Schematic

g01012723

Illustration 131
P2 ECM connector

Test Step 1. Inspect Electrical Connectors


and Wiring
A. Turn the key switch to the OFF position.
B. Thoroughly inspect the J2/P2 ECM connector and
the solenoid connector. Refer to Troubleshooting,
Electrical Connectors - Inspect for details.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and the solenoid
connector.
D. Check the ECM connector (allen head screw) for
the proper torque of 6 Nm (55.0 lb in).
E. Check the harness and wiring for abrasion and for
pinch points.
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, or of pinch points.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.

Test Step 2. Determine the Condition that


is Present
A. Connect the Caterpillar Electronic Technician (Cat
ET) to the data link connector.
B. Turn the key switch to the ON position.
C. Access the Special Tests under the Service
menu.
D. Start the Intake Valve Actuation Pressure
Solenoid Test on Cat ET.

Results:

E. Once Cat ET displays the status of the intake


valve actuation pressure solenoid, stop the Intake
Valve Actuation Pressure Solenoid Test.

OK The electrical connectors and wiring are OK.

Expected Result:

Not OK There is a problem with the electrical

The test indicated Not Active: Device Open or Not


Active: Device Short.

Proceed to Test Step 2.

connectors and/or the wiring.

SENR9698-09

293
Troubleshooting Section

Results:

Expected Result:

Open The test indicated Not Active: Device

The resistance is less than 15 Ohms for 12 volt


systems and the resistance is less than 50 Ohms for
24 volt systems.

Open. Proceed to Test Step 3.

Short The test indicated Not Active: Device


Short. Proceed to Test Step 6.

Test Step 3. Short the Wires at the


Solenoid
A. Turn the key switch to the OFF position.
Note: It is important to cycle the key switch between
steps when the Intake Valve Actuation Pressure
Solenoid Test is used.
B. Disconnect the intake valve actuation pressure
solenoid at the solenoid connector.
C. Fabricate a jumper wire to short terminal 1 and
terminal 2 of the connector for the solenoid on the
engine harness.

Results:

OK The resistance is within the specifications.


Repair: Inspect the solenoid connector, terminals,
and wiring.
Verify that all of the connectors, terminals, and
wiring are OK.
If the problem is intermittent refer to
Troubleshooting, Electrical Connectors - Inspect.
STOP.

Not OK The resistance is not within the


specifications.

D. Turn the key switch to the ON position.

Repair: Temporarily connect a new solenoid.

E. Access the Special Tests under the Service


menu.

If the new solenoid fixes the problem, reconnect


the suspect solenoid.

F. Start the Intake Valve Actuation Pressure


Solenoid Test on Cat ET.

If the problem returns, permanently replace the


solenoid.

G. Once Cat ET displays the status of the intake


valve actuation pressure solenoid, stop the Intake
Valve Actuation Pressure Solenoid Test.

Verify that the repair eliminates the problem.


STOP.

Expected Result:

Test Step 5. Short the Circuit at the ECM

The test indicated Not Active: Device Short with the


jumper wire in place.

A. Turn the key switch to the OFF position.

Results:

OK The test indicated Not Active: Device Short.


Proceed to Test Step 4.

Not OK The test indicated Not Active: Device


Open.

Repair: Reconnect the solenoid to the solenoid


connector.
Proceed to Test Step 5.

Test Step 4. Check the Resistance of the


Solenoid
A. Turn the key switch to the OFF position.
B. Use a multimeter to measure the resistance
between terminal 1 and terminal 2 of the intake
valve actuation pressure solenoid.

Note: It is important to cycle the key switch between


steps when the Intake Valve Actuation Pressure
Solenoid Test is used.
B. Disconnect the P2 ECM connector.
C. Remove the wires from P2:31 (Intake valve
acutation pressure solenoid) and P2:53 (Solenoid
common).
D. Fabricate a jumper wire to short P2:31 (Intake
valve acutation pressure solenoid) and P2:53
(Solenoid common).
E. Reconnect the P2 ECM connector.
F. Turn the key switch to the ON position.
G. Access the Special Tests under the Service
menu.
H. Start the Intake Valve Actuation Pressure
Solenoid Test on Cat ET.

294
Troubleshooting Section

I. Once Cat ET displays the status of the intake


valve actuation pressure solenoid, stop the Intake
Valve Actuation Pressure Solenoid Test.
Expected Result:
The test indicated Not Active: Device Short with the
jumper wire in place.

SENR9698-09

Results:

OK The test indicates Not Active: Device Open.


Proceed to Test Step 7.

Not OK The test indicates Not Active: Device


Short. Proceed to Test Step 8.

Results:

Test Step 7. Check the Resistance of the


Solenoid

OK The test indicated Not Active: Device Short

A. Turn the key switch to the OFF position.

Not OK The test indicated Not Active: Device

B. Use a multimeter to measure the resistance


between terminal 1 and terminal 2 of the intake
valve actuation pressure solenoid.

with the jumper wire in place. Proceed to Test Step


9.
Open with the jumper wire in place.

Repair: Temporarily connect a test ECM.


If the test ECM fixes the problem, reconnect the
suspect ECM.
If the problem returns, permanently replace the
ECM.
Verify that the repair eliminates the problem.
STOP.

Expected Result:
The resistance is greater than 6 Ohms for 12 volt
systems and the resistance is greater than 23 Ohms
for 24 volt systems.
Results:

OK The resistance is within the specifications.


Repair: Check the solenoid connector for corrosion
and moisture.

Test Step 6. Create an Open at the


Solenoid

If the problem is intermittent, refer to


Troubleshooting, Electrical Connectors - Inspect.

A. Turn the key switch to the OFF position.

STOP.

Note: It is important to cycle the key switch between


steps when the Intake Valve Actuation Pressure
Solenoid Test is used.

Not OK There is a short circuit in the solenoid.


Repair: Temporarily connect a new solenoid.

B. Disconnect the intake valve actuation pressure


solenoid at the solenoid connector.

If the new solenoid fixes the problem, reconnect


the suspect solenoid.

C. Turn the key switch to the ON position.

If the problem returns, permanently replace the


solenoid.

D. Access the Special Tests under the Service


menu.
E. Start the Intake Valve Actuation Pressure
Solenoid Test on Cat ET.
F. Once Cat ET displays the status of the intake
valve actuation pressure solenoid, stop the Intake
Valve Actuation Pressure Solenoid Test.
Expected Result:
The test indicates Not Active: Device Open.

Verify that the repair eliminates the problem.


STOP.

Test Step 8. Create an Open at the ECM


A. Turn the key switch to the OFF position.
Note: It is important to cycle the key switch between
steps when the Intake Valve Actuation Pressure
Solenoid Test is used.
B. Disconnect the P2 ECM connector.

SENR9698-09

C. Remove the wires from P2:31 (Intake valve


acutation pressure solenoid) and P2:53 (Solenoid
common).
D. Reconnect the P2 ECM connector.

295
Troubleshooting Section

E. Insert one of the jumper wires into P2:31 and


P701:1.
F. Turn the key switch to the ON position.

E. Turn the key switch to the ON position.

G. Access the Special Tests under the Service


menu.

F. Access the Special Tests under the Service


menu.

H. Start the Intake Valve Actuation Pressure


Solenoid Test on Cat ET.

G. Start the Intake Valve Actuation Pressure


Solenoid Test on Cat ET.

I. Once Cat ET displays the status of the intake


valve actuation pressure solenoid, stop the Intake
Valve Actuation Pressure Solenoid Test.

H. Once Cat ET displays the status of the intake


valve actuation pressure solenoid, stop the Intake
Valve Actuation Pressure Solenoid Test.
Expected Result:
The test indicates Not Active: Device Open.
Results:

OK The test indicates Not Active: Device Open.


Proceed to Test Step 9.

Not OK The test indicates Not Active: Device


Short.

Repair: Temporarily connect a test ECM.


If the test ECM fixes the problem, reconnect the
suspect ECM.
If the problem returns, permanently replace the
ECM.
Verify that the repair eliminates the problem.
STOP.

Test Step 9. Bypass the Harness


A. Turn the key switch to the OFF position.
Note: It is important to cycle the key switch between
steps when the Intake Valve Actuation Pressure
Solenoid Test is used.
B. Disconnect the P2 ECM connector and the
P701 Intake valve actuation pressure solenoid
connector.
C. Remove the wire from P2:31 (Intake valve
acutation pressure solenoid) and P701:1 (Intake
valve acutation pressure solenoid).
D. Fabricate two jumper wires that can reach from
the ECM to the intake valve actuation pressure
solenoid.

J. Turn the key switch to the OFF position.


Note: It is important to cycle the key switch between
steps when the Intake Valve Actuation Pressure
Solenoid Test is used.
K. Disconnect the P2 ECM connector and the
P701 Intake valve actuation pressure solenoid
connector.
L. Remove the wire from P2:53 (Solenoid common)
and P701:2 (Solenoid common).
M. Insert the other jumper wire into P2:53 and
P701:2.
N. Turn the key switch to the ON position.
O. Access the Special Tests under the Service
menu.
P. Start the Intake Valve Actuation Pressure
Solenoid Test on Cat ET.
Q. Once Cat ET displays the status of the intake
valve actuation pressure solenoid, stop the Intake
Valve Actuation Pressure Solenoid Test.
Expected Result:
The test indicates Active with one or both of the
jumper wires in place.
Results:

OK The bypass harness repaired the problem.


Repair: Repair the suspect wires or replace the
suspect wires.
Verify that the repair eliminates the problem.
STOP.

Not OK The bypass harness did not repair the


problem.

296
Troubleshooting Section

SENR9698-09

Repair: Verify that the bypass harness is properly


connected.
Check the ECM connector and the solenoid
connector for damage and/or moisture.
If the problem is intermittent, refer to
Troubleshooting, Electrical Connectors - Inspect.
STOP.
i02358517

Intake Valve Actuator Circuit Test


SMCS Code: 5479-038-IL
System Operation Description:
Use this procedure to troubleshoot any suspect
problems with the intake valve actuators.

The intake valve actuators are used to hold down the


rocker arms for the intake valves. This prevents the
intake valves from closing. The intake valve actuator
is a hydraulic system that uses the engine oil to
operate. Oil is allowed to flow in and out of the intake
valve actuator when the intake valve actuator is not
activated. The intake valve actuator is activated by
an electric solenoid. When the solenoid is energized
the intake valve actuator traps the oil. This allows the
actuator to hold the rocker arm down.
Intake Valve Actuator Solenoid Test
The Intake Valve Actuator Solenoid Test is a
diagnostic test that is available on the Caterpillar
Electronic Technician (ET). The test helps diagnose
problems with the solenoid for the intake valve
actuator. A small current is applied to the circuit at
all times. This allows the Engine Control Module
(ECM) to detect open circuits when the valve is not
actuated. A short circuit will only be detected when
the valve is actuated.

Use this procedure for the following diagnostic codes:

The following conditions must be met before the


Intake Valve Actuator Solenoid Test will function:

285-05 Intake Valve Actuator #1 current low

Engine speed is 0.

285-06 Intake Valve Actuator #1 current high

Vehicle speed is 0.

286-05 Intake Valve Actuator #2 current low

The neutral switch is in the Neutral position.

286-06 Intake Valve Actuator #2 current high


287-05 Intake Valve Actuator #3 current low
287-06 Intake Valve Actuator #3 current high
288-05 Intake Valve Actuator #4 current low
288-06 Intake Valve Actuator #4 current high
289-05 Intake Valve Actuator #5 current low
289-06 Intake Valve Actuator #5 current high
290-05 Intake Valve Actuator #6 current low
290-06 Intake Valve Actuator #6 current high
You have been directed to this procedure from
Troubleshooting, Troubleshooting without a
Diagnostic Code.

SENR9698-09

Illustration 132

297
Troubleshooting Section

g01098702

Schematic for C11 and C13 engines

Illustration 133
Schematic for C15 engine

g01098709

298
Troubleshooting Section

SENR9698-09

g01110848

Illustration 134
P2 ECM connector for C11, C13, and C15 engines
(P2-20) Actuator 1 return
(P2-21) Actuator 2 return
(P2-28) Actuator 5 return

(P2-29) Actuator 6 return


(P2-39) Actuator 1 & 2 supply
(P2-54) Actuator 3 & 4 supply

(P2-55) Actuator 5 & 6 supply


(P2-65) Actuator 3 return
(P2-66) Actuator 4 return

g01098714

Illustration 135
Valve cover connectors for C11 and C13 engines
(P681-9) Actuator 1 return
(P681-10) Actuator 2 return
(P681-11) Actuator 1 & 2 supply
(P681-13) Actuator 3 return

(P681-14) Actuator 3 & 4 supply


(P682-8) Actuator 5 & 6 supply
(P682-9) Actuator 4 return
(P682-10) Actuator 5 return

(P682-11) Actuator 6 return


(P682-12) Actuator 3 & 4 supply

SENR9698-09

299
Troubleshooting Section

g01098716

Illustration 136
Valve cover connectors for the C15 engine
(P681-7) Actuator 1 return
(P681-8) Actuator 2 return
(P681-9) Actuator 1 & 2 supply

(P682-6) Actuator 3 return


(P682-7) Actuator 4 return
(P682-8) Actuator 5 return

(P682-9) Actuator 6 return


(P682-10) Actuator 3 & 4 supply
(P682-11) Actuator 5 & 6 supply

g01107530

Illustration 137
Location of components for C11 and C13 engines
(1) Actuator solenoids

(2) Valve cover connectors

(3) Intake valve actuation pressure solenoid

300
Troubleshooting Section

SENR9698-09

g01107546

Illustration 138
Location of components for C15 engine
(1) Actuator solenoids

(2) Intake valve actuation pressure solenoid

Test Step 1. Inspect the Electrical


Connectors and the Wiring
A. Thoroughly inspect the J2/P2 ECM connector
and the front valve cover connector. Thoroughly
inspect the valve cover connectors for the intake
valve actuators.
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector for the solenoids for
the intake valve actuators.
C. Check the allen head screw of each ECM
connector for the proper torque. Refer to
Troubleshooting, Electrical Connectors - Inspect
for the correct torque values.
D. Check the harness and wiring for abrasion and for
pinch points.
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, and of pinch points.
Results:

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.

Test Step 2. Check for Active Diagnostic


Codes
A. Connect Cat ET to the service tool connector.
B. Turn the key switch to the ON position.
C. Check for active diagnostic codes that are related
to the solenoids for the intake valve actuators.
D. Monitor the active diagnostic code screen on the
electronic service tool. Check and record any
active diagnostic codes.
Note: Wait at least 15 seconds in order for the
diagnostic codes to become active.

OK Proceed to Test Step 2.

E. Determine if the problem is related to a low current


diagnostic code 05 or a high current diagnostic
code 06.

Not OK There is a problem in the connectors

Expected Result:

and/or wiring.

No diagnostic codes are active.

SENR9698-09

Results:

OK No diagnostic codes are active.


Repair: The problem may have been related
to a faulty connection in the harness. Carefully
reinspect the connectors and wiring. Refer to
Troubleshooting, Electrical Connectors - Inspect.
STOP.

Not OK A low current diagnostic code (05) is


active at this time. Proceed to Test Step 3.

Not OK An high current diagnostic code (06) is


active at this time. Proceed to Test Step 5.

Test Step 3. Short the Wires of the


Suspect Solenoid for the Intake Valve
Actuator at the Valve Cover Connector
A. Turn the key switch to the OFF position.
B. Disconnect the valve cover connector for the
suspect solenoid for the intake valve actuator.
C. Fabricate a jumper wire in order to create a short
between the supply and the return for the suspect
solenoid for the intake valve actuator.
D. Turn the key switch to the ON position.
E. Access the Special Tests under the Diagnostics
menu.
F. Start the Intake Valve Actuator Solenoid Test on
Cat ET.
G. Once Cat ET displays the status of the solenoid
for the intake valve actuator, stop the Intake Valve
Actuator Solenoid Test.

301
Troubleshooting Section

Test Step 4. Create a Short Circuit at the


ECM
A. Turn the key switch to the OFF position.
B. Disconnect the J2/P2 ECM connector.
C. Inspect the terminals on the J2 and P2 ECM
connectors for damage.
Note: Refer to Illustration 134 for the proper terminal
locations.
D. Remove the return wire and the supply wire for
the suspect solenoid for the intake valve actuator
from the P2 ECM connector.
E. Fabricate a jumper wire in order to short the two
terminals for the suspect solenoid for the intake
valve actuator at the ECM. Crimp a socket to each
end of the jumper wire. Insert the jumper wire into
the P2 ECM connector.
F. Reconnect the J2/P2 ECM connector.
G. Turn the key switch to the ON position.
H. Access the Special Tests under the Diagnostics
menu.
I. Start the Intake Valve Actuator Solenoid Test on
Cat ET.
J. Once Cat ET displays the status of the solenoid
for the intake valve actuator, stop the Intake Valve
Actuator Solenoid Test.
Expected Result:
The test indicated Not Active: Device Short with the
jumper wire in place.

The test indicated Not Active: Device Short with the


jumper wire in place.

Note: Disconnecting the supply wire for the suspect


solenoid for the intake valve actuator will cause an
Open in the solenoid for the intake valve actuator
that shares the supply wire with the suspect actuator.

Results:

Results:

OK The test indicated Not Active: Device Short.

OK The test indicated Not Active: Device Short

Expected Result:

The ECM detected the short at the valve cover


connector for the solenoid for the intake valve
actuator. The harness wiring between the valve
cover connector for the suspect solenoid for the
intake valve actuator and ECM connector P2 is
OK. Proceed to Test Step 7.

Not OK The test indicated Not Active: Device


Open. The ECM did not detect the short at the
valve cover connector for the solenoid for the
intake valve actuator. Proceed to Test Step 4.

with the jumper wire in place. The ECM detected


the short.

Repair: Check continuity of the supply wire for


the suspect solenoid for the intake valve actuator
between the valve cover connector for the suspect
solenoid for the intake valve actuator and P2. If the
wire is open, replace the wire.

302
Troubleshooting Section

SENR9698-09

Check continuity of the return wire for the suspect


solenoid for the intake valve actuator between the
valve cover connector for the suspect solenoid
for the intake valve actuator and P2. If the wire is
open, replace the wire.

Test Step 6. Create an Open at the ECM

STOP.

C. Inspect the terminals on the J2 and P2 ECM


connectors for damage.

Not OK The test indicated Not Active: Device

A. Turn the key switch to the OFF position.


B. Disconnect the P2 ECM connector.

Open with the jumper wire in place. The ECM did


not detect the short circuit.

Note: Refer to Illustration 134 for the proper pin


locations.

Repair: Replace the ECM. Refer to


Troubleshooting, Replacing the ECM.
Verify that the problem is resolved. Verify that the
repair eliminates the problem.

D. Remove the return wire and the supply wire for


the suspect solenoid for the intake valve actuator
from the P2 ECM connector.

STOP.

Test Step 5. Open the Wires of the


Suspect Solenoid for the Intake Valve
Actuator at the Valve Cover Connector
A. Turn the key switch to the OFF position.
B. Disconnect the valve cover connector for the
suspect solenoid for the intake valve actuator.
C. Turn the key switch to the ON position.
D. Access the Special Tests under the Diagnostics
menu.
E. Start the Intake Valve Actuator Solenoid Test on
Cat ET.
F. Once Cat ET displays the status of the solenoid
for the intake valve actuator, stop the Intake Valve
Actuator Solenoid Test.
Expected Result:
The test indicates Not Active: Device Open.
Results:

OK The test indicates Not Active: Device Open.


The ECM detected the open at the valve cover
connector for the solenoid for the intake valve
actuator. The harness wiring between the valve
cover connector for the suspect solenoid for the
intake valve actuator and ECM connector P2 is
OK. Proceed to Test Step 8.

Not OK The test indicates Not Active: Device


Short. The ECM did not detect the open at the
valve cover connector for the solenoid for the
intake valve actuator. Proceed to Test Step 6.

E. Reconnect the P2 ECM connector.


F. Turn the key switch to the ON position.
G. Access the Special Tests under the Diagnostics
menu.
H. Start the Intake Valve Actuator Solenoid Test on
Cat ET.
I. Once Cat ET displays the status of the solenoid
for the intake valve actuator, stop the Intake Valve
Actuator Solenoid Test.
Expected Result:
The test indicates Not Active: Device Open.
Results:

OK The test indicates Not Active: Device Open.


The ECM detected the open at the ECM.

Repair: Disconnect the P2 ECM connector.


Measure the resistance between the supply wire
for the suspect solenoid for the intake valve
actuator and every terminal on ECM connector P1
and ECM connector P2. Measure the resistance
between the supply wire for the suspect solenoid
for the intake valve actuator and engine ground. If
the wire is shorted, replace the wire.
Measure the resistance between the return wire for
the suspect solenoid for the intake valve actuator
and every terminal on ECM connector P1 and
ECM connector P2. If the wire is shorted, replace
the wire.
STOP.

Not OK The test indicates Not Active: Device


Short. The ECM did not detect the open.

SENR9698-09

Repair: Replace the ECM. Refer to


Troubleshooting, Replacing the ECM.
Verify that the problem is resolved.
STOP.

Test Step 7. Create a Short Circuit at the


Solenoid for the Intake Valve Actuator
A. Turn the key switch to the OFF position.
B. Reconnect the valve cover connector.
C. Remove the valve cover.
D. Disconnect the connector on the suspect solenoid
for the intake valve actuator.
E. Inspect the terminals on the solenoid connector
for damage.

303
Troubleshooting Section

Repair: Temporarily connect a new intake valve


actuator to the harness, but do not install the new
actuator onto the engine. Verify that there are no
active diagnostic codes for the new actuator. If
there are no active diagnostic codes, permanently
install the new intake valve actuator. Clear any
logged diagnostic codes.
STOP.

Not OK The test indicated Not Active: Device

Open with the jumper wire in place. The ECM did


not detect the short circuit. There is a problem with
the wiring harness.
Repair: Repair the harness or replace the harness.
Verify that the repair eliminates the problem.
STOP.

F. Fabricate a jumper wire in order to short the two


wires for the suspect solenoid on the solenoid
connector. Crimp a pin to each end of the jumper
wire.

Test Step 8. Create an Open Circuit at the


Solenoid for the Intake Valve Actuator

G. Ensure that the solenoid connector securely holds


the jumper wire.

B. Reconnect the valve cover connector.

Note: Worn terminals and/or damaged terminals on


the solenoid connector could cause an intermittent
open circuit.
H. Turn the key switch to the ON position.
I. Access the Special Tests under the Diagnostics
menu.

A. Turn the key switch to the OFF position.

C. Remove the valve cover.


D. Disconnect the connector on the suspect solenoid
for the intake valve actuator.
E. Inspect the terminals on the solenoid connector
for damage.
F. Turn the key switch to the ON position.

J. Start the Intake Valve Actuator Solenoid Test on


Cat ET.

G. Access the Special Tests under the Diagnostics


menu.

K. Once Cat ET displays the status of the solenoid


for the intake valve actuator, stop the Intake Valve
Actuator Solenoid Test.

H. Start the Intake Valve Actuator Solenoid Test on


Cat ET.

Expected Result:
The test indicated Not Active: Device Short with the
jumper wire in place.

I. Once Cat ET displays the status of the solenoid


for the intake valve actuator, stop the Intake Valve
Actuator Solenoid Test.
Expected Result:

Results:

The test indicates Not Active: Device Open.

OK The ECM detected the short at the solenoid

Results:

connector for the solenoid for the intake valve


actuator. The harness wiring between the solenoid
connector for the suspect solenoid for the intake
valve actuator and ECM connector P2 is OK.

OK The test indicates Not Active: Device Open.


The ECM detected the open at the solenoid for the
intake valve actuator. The harness wiring between
the solenoid connector for the suspect solenoid
for the intake valve actuator and ECM connector
P2 is OK.

304
Troubleshooting Section

SENR9698-09

Repair: Temporarily connect a new intake valve


actuator to the harness, but do not install the new
actuator. Verify that there are no active diagnostic
codes. If there are no active diagnostic codes,
permanently install the new intake valve actuator.
Clear any logged diagnostic codes.

Intermittent engine derate

STOP.

Oil leaks in the intake valve actuation system.

Not OK The test indicates Not Active: Device

Short. The ECM did not detect the open. There is


a problem with the wiring harness.
Repair: Repair the harness or replace the harness.
Verify that the repair eliminates the problem.
STOP.
i02375711

Intake Valve Actuator


Response - Test
SMCS Code: 5479-038-IL
System Operation Description:
Use this procedure to diagnose mechanical problems
with the intake valve actuation system. The following
diagnostic codes indicate that there is a mechanical
problem with the system:

283-7 Intake Valve Actuation Oil Pressure not


responding

285-7 Intake Valve Actuator #1 not responding


286-7 Intake Valve Actuator #2 not responding
287-7 Intake Valve Actuator #3 not responding
288-7 Intake Valve Actuator #4 not responding

This procedure troubleshoots system faults that are


caused by the following conditions:

Faulty oil pressure solenoid

Improper response by an intake valve actuator to a


command from the ECM

The technician may be asked to perform a road test


in order to verify that the problem is resolved. If a
road test is performed on the engine, the road test
must be carried out under loaded conditions. The
test must be performed at 75 percent of the engines
rated fuel rate for at least 30 seconds.
Check the box or fill in the appropriate answer in the
appropriate section of each test step. Complete all of
the pages. Return this information with the returned
part and the troubleshooting guide. Ensure that the
items are properly packaged in order to prevent
damage during shipment.
If snapshots are available of the fault codes, provide
a copy of the snapshots with the returned part. If
snapshots are not available, please answer the
following questions and return this sheet with the
returned part.

Engine serial number ________________


Dealer code ________________
Outside temperature at time of fault
________________

Engine coolant temperature at time of fault


________________

Fault codes that were present ________________

289-7 Intake Valve Actuator #5 not responding

Also, answer the following questions concerning the


basic operating conditions:

290-7 Intake Valve Actuator #6 not responding

Did the fault occur immediately after the initial

385-1 Low Intake Valve Actuation System Oil


Pressure

Note: Resolve any electrical problems with the


system before you use this procedure.
Symptoms
The following symptoms may occur if there is a
problem with the intake valve actuation system.

Intermittent check engine light

engine start-up

________________

Did the fault occur after the first heavy pull of the
day

________________

Approximate time the faults started to occur after


starting to drive (example: one hour or two hours
after starting out) ________________

Approximate engine speed ________________.


Approximate fuel position ________________.

SENR9698-09

305
Troubleshooting Section

g01107195

Illustration 139
C11 and C13 engines (typical example)
(1) Check valve
(2) Actuator solenoid

(3) Face seals


(4) Intake valve actuation pressure sensor

(5) Intake valve actuation pressure solenoid

306
Troubleshooting Section

SENR9698-09

g01106745

Illustration 140
C15 engine (typical example)
(1) Check valve
(2) Actuator solenoid

(3) Face seals


(4) Intake valve actuation pressure sensor

(5) Intake valve actuation pressure solenoid

Test Step 1. Check the Engine Oil Level

Results:

A. Stop the engine. Allow the engine to cool


approximately 20 minutes so the oil level can
stabilize.

RESULT 1 The engine oil level is OK.

B. Check the engine oil level.


Expected Result:
________________Result

1 The engine oil level is OK.

________________Result

2 The engine oil level is low.

________________Result

3 The engine oil level is high.

Repair: Record the engine oil level.


________________.
Verify that the dipstick is calibrated correctly. Refer
to Operation and Maintenance Manual, Engine Oil
Level Gauge - Calibrate.
Proceed to Test Step 2.

RESULT 2 The engine oil level is low.

SENR9698-09

307
Troubleshooting Section

Repair: Verify that the dipstick is calibrated


correctly. Refer to Operation and Maintenance
Manual, Engine Oil Level Gauge - Calibrate.
Add engine oil to the proper level.
Record the amount of engine oil that was added.
________________

Road test the vehicle. Verify that the repair


resolved the problem.
If the problem has not been eliminated, proceed
to Test Step 2.

RESULT 3 The engine oil level is high.


Repair: Verify that the dipstick is calibrated
correctly. Refer to Operation and Maintenance
Manual, Engine Oil Level Gauge - Calibrate.
Record the amount of engine oil that was drained.
________________

Illustration 141

g00997504

C11 and C13 oil pressure map

Road test the vehicle. Verify that the repair


resolved the problem.
If the problem has not been eliminated, proceed
to Test Step 2.

Test Step 2. Check the Engine Oil


Pressure
A. Turn the key switch to the OFF position.
B. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector.
C. Start the engine and allow the engine to warm up
to operating temperature.
D. Monitor the status for Engine Oil Pressure on
Cat ET while the engine is operated throughout
the rpm range. Also check the oil pressure gauge
in the cab.
Illustration 142

E. Verify that the oil pressure is above the trip point


in Illustration 141 or Illustration 142.
F. Turn the key switch to the OFF position.

g00997505

C15 oil pressure map

Expected Result:
The engine oil pressure is above the trip point.
Results:

OK
Repair: The engine oil pressure is OK.
Record the engine oil pressure. ________________
Record the engine rpm. ________________
Proceed to Test Step 3.

308
Troubleshooting Section

SENR9698-09

Not OK The engine oil pressure is low.


Repair: Record the engine oil pressure.
________________

Record the engine rpm.

________________

If there are any active diagnostic codes that are


related to low oil pressure, refer to the appropriate
topic in Troubleshooting, Troubleshooting with a
Diagnostic Code.
If the pressure is constant throughout the rpm
range, there is a problem with the circuit for the
engine oil pressure sensor. Check the wire for the
pressure sensor supply (terminal A) for an open
circuit.
If there are no diagnostic codes that are related
to low oil pressure, refer to Testing and Adjusting,
Engine Oil Pressure - Test.
Road test the vehicle in order to verify that the
problem has been resolved.
Proceed to Test Step 8.

Test Step 3. Check for Active or Logged


Diagnostic Codes

Note: If multiple diagnostic codes are present,


diagnose the problems in the following order and
then analyze the problems after troubleshooting each
diagnostic code.
Results:

RESULT 1 Diagnostic codes with 05 or 06


extensions are active or logged.

Repair: Refer to Troubleshooting, Intake Actuator


Circuit - Test.
STOP.

RESULT 2 283-07 is active or logged. Proceed


to Test Step 4.

RESULT 3 385-01 is active or logged. Proceed


to Test Step 5.

RESULT 4 285-07 to 290-07 are active or


logged. Proceed to Test Step 8.

Test Step 4. Check the Intake Valve


Actuation Oil Pressure Valve
A. Turn the key switch to the OFF position.

A. Turn the key switch to the ON position.

B. Remove the intake valve actuation oil pressure


valve from the engine.

B. Check for the following logged diagnostic codes:

C. Inspect the valve for debris. Clean the valve.

Note: Repair all electrical faults before


troubleshooting the diagnostic codes that are listed
below.

D. Check for debris that could cause the valve to stay


in the open position.

283-07 Intake Valve Actuation Oil Pressure not


responding

Note any debris that was found in the


valve.________________

385-01 Low Intake Valve Actuation System Oil

Note: If large amounts of debris are found, determine


the source of the debris before continuing with this
procedure.

285-07 through 290-07 Intake Valve Actuator

E. Reinstall the valve.

Pressure

not responding

F. Turn the keyswitch to the ON position.

Expected Result:

G. Clear all logged diagnostic codes.

________________Result

1 Diagnostic codes that have


05 or 06 fault code extensions are logged.
________________Result

2 283-07 is logged.

H. Start the engine and run the engine for at least 30


seconds until the engine coolant temperature is
greater than 20 C (68 F).

________________Result

3 385-01 is logged.

Expected Result:

________________Result

4 285-07 through 290-07 are

There are no active diagnostic codes or logged


diagnostic codes that are associated with the intake
valve actuation oil pressure solenoid.

logged.

SENR9698-09

309
Troubleshooting Section

Results:

H. Verify that all of the ports in the oil rail are plugged.

OK The intake valve actuation oil pressure

Note: Some ports are located under the valve cover


base between the valve cover base and the cylinder
head. It may be necessary to have a second person
crank the engine while the technician checks for
leaks.

solenoid is operating properly.

Repair: 283-07 is the only diagnostic code that is


logged.
STOP.

Not OK 283-07 returns


Repair: The intake valve actuation oil pressure
solenoid may or may not be the cause of the
problem. Further testing is required in order to
determine the root cause.
Proceed to Test Step 5.

Test Step 5. Perform a Leak Test


A. Turn the key switch to the OFF position.
B. Disconnect the front valve cover connector and
the rear valve cover connector.
Note: Disconnecting the valve cover connectors will
prevent the engine from starting.
C. Disconnect the connector for the intake valve
actuation pressure solenoid.
Note: Disconnecting the connector for the intake
valve actuation oil pressure solenoid will prevent the
solenoid from opening during the leak test.
D. Remove the valve covers.
E. Wipe all of the engine oil away from the following
components:

Face seals for the intake valve actuators


The solenoid for the intake valve actuation oil
pressure

Connection between the cylinder head and the


valve cover base

Plugged ports on the intake valve actuators


Plugged ports on the valve cover base
The solenoids for the intake valve actuator

I. Verify that the oil flows through the bleed orifice on


the intake valve actuator.
Expected Result:
________________Result

1 No leaks were detected.

________________Result 2 No leaks were detected


and no oil flowed through the bleed orifice.
________________Result

3 A leak was detected.

Results:

RESULT 1 No leaks were detected. Proceed to


Test Step 6.

RESULT 2 No leaks were detected and no oil


flowed through the bleed orifice.

Repair: Check the intake valve actuator system for


debris that could restrict the flow of oil.
STOP.

RESULT 3 A leak was detected.


Repair: Check the appropriate box that indicates
the location of the leak.
________________

actuators.

Face seals for the intake valve

________________ The intake valve actuation oil


pressure solenoid.
________________ The sealing joint that is between
the cylinder head and the valve cover base.
________________

actuators.
________________

cover base.
________________

Plugged ports on the intake valve


Plugged ports on the the valve
Intake valve actuators solenoids.

Note: Do not crank the engine for more than 30


seconds.

Determine the source of the leak and repair the


leak. Clear all logged diagnostic codes.

F. Crank the engine. Do not start the engine.

Start the engine if 283-07 was the only diagnostic


code that was logged. Run the engine for at least
30 seconds until the engine coolant temperature
is greater than 20 C (68 F). If 283-07 does not
return, the repair is complete.

G. Check for oil leaks around all of the components


under the valve cover.

310
Troubleshooting Section

If other diagnostic codes were logged, road test the


vehicle. Some problems will only occur when the
engine is under a load. If logged diagnostic codes
do not return, the repair is complete.
Proceed to Test Step 6.

Test Step 6. Check the Check Valve


Note: Do not perform this procedure on engines with
serial numbers (S/N: KCA1-160; KCB1-508). Assume
that the check valve is OK. Proceed to the results.

SENR9698-09

Test Step 7. Test the Intake Valve


Actuation Oil Pressure Sensor
A pressure regulating assembly will be used to
regulate air pressure to the intake valve actuation oil
pressure sensor. Refer to Illustration 143. In addition
to the pressure regulating assembly, the technician
will need a 146-4080 Digital Multimeter Gp and two
7X-1708 Multimeter Probes.

A. Remove the check valve for the intake valve


actuation system. Refer to Illustrations 139 and
140.
B. Inspect the check valve. Look for debris that could
cause the check valve to stick.
List any debris that was found in the check valve.
________________

Note: If large amounts of debris are found, determine


the source of the debris before continuing with this
procedure.
Expected Result:
The check valve is OK.
Results:

OK The check valve is OK. Proceed to Test


Step 7.

Not OK The check valve is damaged.


Repair: Replace the check valve. Verify that the
repair has corrected the problem. If 283-07 was
the only diagnostic code that was logged, start the
engine and allow the engine to run for at least 30
seconds once the engine coolant temperature is
greater than 20 C (68 F). Verify that the repairs
have eliminated the problem. If 283-07 does not
return, the repair is complete.
If 283-07 returns or if 385-01
returns, proceed to Test Step 7.
If 285-07 through 290-07 returns, proceed
to Test Step 8.

g01106067

Illustration 143
Typical example
(6) Sensor connector
(7) Intake valve actuation oil pressure sensor
(8) Fabricated tool

The fabricated tool consists of the following fittings


and components:

5/16 JIC Female to 1/4 JIC Male


1/4 JIC Female Swivel to 1/4 NPT Male
1/4 to 1/4 Male NPT
Pressure regulator
Note: The technician is allowed to determine the
exact assembly of this tool.
Table 148

Air
Pressure
(psi)

Range Low
(VDC)

Typical
voltage
(VDC)

Range
High (VDC)

0.3

0.5

0.7

50

0.8

0.9

1.1

100

1.2

1.3

1.5

SENR9698-09

311
Troubleshooting Section

Repair: Start the engine and allow the engine to


run for at least 30 seconds once the engine coolant
temperature is greater than 20 C (68 F). If 283-07
does not return, the repair is complete.
If 283-07 returns, proceed to Test Step 8.
If 385-01 returns, proceed to Test Step 13.

Not OK The voltage measurements are not


within the given range.

Illustration 144

g01105023

Intake valve actuation oil pressure sensor

A. Fabricate the above assembly.


B. Turn the key switch to the OFF position.
C. Disconnect the connector for the intake valve
actuation oil pressure sensor.
D. Remove the intake valve actuation oil pressure
sensor from the valve cover base.
Note: If this procedure is used on a C11 or C13
engine the valve cover must be removed.
E. Install the fittings and the pressure regulator onto
the intake valve actuation oil pressure sensor.
F. Reconnect the connector for the intake valve
actuation oil pressure sensor to the engine
harness.
G. Install shop air pressure onto the assembly.
Note: Ensure that the air pressure setting is less
than 50 psi before installing air pressure onto the test
apparatus.
H. Turn the key switch to the ON position.
I. Measure the voltage between terminal B and
terminal C at the sensor connector. Refer to
Illustration 144 for pin locations.
J. Apply the air pressure that is indicated in Table
148 to the intake valve actuation oil pressure
sensor. Record the voltage measurements at the
different air pressures.
Expected Result:
The voltage measurements are within the ranges
listed in Table 148.
Results:

OK The voltage measurements are within range.

Repair: Replace the intake valve actuation oil


pressure sensor. Verify that the repair resolved the
problem.
STOP.

Test Step 8. Perform the Automatic


Cylinder Cutout Test
A. Start the engine.
B. Access the Cylinder Cutout Test in the
Diagnostic Tests under the Diagnostics menu.
C. Select the Automatic Cylinder Cutout Test on
Cat ET.
D. Start the test.
Expected Result:
All of the cylinders indicated OK during the Cylinder
Cutout Test.
Check the appropriate box in front of the cylinders
that indicates OK.
________________

#1 cylinder

________________

#2 cylinder

________________

#3 cylinder

________________

#4 cylinder

________________

#5 cylinder

________________

#6 cylinder

Results:

OK Proceed to Test Step 9.


Not OK One or more cylinders failed the
Cylinder Cutout Test.

312
Troubleshooting Section

Repair: Diagnose the problem and then repair


the cylinders that failed the Cylinder Cutout Test
before continuing with this procedure. Clear all
logged diagnostic codes. Verify that the repair has
eliminated the problem in the cylinder.

SENR9698-09

Not OK One or more cylinders indicate Not OK.


Repair: Check the appropriate box in front of the
cylinders that indicate Not OK.
________________

#1 cylinder

________________

#2 cylinder

________________

#3 cylinder

Note: The Intake Valve Actuator Test is not valid


until a Cylinder Cutout Test has shown all of the
cylinders to be functioning properly.

________________

#4 cylinder

________________

#5 cylinder

A. Start the engine. Allow the engine to warm up


to operating temperatures. Coolant temperature
should be greater than 60 C (140 F).

________________

#6 cylinder

Proceed to Test Step 9.

Test Step 9. Perform the Intake Valve


Actuator Test

Proceed to Test Step 10.

B. Access the Intake Valve Actuator Test in the


Diagnostic Tests under the Diagnostic menu.

Test Step 10. Check the Lash Settings for


the Intake Valve Actuator

C. After you adhere to the warnings, start the


automatic Intake Valve Actuator Test.

A. Turn the key switch to the OFF position.

Note: The test will cycle two times. Once the test is
complete the engine speed will increase to 2100 rpm
for 15 seconds. An OK or Not OK will be displayed
once the test is complete.
Expected Result:
All cylinders indicate OK during the Intake Valve
Actuator Test.

B. Allow the engine to cool.


C. Remove the valve cover(s) from the engine.
D. Check the lash settings for the intake valve
actuators. Refer to Testing and Adjusting for the
proper procedure.
Expected Result:
The lash settings are within the specification.

Results:

OK All cylinders indicate OK.


Repair: Check the appropriate box in front of the
cylinders that indicates OK.
________________

#1 cylinder

________________

#2 cylinder

________________

#3 cylinder

________________

#4 cylinder

________________

#5 cylinder

________________

#6 cylinder

Record the initial lash settings for each unit prior to


adjustment. Also, record the current mileage and the
mileage of the last lash setting for the intake valve
actuators.
________________

Current Mileage

________________

Mileage at last Adjustment

________________

#1

________________

#2

________________

#3

________________

#4

________________

Warm the engine until the engine coolant


temperature reaches 75 C (167 F).

#5

________________

#6

Repeat the Intake Valve Actuator Test.

Results:

If all cylinders indicate OK, proceed to Test Step


11.

OK The lash settings are within the specification.


Proceed to Test Step 11.

SENR9698-09

Not OK The lash settings are not within the


specification.

Repair: Adjust the lash settings. Refer to Testing


and Adjusting for the proper procedure. If the
mileage between the lash adjustment intervals
that are indicated above (current mileage minus
the mileage of the last adjustment) exceeds the
recommended interval, the root cause of the
problem could indicate a lack of maintenance.
Refer to OMM, Maintenance Interval Schedule.
Verify that the repair eliminates the problem by
repeating the Intake Valve Actuator Test. If all
cylinders indicate OK, return the vehicle to the
customer.
If one or more cylinders indicate Not OK proceed
to Test Step 11.

Test Step 11. Perform a Leak Test


A. Turn the key switch to the OFF position.
B. Disconnect the front valve cover connector and
the rear valve cover connector.
Note: Disconnecting the valve cover connectors will
prevent the engine from starting.
C. Disconnect the solenoid for the intake valve
actuation pressure.
Note: Disconnecting the solenoid for the intake valve
actuation pressure solenoid will prevent the solenoid
from opening during the leak test.
D. Remove the valve covers.
E. Wipe all of the engine oil away from the following
components:

Face seals for the intake valve actuators


Solenoid for the intake valve actuation oil
pressure

Connection between the cylinder head and the


valve cover base

Plugged ports on the intake valve actuators


Plugged ports on the valve cover base
Intake valve actuator solenoids

313
Troubleshooting Section

H. Verify that all of the ports in the oil rail are plugged.
Note: Some ports are located under the valve cover
base between the valve cover base and the cylinder
head. It may be necessary to have a second person
crank the engine while the technician checks for
leaks.
I. Verify that oil flows through the bleed orifice on
the intake valve actuator.
Expected Result:
________________Result

1 No leaks were detected.

________________Result 2 No leaks were detected


and no oil flowed through the bleed orifice.
________________Result

3 A leak was detected.

Results:

RESULT 1 No leaks were detected. Proceed to


Test Step 12.

RESULT 2 No leaks were detected and no oil


flowed through the bleed orifice.

Repair: Check the intake valve actuator system for


debris that could restrict the flow of oil.
STOP.

RESULT 3 A leak was detected.


Repair: Check the appropriate box in order to
indicate the location of the leak.
________________

actuators.

Face seals for the intake valve

________________ The intake valve actuation oil


pressure solenoid.

Connection between the cylinder


head and the valve cover base

________________

________________

actuators.
________________

cover base.
________________

Plugged ports on the intake valve


Plugged ports on the the valve
Intake valve actuator solenoids.

Note: Do not crank the engine for more than 30


seconds.

Determine the source of the leak and repair the


leak. Clear all logged diagnostic codes.

F. Crank the engine. Do not start the engine.

Start the engine if 283-07 was the only diagnostic


code that was logged. Run the engine for at least
30 seconds until the engine coolant temperature
is greater than 20 C (68 F). If 283-07 does not
return, the repair is complete.

G. Check for oil leaks around all of the components


under the valve cover.

314
Troubleshooting Section

If other diagnostic codes were logged, road test the


vehicle. Some problems will only occur when the
engine is under a load. If logged diagnostic codes
do not return, the repair is complete.
Proceed to Test Step 12.

Test Step 12. Check the Check Valve


Note: Do not perform this procedure on engines with
serial numbers (S/N: KCA1-160; KCB1-508). Assume
that the check valve is OK. Proceed to the results.
A. Remove the intake valve actuation system check
valve. Refer to Illustrations 139 and 140.
B. Inspect the check valve. Look for debris that could
cause the check valve to stick.
List any debris that was found in the check valve.

SENR9698-09

Results:

OK There is no debris in the assembly and the


face seals are not damaged.

Repair: Replace only the suspect intake valve


actuator assembly. Refer to Testing and Adjusting
for the proper procedure.
Verify that the repair eliminates the problem by
performing the Intake Valve Actuator Test. Road
test the vehicle. Some problems will only occur
when the engine is under a load. Always road
test the vehicle under a load before returning the
vehicle to the customer.
STOP.

Not OK There is debris in the assembly or there


is a damaged face seal.

________________

Note: If large amounts of debris are found, determine


the source of the debris before continuing with this
procedure.
Expected Result:
The check valve is OK.
Results:

OK The check valve is OK. Proceed to Test Step


13.

Not OK The check valve is damaged.


Repair: Replace the check valve. Road test
the vehicle. Verify that the repair eliminates the
problem.
If the repair does not eliminate the problem,
proceed to Test Step 13.

Test Step 13. Inspect the Hardware


Inspect the suspect intake valve actuator unit.

Repair: List any debris that was found in the


assembly. ________________
Replace any damaged face seals. Remove any
debris that is found in the intake valve actuator
assembly. If the intake valve actuator failed the
Intake Valve Actuator Test, verify that the repair
eliminates the problem by performing another
Intake Valve Actuator Test.
If the intake valve actuator did not fail the Intake
Valve Actuator Test, perform a road test. Some
problems will only occur when the engine is under
a load.
STOP.
i02375725

Multi-Torque - Test
SMCS Code: 1901-038
System Operation Description:

A. Remove the suspect intake valve actuator.

Use this procedure to determine if the multitorque


feature is working correctly. There are no diagnostic
codes for the multitorque feature.

B. Inspect the face seal for damage.

Background Information

C. Inspect the intake valve actuator for damage.

The multitorque feature is optional. The feature


provides two different torque curves for the engine.
The torque curve for the lower gears functions as a
standard engine. The torque curve for the top gears
provides additional torque. Typically, the additional
torque is approximately 136 Nm (100 lb ft).

D. Check for debris in the intake valve actuator


assembly. Do not disassemble the unit.
Expected Result:
The intake valve actuators are free of debris and the
face seals are OK.

SENR9698-09

The Engine Control Module (ECM) determines when


the vehicle is in the top gears by sensing the ratio of
engine speed to vehicle speed. The engine operates
with the higher torque curve if the ratio of engine
speed to vehicle speed is above a trip point. The trip
points are listed below.

MT-A Ratio is 21.9 rpm/mph & below (Top 1 Gear)


MT-B Ratio is 33.0 rpm/mph & below (Top 2 Gears)
MT-C Ratio is 38.0 rpm/mph & below (Top 2 Gears)
Note: The PTO Torque Limit overrides the
multitorque feature. This protects the equipment that
is powered by the PTO from excessive torque.
Access the Instantaneous Screen if the vehicle is
equipped with the Messenger (Driver Information
Display). This screen shows the status of the
multitorque feature in order to determine if the
multitorque feature is activating.

Test Step 1. Repair all Diagnostic Codes


A. Repair any active diagnostic codes before you
begin this procedure.

315
Troubleshooting Section

Results:

Yes Rating Type indicates Multitorque.


Proceed to Test Step 3.

No Rating Type does not indicate Multitorque.


The engine is not equipped with the multitorque
feature. No further repairs are required. STOP.

Test Step 3. Verify a Change in the Rated


Fuel Limit
A. Put the vehicle on a dynamometer or take the
vehicle for a road test.
B. Operate the vehicle in the lower gears at an
approximate engine speed of 1200 rpm. A load on
the engine is not required.
C. Read the Rated Fuel Limit and record the Rated
Fuel Limit from the status screen on Cat ET.
D. Operate the vehicle in the top gear at 1200 rpm.
Read the Rated Fuel Limit and record the Rated
Fuel Limit.
Expected Result:

B. investigate any logged codes. Resolve the logged


codes, if necessary.

The Rated Fuel Limit in the top gear is greater than


the Rated Fuel Limit in the lower gears.

Expected Result:

Results:

There are no active codes or logged codes that


require repair.

OK The Rated Fuel Limit in the top gear

Results:

OK There are no active codes or logged codes


that require repair. Proceed to Test Step 2.

Not OK Active codes or logged codes require


repair.

Repair: Make the necessary repairs.


Proceed to Test Step 2 after the repairs are
complete.

Test Step 2. Verify that the Software is


Installed
A. Establish communication between Cat ET and the
ECM.
B. Observe the value of the Rating Type in the
customer specified parameters.
Expected Result:
Rating Type indicates Multitorque.

is greater than the Rated Fuel Limit in the


lower gears. The multitorque feature is operating
correctly. STOP.

Not OK The Rated Fuel Limit in the top gear is

not greater than the Rated Fuel Limit in the lower


gears. The multitorque feature is not operating
correctly.
Repair: Verify that the vehicle specifications are
compatible with the multitorque feature. The ratio
of engine speed to vehicle speed should be less
than 38.0 in top gear. The ratio of engine speed
to vehicle speed should be less than 23.6 when
metric vehicle speed is used.
Verify that the repair eliminates the problem.
STOP.

316
Troubleshooting Section

SENR9698-09

i02049755

Neutral Switch Circuit - Test


SMCS Code: 1435-038
System Operation Description:
Use this procedure to determine if the neutral switch
is preventing normal operation of cruise control, idle
set speed, or PTO operation:
The following switch circuits can also prevent the
correct operation of the cruise control, idle set speed
or PTO operation:

Service Brake Pedal Position (Switch 1)

With DEC03 software, the neutral switch is


now independent from the Transmission Style
parameter. Programming the neutral switch, but not
connecting the neutral switch can prevent the Idle
Set Speed, Cruise Control, and PTO parameters
from functioning properly.
The transmission neutral switch is an open circuit
when the transmission is in gear. Shifting the
transmission to the neutral position should close
the circuit, which connects the input to the battery
voltage. Many other switches in the system connect
the input to ground when the circuit is closed.
Usage of Transmission Style Switches (DEC03
and later software)

Cruise Control Set/Resume Switch

The Transmission Style parameter determines the


switches that will be used. The following switches
can be used with being dependent on the parameter
setting:

Cruise Control On/Off Switch

Clutch Pedal Position

PTO On/Off Switch

Neutral

The switches are described in the respective circuit


tests in Troubleshooting.

Service Brake Pedal Position (Switch 1)

Service Brake Pedal Position (Switch 2)

All of the following customer programmable


parameters can affect cruise control, idle set speed,
and PTO operation:

Low Cruise Control Speed Set Limit


High Cruise Control Speed Set Limit
Idle Vehicle Speed Limit

Service Brake Pedal Position (Switch 2)


Refer to Table 149 for additional information.
Table 149

Setting For
Transmission
Style
Parameter

Switch Usage.
Service
Brake 1

Service
Brake 2

Manual
Option 1

Idle/PTO Bump rpm

Automatic
Option 1

Idle/PTO rpm Ramp Rate

Automatic
Option 2

PTO Vehicle Speed Limit

Automatic
Option 3

Automatic
Option 4

Eaton Top 2

Cruise/Idle/PTO Switch Configuration

The vehicle speed calibration can also affect the


cruise control, the idle set speed, and the PTO if the
vehicle speed calibration is incorrectly programmed.
Refer to Troubleshooting, Customer Specified
Parameters.
Transmission Neutral Switch
With software prior to DEC03, the transmission
neutral switch is required when the Transmission
Style parameter is programmed to Automatic
Option 3 or Automatic Option 4. This switch is
used to indicate when the automatic transmission
is in neutral.

Clutch

Neutral

X
X
X

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 neutral switch connects to the ECM
through connector P1:62. With DEC03 software, the
neutral switch can also connect to the ECM through
J1939.

SENR9698-09

317
Troubleshooting Section

g00646460

Illustration 145
Schematic for transmission neutral switch

Test Step 1. Determine the Type of


Problem
A. Connect the electronic service tool to the data link
connector.
B. Turn the key switch to the ON position.
C. If the vehicle will not allow setting a cruise speed,
an idle speed or a PTO speed, check the following
customer parameters:

Expected Result:
The problem is due to a parameter setting or the
problem is due to a normal kickout.
Results:

OK Explain the proper operation of system to


the driver. STOP.

Not OK

Low Cruise Control Speed Set Limit

Repair: If a problem is still suspected with


the neutral switch circuit perform the following
procedure:

High Cruise Control Speed Set Limit

Proceed to Test Step 2.

Cruise Control Parameters

Idle Parameters

Idle Vehicle Speed Limit


Idle RPM Limit
Top Engine Limit (TEL)
PTO 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.
E. Check the status screen on the electronic service
tool that indicates the last cause of a kickout for
one of the following modes:

Cruise Kickout
Idle Kickout
PTO Kickout

318
Troubleshooting Section

SENR9698-09

Test Step 2. Inspect Electrical Connectors


and Wiring

g00705233

Illustration 146

A. Thoroughly inspect the J1/P1 ECM connector, the


firewall bulkhead connector and the terminals for
the following switches in the connectors:

J1/P1:62 (Neutral Switch)


Refer to Troubleshooting, Electrical Connectors Inspect for details.
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated
with the switches.
Refer to Illustration 146.
C. Check the ECM connector (allen head screw) for
the proper torque of 6.0 Nm (55 lb in).
D. Check the harness and wiring for abrasion and
pinch points from the sensor to the ECM.
Expected Result:
All connectors, pins, and sockets should be
completely coupled and/or inserted and the harness
and wiring should be free of corrosion, abrasion, or
pinch points.

Results:

OK Proceed to Test Step 3.


Not OK
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.

SENR9698-09

319
Troubleshooting Section

Test Step 3. Check the Status of the


Transmission Neutral Switch
Table 150

Transmission Neutral Switch Status


Switch Position

Switch Status

Circuit

The Transmission is in Neutral.

ON

Closed

The Transmission is in Gear.

OFF

Open

A. Access the status screen on the electronic service


tool.
B. Turn the key switch to the ON position.
C. Shift the transmission into the Neutral position
while the status for the Transmission Neutral
Switch is being observed. Also, shift out of neutral
while the status for the Transmission Neutral
Switch is being observed.

B. For an intermittent idle kickout, talk to the driver


in order to determine the conditions when the
kickout occurs. A topic of examination could be
the following example:

Specific engine rpm


Start the engine. Duplicate these conditions and
set the idle rpm. Operate the vehicle in idle until
the problem reoccurs.

Note: If the status indicates Not Installed, check the


programming of the Transmission Style parameter.
The Transmission Style must be programmed to
Automatic Option 3 or Automatic Option 4. With
DEC03 and later software, the Transmission Style
parameter must be programmed to NONE, J1/P1:62,
or J1939.

Note: The status screen on the electronic service tool


will only indicate the last kickout. The status screen
on the electronic service tool will lose this information
if the key switch is turned OFF.

Expected Result:

D. If the status screen on the electronic service


tool is blank, then either there was no kickout of
the cruise control, or the power to the ECM was
turned off before the information could be read.
Repeat this test step.

The switch status changes per the information in


Table 150.
Results:

C. Connect the electronic service tool and check the


status screen for the last cause of the kickout.

OK The switch is operating normally. STOP.

Note: A status screen that is blank indicates No


Occurrence.

Intermittent Problem Suspected Proceed to Test

Expected Result:

Not OK The ECM is not reading the switch status

RESULT 1 The status for the kickout displays the


following result:

Step 4.

change. Proceed to Test Step 5.

Test Step 4. Operate the Vehicle and


Check the Kickout Status Parameter
A. For an intermittent cruise control kickout, talk to
the driver in order to determine the conditions
when the kickout occurs. Topics of examination
could be the following examples:

Specific Speed
Road Conditions
Weather Conditions
Take the vehicle for a road test in order to
duplicate these conditions and set the cruise
control. Operate the vehicle in cruise control until
the problem reoccurs.

Neutral
RESULT 2 The status for the kickout displays the
following result:

Switch Turned Off


RESULT 3 The status for the kickout displays the
following result:

Brake
RESULT 4 The status for the kickout displays the
following result:

Vehicle Speed < Limit


Bad Vehicle Speed

320
Troubleshooting Section

Vehicle Speed Limit


RESULT 5 The status for the kickout displays the
following result:

PTO Switch ON
RESULT 6 The status for the kickout displays the
following result:

Clutch
RESULT 7 The status for the kickout displays the
following result:

No Engine Speed
Results:

SENR9698-09

Repair: Perform the following diagnostic


procedure:
Troubleshooting, Clutch Pedal Position Switch
Circuit - Test
STOP.

Result 7
Repair: Perform the following diagnostic
procedure:
Troubleshooting, Engine Speed/Timing Circuit Test
STOP.

Result 1 Proceed to Test Step 5.

Test Step 5. Check the Switch Circuit for


the ECM

Result 2

A. Turn the key switch to the OFF position.

Repair: Perform the following diagnostic


procedure:

B. Fabricate a jumper wire 100 mm (4 inch) long.


Crimp a Deutsch pin to both ends of the wires.

Troubleshooting, Cruise Control Switch Circuit Test

C. Disconnect the P1 ECM connector from the ECM.

STOP.

Result 3
Repair: Perform the following diagnostic
procedure:
Troubleshooting, Service Brake Pedal Position
(Switch 1) Circuit - Test
STOP.

Result 4
Repair: Perform the following diagnostic
procedure:
Troubleshooting, Vehicle Speed Circuit - Test
STOP.

Result 5
Repair: Perform the following diagnostic
procedure:
Troubleshooting, PTO Switch Circuit - Test
STOP.

Result 6

D. Connect a 140-2266 Cable (Seventy-Pin


Breakout) between the P1 ECM connector and
the ECM.
E. Install the jumper into terminal 62 (Neutral Switch)
of the breakout T. Connect the other end of the
jumper to terminal 52 (Unswitched +Battery) of
the breakout T.
F. Turn the key switch to the ON position.
G. Connect the electronic service tool to the data link
connector.
H. Access the status screen on the electronic service
tool.
I. While the status for the Transmission Neutral
Switch is being monitored on the status screen
slowly remove the jumper from terminal 52
(Unswitched +Battery). Now, slowly insert the
jumper into terminal 52 (Unswitched +Battery).
Expected Result:
When the jumper wire is installed, the status for
the Transmission Neutral Switch is On. When
the jumper wire is removed, the status for the
Transmission Neutral Switch is Off.

SENR9698-09

321
Troubleshooting Section

Results:

Repair: Perform the following repair:

OK The ECM is functioning properly. Proceed

Replace the faulty switch.

to Test Step 6.

Not OK The ECM is not functioning properly.


Repair: Perform the following repair:
1. Temporarily connect a test ECM.
2. Remove all jumpers and replace all connectors.

Verify that the repair eliminates the problem.


STOP.

Not OK There is a problem in the harness

between the switch and the ECM. Proceed to Test


Step 7.

3. Recheck the system for active diagnostic codes.

Test Step 7. Insert a Jumper at the


Bulkhead Connector

4. Repeat the Test Step.

A. Turn the 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 each end of the wires.

6. If the problem returns with the suspect ECM,


replace the ECM.

C. Find the neutral switch terminal and the +Battery


connection in the engine side of the bulkhead
connector for the vehicle harness.

7. Verify that the repair eliminates the problem.


STOP.

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.
E. Turn the key switch to the ON position.

A. Turn the key switch to the OFF position.

F. Connect the electronic service tool to the data link


connector.

B. Ensure that the J1/P1 ECM connector is


connected.

G. Access the status screen on the electronic service


tool.

C. Find the neutral switch in the vehicle.


D. Disconnect the wires from the neutral switch
terminals.

H. While the switch status is being monitored,


alternately remove the jumper wire between the
two terminals, and alternately insert the jumper
wire between the two terminals.

E. Turn the key switch to the ON position.

Expected Result:

F. Connect the electronic service tool to the data link


connector.

When the jumper wire is installed, the status for


the Transmission Neutral Switch is On. When
the jumper wire is removed, the status for the
Transmission Neutral Switch is Off.

G. Access the status screen on the electronic service


tool.
H. While the status for the Transmission Neutral
Switch is being monitored, connect the switch
wires and disconnect the switch wires.

Results:

OK The problem is in the vehicle wiring between


the bulkhead connector and the switch.

Expected Result:

Repair: Perform the following repair:

When the switch wires are connected, the status for


the Transmission Neutral Switch is On. When the
switch wires are disconnected, the status for the
Transmission Neutral Switch is Off.

Inspect the vehicle wiring and repair the vehicle


wiring, as required. If the problem still exists with
the wiring, send the vehicle to the OEM dealer.

Results:

OK The switch is not functioning properly.

STOP.

Not OK The problem is in the vehicle wiring

between the bulkhead connector and the ECM.

322
Troubleshooting Section

SENR9698-09

Repair: Perform the following repair:

Power Train Data Link

Inspect the vehicle wiring and repair the vehicle


wiring, as required. If the problem still exists with
the wiring, send the vehicle to the OEM dealer.

Transmission Neutral Switch

STOP.
i02186433

Powertrain Data Link Circuit Test

Note: Use Caterpillar Electronic Technician (ET) to


view the Configuration screen in order to determine
if any of these parameters are configured to use
the J1939 data link. Some of the feature must use
the J1939 data link if the components are installed.
Features that must use the J1939 data link include
the Adaptive Cruise Control Enable, Cruise Control
Pause Switch, and the Power Train Data Link.

SMCS Code: 1901-038

The following background information is related


to this procedure:

System Operation Description:

Power train Data Link

Use this procedure under the following situation:

The power train data link is designed to offer


electronically controlled Anti-Lock Brakes (ABS),
traction control systems, and/or transmission
controls. This is accomplished by a momentary
reduction of engine rpm and/or engine torque, that
is triggered by a signal from an off-engine control
module for the ABS, for the traction control, or for
the transmission. An off-engine control module is
a control module that is not part of the Caterpillar
engine control system.

One of the following diagnostic codes are active:

231-02 J1939 Data Incorrect


231-12 J1939 Device Not Responding
Also, use this procedure when a feature that uses
the J1939 data link is not operating correctly. The
following features can be configured to use the J1939
data link:

Adaptive Cruise Control Enable


Fan Overide Switch
Diagnostic Enable
PTO On/Off Switch
Remote PTO Set Switch
Remote PTO Resume Switch
PTO Engine RPM Set Speed Input A
Two-Speed Axle Switch
Cruise Control On/Off Switch

Any combination of the following systems may be


installed together on a vehicle:

Traction control
Transmission control
ABS
The required components are installed at the OEM
when the vehicle is built.
Power train data link sensors, off-engine control
modules, and wiring are installed by the vehicle
OEM. Refer to the vehicle OEM for questions that
are related to these components.
Anti-Lock Brake Systems (ABS)

Clutch Pedal Position Switch

The Power Train Data Link may be used by an


anti-lock brake system (ABS) in order to disable the
engine retarder when the anti-lock brake control
determines that the engine retarder should be
disabled. This is usually achieved when the ABS is
active.

Retarder Off/Low/Medium/High Switch

Traction Control Systems

Service Brake Pedal Position Switch #1

Loss of traction is determined by sensors on the


vehicle that are mounted near the wheels. These
sensors are also used by the ABS. Typically, a
system with traction control includes anti-lock brakes.

Cruise Control Set/Resume/Accel/Decel Switch


Cruise Control Pause Switch

Vehicle Speed Input

SENR9698-09

323
Troubleshooting Section

Transmission Control
The following characteristics are determined by a
vehicle speed sensor in the transmission:

Transmission shift points


Engine rpm
Load
The sensors for power train control provide signals
to the vehicle control module of the Power Train
Data Link. The vehicle control module of the Power
Train Data Link then communicates with the Engine
Control Module (ECM). The ECM receives a request
from the Power Train Data Link. The ECM responds
by momentarily limiting the following characteristics:

Engine rpm
Torque
Both engine rpm and torque
The presence of an active J1939 data link circuit can
be determined by observing the Power Train Status
screen on Cat ET. The status screen will display
Installed if the proper software is installed in the
ECM, and there is no action that is being requested
at that time by any of the control modules on the data
link.
If an action is being requested by one of the vehicle
control modules, the display will indicate the control
that is making the request (traction control or
transmission control) or a combination of the two
(traction control and transmission control). Power
train control is also displayed in the upper right hand
corner of the display status screen. This space is
replaced by the low oil pressure indicator, when a
condition of low oil pressure exists.
J1939 Data Link
SAE J1939 is standard on all engines.
Note: The wiring for the J1939 data link is a shielded
twisted pair cable and the wiring is not serviceable.
The wiring must be replaced when the wiring is
damaged.

Illustration 147
Schematic for power train data link

g00941844

324
Troubleshooting Section

Illustration 148
Diagnostic connectors

SENR9698-09

g00714306

SENR9698-09

325
Troubleshooting Section

Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, or of pinch points.
Results:

OK The harness and connectors appear to be


OK. Proceed to Test Step 2.

Not OK There is a problem with the connectors


and/or wiring.

Repair: Repair the