3406E, C-10, C-12, C-15, C-16 AND C-18 TRUCK ENGINE Troubleshooting

CATERPILLAR
3406E, C-10, C-12, C-15, C-16 AND C-18 TRUCK ENGINE

TROUBLESHOOTING
TABLE OF CONTENTS
DESCRIPTION PAGE
TROUBLESHOOTING............................................................................................................................................................ 5
PROGRAMMING PARAMETERS ......................................................................................................................................... 38
CUSTOMER SPECIFIED PARAMETERS .............................................................................................................................. 45
SYSTEM CONFIGURATION PARAMETERS ......................................................................................................................... 82
TROUBLESHOOTING WITHOUT A DI AGNOSTIC CODE ..................................................................................................... 83
TROUBLESHOOTING WITH A DIAGNOSTIC CODE........................................................................................................... 115
DIAGNOSTIC FUNCTIONAL TESTS .................................................................................................................................. 155
CALIBRATION PROCEDURES .......................................................................................................................................... 403
ALPHABETICAL INDEX ..................................................................................................................................................... 410

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 Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
CATERPILLAR
TROUBLESHOOTING
TABLE OF CONTENTS
DESCRIPTION PAGE
SYSTEM OVERVIEW .............................................................................................................................................................5
GLOSSARY......................................................................................................................................................................... 16
ELECTRONIC SERVICE TOOLS .......................................................................................................................................... 23
REPLACING THE ECM ........................................................................................................................................................ 25
SENSORS AND ELECTRICAL CONNECTORS .................................................................................................................... 27
ENGINE WIRING HARNESS DIAGRAM ............................................................................................................................... 34
VEHICLE WIRING HARNESS DIAGRAM.............................................................................................................................. 36
5
Troubleshooting Section
Troubleshooting Section The desired engine speed is typically determined

by one of the following conditions:
• The position of the accelerator pedal

Electronic Troubleshooting • The desired vehicle speed in cruise control
i01914266 • The desired engine rpm in PTO control

System Overview Timing Considerations
SMCS Code: 1900
Once the governor has determined the amount of
fuel that is required, the governor must determine
System Operation the timing of the fuel injection. Fuel injection timing
is determined by the ECM after considering input
These engines were designed for electronic control. from the following components:
The injection pump, the fuel lines and the nozzles
that are used in mechanical engines have been • Coolant Temperature Sensor
replaced with an electronic unit injector in each
cylinder. A solenoid on each injector controls the • Intake Manifold Air Temperature Sensor
amount of fuel that is delivered by the injector. An
Engine Control Module (ECM) sends a signal to • Atmospheric Pressure Sensor
each injector solenoid in order to provide complete
control of the engine. • Boost Pressure Sensor
Electronic Controls At start-up, the ECM determines the top center

position of the number 1 cylinder from the signal
The engine's electronic system consists of the from the secondary engine speed/timing sensor.
Engine Control Module (ECM), the engine sensors After start-up, the ECM determines the top center
and the vehicle interface. The ECM is the computer. position of the number 1 cylinder from the primary
The personality module is the software for the engine speed/timing sensor. The ECM decides
computer. The personality module contains the when fuel injection should occur relative to the top
operating maps. The operating maps define the center position and the ECM provides the signal to
following characteristics of the engine: the injector at the desired time. The ECM adjusts
timing for the best engine performance, the best
• Horsepower fuel economy and the best control of white smoke.
Actual timing cannot be viewed with the Caterpillar
• Torque curves Electronic Technician (Cat ET), and desired timing
cannot be viewed with Cat ET.
• RPM
Fuel Injection
• Other characteristics
The ECM controls the amount of fuel that is injected
Engine Governor by varying the signals to the injectors. The injectors
will pump fuel only if the injector solenoid is
The Electronic Controls on the engine serves as the energized. The ECM sends a high voltage signal
engine governor. to the solenoid. This high voltage signal energizes
the solenoid. By controlling the timing and the
The Electronic Controls determine the timing and duration of the high voltage signal, the ECM can
the amount of fuel that is delivered to the cylinders. control injection timing and the ECM can control the
These decisions are based on the actual conditions amount of fuel that is injected.
and the desired conditions at any given time.
The personality module inside the ECM sets certain
The governor uses the accelerator pedal position limits on the amount of fuel that can be injected. The
sensor to determine the desired engine speed. FRC Limit (Fuel) is based on the boost pressur e.
The governor compares the desired engine speed The FRC Limit (Fuel) is used to control the air/fuel
to the actual engine speed. The actual engine ratio for control of emissions. When the ECM senses
speed is determined through the primary engine a higher boost pressure, the ECM increases the
speed/timing sensor. If the desired engine speed is FRC Limit (Fuel). A higher boost pressure indicates
greater than the actual engine speed, the governor that there is more air in the cylinder. The ECM allows
injects more fuel in order to increase engine speed. more fuel into the cylinder when the ECM increases
the FRC Limit (Fuel).
6
The Rated Fuel Limit is a limit that is based on the Customer Parameters And Engine Speed
power rating of the engine and engine rpm. The Governing
Rated Fuel Limit is similar to the rack stops and the
torque spring on a mechanically governed engine. A unique feature with electronic engines is customer
The Rated Fuel Limit provides the power curves specified parameters. These parameters allow the
and the torque curves for a specific engine family vehicle owner to fine tune the ECM for engine
and a specific engine rating. All of these limits operation. Fine tuning the ECM for engine operation
are determined at the factory. These limits are in allows the vehicle owner to accommodate the
the Personality Module and these limits cannot be typical usage of the vehicle and the power train of
changed. the vehicle.
Many of the customer parameters provide additional

restrictions on the actions that will be performed
(1) TC Reference by the ECM in response to the driver's input. For
example, the "PTO Top Engine Limit" is an engine
~ 2 SpeedTiming rpm limit. The "PTO Top Engine Limit" is an engine
m
) Signol rpm limit that is used by the ECM as a cutoff for
LFll ,
I
ElectricolCurrent
the fuel. The ECM will not fuel the injectors above
this rpm.
~ 5 ) to the Injector
Solenoid Some parameters are intended to notify the driver
of potential engine damage ("Engine Monitoring
Parameters"). Some parameters enhance fuel
Injection economy ("Vehicle Speed Parameters", "Cruise
(4) Pressure Control Parameters", "Engine/Gear Parameters" and
~....~ /.~...-." Curve
"Smart 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.
900628178
Illustration 1 Engine Monitoring
(1) TC reference
(2) Speed-timing signal Caterpillar provides a factory installed engine
(3) Electrical current to injector solenoid monitoring system. The Caterpillar engine monitoring
(4) Injection pressure curve
system monitors engine oil pressure, coolant
Note: The signals and the timing of Illustration 1 are temperature, intake manifold air temperature, and
not to scale. coolant level (optional device). Optional devices are
OEM installed.
Cold Mode The oil pressure, intake manifold air temperature,
and coolant temperature sensors are standard on
The ECM will set cold mode when the coolant all engines. The Vehicle OEM installs the coolant
temperature is below 18 °C (64 °F). level sensor and the associated harness. The
coolant level sensor is the only optional component
Cold mode is activated five seconds after the start of Caterpillar engine monitoring. Coolant level
of the engine. During cold mode, low idle speed is selected through a customer programmable
will be increased to 800 rpm. After 60 seconds, the parameter.
engine speed is reduced to 600 rpm. Engine power
will be limited until cold mode is deactivated. Caterpillar engine monitoring can be programmed
to four different modes. These four modes of
Cold mode will be deactivated when the coolant programming are the following modes: OFF,
temperature reaches 18 °C (64 °F). 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.
7
For example, if DERATE mode was selected, the DERATE Operation

engine will derate engine power and vehicle speed.
The engine will derate engine power and vehicle If the system is programmed to DERATE, the ECM
speed if the coolant temperature sensor, the oil causes the warning lamp to turn ON. The warning
pressure sensor or the coolant level sensor detects lamp does not flash. Also, the ECM begins flashing
conditions that exceed acceptable limits. the check engine lamp. The flashing check engine
lamp indicates that a problem has been detected
An excessive intake manifold air temperature will by the engine monitoring system.
not derate the engine. Also, an excessive intake
manifold air temperature will not shut down the This response is identical to the response when the
engine. system is in the WARNING mode.
Caterpillar Engine Monitoring The DERATE mode alters the engine performance
when any of the following conditions exist:
OFF
• Oil pressure becomes Very Low Oil Pressure.
If Caterpillar Engine Monitoring is programmed
to OFF, the ECM will not flag low oil pressure, • Coolant level becomes Very Low Coolant Level.
high coolant temperature, and low coolant level.
No warnings will occur even though conditions • Coolant temperature becomes High Coolant
that could cause the ECM to take action (Engine Temperature.
Monitoring) are exceeded.
• Coolant temperature becomes Very High Coolant
The ECM still uses these sensors for engine Temperature.
operation. As an example, the Coolant Temperature
Sensor is still used for cold mode operation. Whenever the warning lamp is flashing, the ECM is
limiting or derating the engine.
Note: NOV01 and newer software does not allow
the "Engine Monitoring Mode" to be programmed The ECM limits the maximum vehicle speed and the
to "Off" except on engine serial numbers (S/N: ECM reduces the available power when any of the
WlA1-Up; MDP1-Up; MEP1-Up). following conditions exist:
WARNING Operation • High Coolant Temperature
If the system is programmed to WARNING, the ECM • Very High Coolant Temperature
causes the warning lamp to turn on. This will also
cause the Check Engine Lamp to flash because • Very Low Coolant Level
of the active diagnostic code. The flashing check
engine lamp indicates that a problem has been If the ECM detects Very Low Oil Pressure, the ECM
detected by the engine monitoring system. No limits the following parameters:
further action by the ECM or action by the engine
occurs if the ECM is programmed to WARNING. • Maximum vehicle speed
If the problem is due to one of the following • Available power

conditions, the ECM will cause the Warning lamp to
turn ON and the ECM will cause the check engine • Engine rpm
lamp to flash:
This derating of engine performance is provided in
• Low Coolant Level order to get the driver's attention so the driver can
take action in order to avoid engine damage.
• High Coolant Temperature
SHUTDOWN Operation
• High Intake Manifold Air Temperature
If the system is programmed to SHUTDOWN, the
• Low Oil Pressure 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.

8
• Coolant level becomes Very Low Coolant Level.

Low Level Effect
• Coolant temperature becomes Very High Coolant (1) Wornin9
Temperature. Derote'~ Maximum rote will
Rated ~ (2) not exceed 10% per
~ second.
(1) Start/Restart Maximum rote will 160 hp (119 kW}
Wornin9 Derote 7 (2) not exceed I0% per
second. 45 mph (72.5 kin/h)
Rated kQ
iiiiiiiiiiiiiiiiiilili!iiiiiiiiiiiiiiiiiiiiiiiiii
iiiiiiiiiii
i (3) Shutdown
o: ::::::::::30 Second::::::::: / (3) Shutdown
,., :i:i:i:i:i:!:i:
:i:!:Oeloy:!:i:i:i:i:i:i:i:i:i:
i
lYl
I I
I'Z'I'X'X'X'X'X'X'X'I'X'X'X'I'X'X'I'I
Low Very
Low
v.v.v.'.v::.'.v.v.v.v.v, .'.'.v.v.'.
illustration 5 g00628189
............................... j
I
Graph of engine monitoring coolant level
0 10 20 30 40 50 60
Time (seconds) (1) Warning derate
(2) The maximum rate will not exceed 10 percent per second.
Illustration 2 g00628179 (3) Shutdown
Graph of engine monitoring coolant temperature
(1) Start or Restart warning derate
(2) The maximum rate will not exceed 10 percent per second.
(3) Shutdown
Maximum rote will
not exceed lOg per
Temperature Effect (1~ Star t/Restart second.
"" ~ ~ ~ Tripped~:7
W a r n i n g /
R ° t e d ~ ~ ~ l G O hp (119 kW)
Rated ,~ Maximum rote will
not exceed 10% per ~(Smph(72.Skm/h)
second.
-25% ,.
o J~,~.30 Sec0ndT/~ ~L~.~, ~
Il
-50%-
0
eL.
-75%- 160 ho (119kW}
45 mph (72.5 kin/h)
-100%
, (1)Shutdown
(Deg F) 216 217 219 221 223 230
(De9 C) 102 10) 104 105 106 110
Time (seconds) (2) Shutdown
Coolant Temperature
Illustration 3 g00628181
C-10 and C-12 Graph of engine monitoring coolant temperature
(1) Shutdown Illustration 6 g00628190
Graph of engine monitoring coolant level time
Temperature Effect (1) Start or Restart warning tripped
(2) Shutdown
Maximum rote will
Rated '~- not exceed 10% per
I second.
- 25%
) - 50%.
0
o. -75g" 160 ho (119kW)

45 mph (72.5 kin/h)
-I00%
I I I
1-'"_(1) Sh.tdown
(Deq F) 225 226 228 230 233 2)4
(Deg C) 107 108 109 110 111 I12
Coolant Temperature
3406E, C-15, C-16 and C-18 Graph of engine monitoring coolant
temperature
(1) Shutdown
9
50
25 45 (1) Low Oil P r e s s u r e
jJ~ 40
2C (1) Low Oil Pressure j _~_
~0 . 35
G, 30
~-~-
®
15 L.
~,
O~
25
¢P
4" 10 • . 20
8 /' (2)Very Low Oil Pressure o 15
10 Pressure
/ //
/
5
...... J
0
1000 1500 2000 100 600 1000 1500 2000
Engine rpm
Engine rpm
Illustration 7 g00732031 Illustration 9 g00628192

C-10 and C-12 Graph of low oil pressure for OCT99 and newer 3406E, C-15, C-16 and C-18 Graph of low oil pressure
Personality Modules (1) Low oil pressure
(1) Low Oil Pressure (2) Very low oil pressure
(2) Very Low Oil Pressure
Stort/Restort
3O
27
(1) Low Oil Pressure 16o
(119 kW)
45 mph
~ / ~
) Warning Derote
(2) Shutdown
(72.5 km/h)
24 1350 rpm
~21
G, 18
§ 15
/ I / I
~- 12 0 10 20 30 40 50 6O
ow Oil Pressure Time (seconds)
o 9
3 Graph of Very low oil pressure start-up or restart

(1) Warning derate
0 (2) Shutdown
100 600 1000 1500 2000
Engine rpm
Monitoring Fuel Temperature
Illustration 8 g00628191 The fuel temperature sensor monitors the fuel
C-10 and C-12 Graph of low oil pressure for JUL99 and older temperature. The fuel rate that is calculated by
Personality Modules the ECM is adjusted in order to compensate for
(1) Low oil pressure changes in fuel temperature. The fuel rate is also
(2) Very low oil pressure 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.
10
Other ECM Functions Of Engine Snapshot Data

Performance Whenever most diagnostic codes occur, the ECM
records the time in engine hours of the occurrence.
The ECM also provides enhanced control of the
Also, the ECM records the operating parameters of
engine for vehicle functions such as retarding
the engine and controlling the cooling fan. Refer the engine for 9.6 seconds before the diagnostic
to Troubleshooting, "Sensors and Electrical code and 3.4 seconds after the diagnostic code.
The operating parameters of the engine that are
Connectors" for supplemental information about
the systems that can be monitored by the ECM in recorded are similar to the operating parameters of
the engine that are displayed in the status screens
order to provide enhanced vehicle performance,
fuel economy and convenience for the driver. on Cat ET. Not all of the status screens on Cat ET
or parameters are recorded. The Engine Snapshot
can also be triggered from the Cruise Control
Self-Diagnostics Set/Resume switch. In order to trigger the Engine
Snapshot from the Cruise Control Set/Resume
The electronic system has the ability to diagnose switch, quickly toggle the switch to the Set position.
problems. When a problem is detected, a diagnostic Then, quickly toggle the switch to the Resume
code is generated and the check engine/diagnostic position. You can also toggle the Cruise Control
lamp may be turned ON. In most cases, the code is Set/Resume switch from the Resume position to
also stored in permanent memory or logged in the the Set position. The Engine Snapshot can also be
Engine Control Module (ECM). triggered from Cat ET.
When diagnostic codes occur, the diagnostic

codes are called active diagnostic codes. Active
Effect Of Diagnostic Codes On
diagnostic codes indicate that a problem of some Engine Performance
kind currently exists. Active diagnostic codes
should always be serviced before any other work is The discussion on engine monitoring mentions that
performed. If a truck is brought in with an active the check Engine Lamp flashes when a specific
code, find the code in this manual and proceed to condition exists. When the ECM detects the engine
diagnose the cause. problem, the ECM generates an active diagnostic
code. Also, the ECM logs the diagnostic code
Diagnostic codes that are stored in memory are in order to indicate the time of the problem's
called logged diagnostic codes. Logged diagnostic occurrence. The ECM also logs the number of
codes do not necessarily indicate that something occurrences of the problem. There are two types of
needs to be repaired. The problem may have been diagnostic codes. There are fault codes and event
temporary, or the problem may have been repaired codes.
since the problem was logged. Logged diagnostic
codes are instead meant to be an indication of Diagnostic Fault Codes
probable causes for intermittent problems.
Diagnostic fault codes are provided in order to
Diagnostic codes that identify operating conditions indicate that an electrical problem or an electronic
outside the normal operating range are called problem has been detected by the ECM. In some
events. Event codes are not typically an indication cases, the engine performance can be affected
of an electronic system problem. when the condition that is causing the code exists.
More frequently, the driver cannot detect any
Some of the diagnostic codes require passwords to difference in the engine performance.
be cleared from memory. Diagnostic codes that do
not require passwords to be cleared from memory If the check engine lamp is flashing and the driver
are automatically deleted after 100 hours of engine indicates that a performance problem occurs, the
operation. diagnostic code may indicate the cause of the
problem. The problem should be corrected.
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:
11
• There are several occurrences of the diagnostic "Total Distance" Data requires a vehicle speed
code in a very short period of time. sensor or an electronic vehicle speed source to be
connected to the ECM. The same sensor is used for
• The ECM is indicating an active code at the ECM vehicle speed. Distance can be displayed in
present time. miles or kilometers.
Diagnostic Event Codes "PTO Time" and "PTO Fuel" are logged when the
engine rpm is set by the use of the cruise switches
Diagnostic event codes are used to indicate that and the engine is operating under some load. Also,
some operational problem has been detected in "PTO Time" and "PTO Fuel" are logged when the
the engine or in the truck by the ECM. Usually, this PTO On/Off Switch is in the QN position and vehicle
does not indicate an electronic malfunction. speed is within the range of the "PTO Vehicle Speed
Limit" Parameter.
The ECM also provides an ECM date/time clock
that is used to time stamp the following diagnostic "Idle Time" and "Idle Fuel" can include operating
event codes: time when all of the following conditions are met:
• 84-00 Vehicle Overspeed Warning • When engine speed is set by using the cruise
switches and the vehicle speed is within the
• 84-14 Quick Stop Occurrence range of the "Idle Vehicle Speed Limit" Parameter.
• 100-11 Very Low Oil Pressure • The engine is not operating under a load.
• 105-11 Very High Intake Manifold Air Temperature Fuel Information can be displayed in US Gallons
or liters.
• 110-11 Very High Coolant Temperature
"Total Fuel" is the total amount of fuel that is
• 111-11 Very Low Coolant Level consumed by the engine during operation.
• 190-00 Engine Overspeed Warning "Total Max Fuel" is the maximum amount of fuel that
could have been consumed by the engine during
Refer to Troubleshooting, "Troubleshooting with a operation.
Diagnostic Code" for a listing of all of the diagnostic
codes. "Average Load Factor" provides relative engine
operating information. "Average Load Factor"
compares actual engine operation information to
ECM Lifetime Totals the maximum engine operation that is available.
"Average Load Factor" is determined by using
The ECM maintains total data of the engine for the "Total Max Fuel", "Idle Fuel", and "Total Fuel".
following parameters: All of these parameters are available on Cat ET.
These parameters are available within the menu for
• "Total Time" (Engine Hours) "Current Totals".
• "Total Distance"
Trip Data That Is Stored In The ECM
• "PTO Time" and "PTO Fuel"
The Trip data allows the tracking of engine operation
• "Idle Time" and "Idle Fuel" by the vehicle owner over intervals that are defined
by the vehicle owner. Two types of Trip Data are
• "Total Fuel" stored in the ECM, Driver Trip Data and Fleet Trip
Data. All of the Trip Data is stored in memory and
• "Total Max Fuel" the Trip Data is maintained through the Unswitched
Battery Lines when the ignition switch is OFF An
• "Average Load Factor"(Engine) internal battery will maintain this information while
the Unswitched Battery Lines are disconnected.
The "Total Time" is the engine's operating hours.
The engine hours do not include operating time Driver Trip Data
when the ECM is powered ON but the engine is
not running. Driver Trip Data is known as the Driver Trip
Segment. The Driver Trip Segment includes data for
the following parameters:
• Total Time
12
• Driving Time Three histograms are available. One histogram

records engine hours versus the engine speed. The
• Distance second histogram records engine hours versus
vehicle speed. The third histogram records engine
• Fuel hours versus engine speed and vehicle speed.
• Overall Fuel Economy Cat ET calculates the percentage of time that is

spent in each of the engine rpm or vehicle speed
• Driving Fuel Economy ranges. Custom Data is available. Custom Data
allows the recording of engine parameters that are
• Idle Time specified by the vehicle owner. The ECM records
the Custom Data.
• Idle Fuel
A reset of the Fleet Trip Data which includes the
• Percent Idle Time Fleet Trip Segment, the Histograms, and the Custom
Data can be done in several ways. The following
• PTO Time tools can be used to reset the Fleet Trip Data:
• PTQ Fuel • Cat ET which may require Customer Passwords
• Percent PTO Time • Caterpillar Fleet Information Software (FIS)
• Average Load Factor • CAT ID which requires Customer Parameters

Programming to provide access
• Average Vehicle Speed
When the data is reset, the ECM records the Current
• Average Driving Speed Totals at the time of the reset. These Totals are used
as the starting point for the Fleet Trip. The following
• Maximum Vehicle Speed tools access the recorded starting point:
• Maximum Engine Speed • Cat ET
• Start Time • Caterpillar Fleet Information Software (FIS)
• End Time • CAT ID
• Start Odometer The tool then subtracts the recorded starting point
from the Current Totals in the ECM in order to
• End Odometer calculate the Fleet Trip Data. Resetting the Fleet Trip
Data requires Customer passwords if the passwords
A Driver Trip Segment can be reset by using Cat ET are programmed.
or a Caterpillar Driver Information Display (CAT ID).
Fleet Trip Custom Data
When the data is reset, the ECM stores the Current
Totals at the time of the reset. This data is used as Fleet Trip Custom Data is part of the Fleet Trip
the starting point for the Driver Trip Data. Cat ET Segment. Fleet Trip Custom Data allows the owner
or the CAT ID accesses this starting point and the of the vehicle to set five customized methods of
Current Totals from the ECM in order to calculate recording data for the vehicle. Refer to Illustration
the data for the Driver Trip Segment. Resetting the 11 for the basic program.
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.
13
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
SUM 1 WHEN ISBETWEEN is between 87 and 137 km/h (55 and 85 mph)"
AND 4 AND WHEN 5 The Custom Data programs are protected by

Customer Passwords. The programs are stored in
I S BETWEEN_ AND 7 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
Basic Program
tuning the calculations for fuel consumption. The
Fuel Correction Factor is protected by Customer
The following list defines the options for Variable Passwords. The Fuel Correction Factor enhances
1 of the basic program: the accuracy of the calculation for fuel consumption.
Altering the Fuel Correction Factor does not affect
• "Engine Hours" data that is already stored in the ECM. Altering
the Fuel Correction Factor only affects data that is
• "Distance Traveled" stored in the ECM after the Fuel Correction Factor
is entered.
• "Fuel Burned"
Note: The Fuel Correction Factor should be adjusted
• "Occurrences" by the use of a long interval, data from the fuel tank
and recorded data in the ECM.
Refer to the following list for information regarding
the options that are available for Variable 2 and
Variable 5. Quick Stop Rate
Variables 3, 4, 6, and 7 define the minimum range A Customer Parameter is available in order to
and the maximum range of variables 2 and 5. record the Quick Stop occurrences. The Parameter
determines the rate of change in vehicle speed that
• Engine RPM is used by the ECM in order to record a Quick Stop
Event Code and a Quick Stop Snapshot. Refer to
• Vehicle Speed Troubleshooting, "ECM Snapshot".
• Fuel Rate Maintenance Indicator Data
• Load Factor The ECM records the Current Totals when a reset
occurs for the following three levels of maintenance:
• Coolant Temperature
• PM1
• Oil Pressure
• PM2
• Fuel Temperature
• Cooling System Clean/Flush
• Inlet Manifold Air Temperature
The ECM uses the previous point of maintenance in
• Cruise order to calculate the timing of the next scheduled
maintenance work.
• PTO
The maintenance Indicator mode is programmable
• Engine Retarder to hours or distance. The PM1 maintenance is
programmable to the Off, Automatic Distance,
• Throttle Position Automatic Hours, Manual Distance, or Manual
Hours setting.
• Brake
14
If the PM1 is programmed to the automatic mode, An available feature of the CAT ID is the Theft
the ECM calculates the next point of maintenance Deterrent. The Theft Deterrent allows the driver
by considering the history of the vehicle's operation to input a password prior to shutdown. The Theft
from the previous maintenance interval. If the Deterrent will prevent the engine from restarting
vehicle has a history of poor fuel economy the until the password is successfully entered. The CAT
maintenance indicator parameter will occur sooner ID must have the version of software that is capable
than a vehicle with better fuel economy. of supporting this feature.
The ECM also uses the Engine Oil Capacity. An "Auto-Enable" option is available as a Theft
A larger engine oil capacity provides a longer Deterrent on Personality Modules which are dated
maintenance interval. The Engine Oil Capacity is OCT99 and newer. If this option is selected,
programmed into the ECM in liters or quarts. If the Theft Deterrent Feature will automatically be
the PM1 is programmed to the Manual mode, the activated when the engine is shut down. The driver
owner can program the ECM in the owner's specific must input the correct password in order to start
maintenance interval. The maintenance interval can the engine.
be programmed to the owner's specific interval
that is based on mileage or time. The interval for "Secure Idle" is another Theft Deterrent Feature.
the PM2 and the interval for the Cooling System This allows the driver to bring the engine to an idle
Clean/Flush are established by the factory. condition. The driver then enters the password. The
engine will remain at low idle until the password is
CAT ID re-entered. If the engine is shutdown, a password
will be required to go above low idle after start-up.
The Caterpillar Driver Information Display (CAT ID)
is available to provide engine operating information Fleet Information Software (FIS)
to the driver. The Driver Trip Segment, the Fleet Trip
Segment, and the Maintenance Indicator data can The Caterpillar Fleet Information Software (FIS) is
be viewed. However, the Fleet Trip Histograms and another method that can be used to review the trip
the Custom Data cannot be viewed from the display. information. The entire Fleet Trip Segment, which
includes the following elements of data can be
The CAT tD provides the ability to enter an ID code accessed with the Caterpillar FIS:
for a driver in order to divide the Fleet Trip Segment
for two drivers. If the driver enters the information • Histograms
regarding the state of travel, the Fleet Trip Segment
can be tagged by the state of travel. • Custom Data
The CAT ID can be used in order to tag portions • Information that is tagged by the ID code
of the Fleet Trip Segment into two ID codes. The
CAT ID can also be used in order to tag portions of • Information that is tagged by the state of travel
the Fleet Trip Segment into the state of travel. The
ID code and the information regarding the state of Maintenance Indicator information can also be
travel cannot be viewed from the display. Only the accessed by the use of the Caterpillar FIS.
Caterpillar Fleet Information Software (FIS) can view
this information. The ability to reset any of these When the Caterpillar FIS downloads the information,
parameters is dependent on Customer Parameters the Caterpillar FIS also resets the ECM in order to
in the ECM. prepare the ECM for the next trip. The information
can be downloaded to a computer with the
The CAT ID will also display engine operating Caterpillar FIS program, or the information can be
parameters such as engine rpm, coolant downloaded to an Argo Mobile Data Tool (MDT).
temperature, boost pressure and many other The Argo Mobile Data Tool (MDT) is then connected
parameters. to a computer in order to download the information.
The CAT ID will also display engine diagnostic

codes. The CAT ID will also display a brief text
description of the diagnostic codes.
15
Driver Reward Feature Programmable Parameters

The Driver Reward Feature automatically adjusts the Certain parameters that affect the engine operation
VSL as a reward to the driver for operating a truck may be changed with Cat ET. The parameters
in a manner that meets the truck engine owner's are stored in the ECM, and the parameters
specifications. Several parameters are monitored in are protected from unauthorized changes by
order to evaluate a driver's operating technique. passwords. These parameters are either System
Weighting factors are applied to the parameters that Configuration Parameters or Customer Parameters.
reflect the operating techniques that are desired
and the operating techniques that are expected. System Configuration Parameters are set at the
If the operating techniques meet the owner's factory. System Configuration Parameters affect
specifications or the operating techniques exceed emissions or power ratings within an engine family.
the owner's specifications, the VSL is automatically Factory Passwords must be obtained and factory
increased as a reward. The VSL will decrease when Passwords must be used to change the System
the operating techniques do not meet the owner's Configuration Parameters.
specifications.
Customer Parameters are variable. Customer
The CAT ID can be used to monitor parameters that Parameters can be used to affect the following
affect the Driver Reward, which allows the driver to characteristics of the engine within the limits that
adjust the operating techniques, as required. are set by the factory, Caterpillar Engine Monitoring,
and PTO operation:
"Wireless Communication Enable"
• Cruise control
The "Wireless Communication Enable" parameter in
the ECM allows the ECM to communicate through • Vehicle speed limits
the SAE J1587 Data Link with certain systems
of communication. Programming this parameter • Progressive shifting
requires Factory Passwords.
• RPM ratings
With this system, the customer can remotely
change the following parameters by the use of the • Power ratings
Caterpillar FIS:
Customer Passwords may be required to change
• Fuel Correction Factor Customer Specified Parameters.
• Custom Data Some of the parameters may affect engine operation

in an unusual way. A driver might not expect this
• Maintenance Indicator Data type of effect. Without adequate training, these
parameters may lead to power complaints or
With this system, the customer can remotely extract performance complaints even though the engine's
the following information from the ECM: performance is to the specification.
• Current Totals Refer to Troubleshooting, "Customer Specified

Parameters".
• Reports on Custom Data
Passwords
• Fleet Trip Data
System Configuration Parameters are protected
• Economy Model by Factory Passwords. Factory passwords are
calculated on a computer system that is available
• Maintenance Information only to Caterpillar dealers. Since factory passwords
contain alphabetic characters, only Cat ET may
• Settings for Customer Parameters change System Configuration Parameters. System
Configuration Parameters affect the power rating
The reports are processed for the owner of the fleet family or emissions.
by the use of the Caterpillar FIS. The frequency and
the timing of the downloading of the information Customer Parameters can be protected by
can be at set intervals or the downloading of the Customer Passwords. The Customer Passwords are
information can be done manually. programmed by the customer. Factory Passwords
can be used to change Customer Passwords if
Customer Passwords are lost.
16
Refer to Troubleshooting, "Customer Passwords" American Wire Gauge (AWG) - AWG is a measure
and Troubleshooting, "Factory Passwords". of the diameter of electrical wire. AWG is also
a measure of the current carrying capacity of
electrical wire. When the AWG number is smaller,
i01909059
the diameter of the wire is larger. When the AWG
Glossary number is larger, the diameter of the wire is smaller.
SMCS Code: 1900 Analog Sensors - Analog sensors produce a DC

output signal. The sensors detect changes in
Note: This glossary contains definitions of temperature or pressure. The change is converted
terminology for all of Caterpillar On-Highway Truck by the sensor to an electrical signal.
Engines. Some of the terms are only applicable to
certain engines. Analog Sensor Return - T h e common line (ground)
for the analog sensor from the ECM is used as a
NC High Pressure Switch - The A/C high pressure ground for the analog sensors.
switch senses refrigerant pressure in the air
conditioning system. The A/C high pressure switch Analog Sensor Supply - The +5 volt supply from
opens the electrical contacts and the A/C high the ECM provides power to the analog sensors.
pressure switch closes the electrical contacts. The
opening and closing of the electrical contacts Anti-Lock Brake System (ABS) - An anti-lock brake
depends on the pressure in the system. The system is a brake system that attempts to reduce a
electrical contacts control the cooling fan. This skid during brake operation. A power train electronic
switch may be connected to the ECM in some control can turn off the engine retarder, if necessary.
applications. Also, a power train electronic control can signal the
engine ECM to deactivate the engine retarder.
Accelerator Pedal Position - T h e accelerator pedal
position is the interpretation by the ECM of the ATA Data Link (American Trucking Association) -
signal from the accelerator pedal position sensor. The ATA data link is a two wire electrical connection
for communication with other microprocessor
Accelerator Pedal Position Sensor - The accelerator based devices. These devices are compatible with
pedal position sensor is an electronic sensor Standards for the American Trucking Association
that is connected to the accelerator pedal. The and Standards for the SAE (J1587 and J1708) such
accelerator pedal position sensor sends a Pulse as trip recorders, electronic dashboards, power
Width Modulated signal to the ECM. train controls, and maintenance systems. The
data link is also the serial communication medium
ACERT - A d v a n c e d Combustion Emissions that is used for programming and troubleshooting
Reduction Technology Caterpillar truck engines.
Active Diagnostic Code - An active diagnostic code Atmospheric Pressure Sensor - The atmospheric
describes a condition that is currently present in pressure sensor measures barometric pressure.
order to alert the driver or the service technician of The sensor sends a signal to the Engine Control
an abnormal parameter of engine operation. Refer Module (ECM). The signal is used in engine control
to a Diagnostic Fault Code. and in engine operation.
Aftermarket Device - An aftermarket device is a Auxiliary Pressure Sensor - This sensor is an

device or an accessory that is installed by the additional pressure sensor that is installed by the
customer after the vehicle is delivered. engine owner.
Air-To-Air Aftercooler - An air-to-air aftercooler is Auxiliary Retarder Relay - The brakes' solenoids
a device that is used on turbocharged engines are driven by an OEM installed relay, which is driven
in order to cool inlet air that has undergone by the ECM.
compression. The inlet air is cooled after the inlet
air passes through the turbocharger. The inlet air Auxiliary Temperature Sensor - This sensor is an
is passed through an aftercooler (heat exchanger) additional temperature sensor that is installed by
that uses ambient air for cooling. The inlet air that the engine owner.
has been cooled advances to the inlet manifold.
Before Top Center (BTC) - BTC is the 180 degrees
Alternating Current (AC) - Alternating current is an of crankshaft rotation before the piston reaches
electric current that reverses direction at a regular the top center position in the normal direction of
interval that is reoccurring. rotation.
17
Boost - T h e difference between the turbocharger Cold Mode - Cold mode is a mode for cold starting
outlet pressure and the atmospheric pressure is and for cold engine operation that includes timing
commonly referred to as boost. that is retarded and low idle that is raised. This
mode is used for engine protection, reduced smoke
Boost Pressure Sensor - The boost pressure sensor emissions and faster warm up time.
measures inlet manifold air pressure. The boost
pressure sensor sends a signal to the ECM. Communication Adapter Tool - The communication
adapter provides a communication link between the
Bypass Circuit - A bypass circuit is a circuit that is ECM and Cat ET.
used as a substitute circuit for an existing circuit. A
bypass circuit is typically used as a test circuit. Control Area Network (CAN) Data Link - The CAN
Data Link is a serial communications port that is
Calibration -Calibration is an electronic adjustment used for communication with other microprocessor
of a sensor signal. based devices. This is also referred to as the J 1939
Data Link.
Camshaft Position Sensor - Refer to Secondary
Engine Speed/Timing Sensor. Coolant Level Sensor - This OEM installed sensor
detects the absence or presence of coolant at the
Caterpillar Driver Information Display (CAT ID) - probe. The sensor then sends a signal to the ECM.
The Caterpillar Driver Information Display is a
digital readout of the performance parameters of Coolant Temperature Sensor - This sensor detects
the vehicle and performance parameters that are the engine coolant temperature for Cold Mode
monitored by the ECM. operation and the Caterpillar Engine Monitoring.
The Caterpillar Engine Monitoring must be enabled
Caterpillar Electronic Technician (Cat ET) - Cat ET for the coolant temperature sensor to be used for
is an electronic service tool that uses a software monitoring purposes.
program to run on a personal computer (PC). Cat
ET is used to service Caterpillar products. This Cooling Fan Override Switch - This switch overrides
program has replaced the ECAP tool. control of the cooling fan relay so the cooling fan
operates continuously. This switch is supplied and
Caterpillar Engine Monitoring - Caterpillar Engine installed by the OEM.
Monitoring is the part of the Caterpillar electronic
engine control that monitors coolant temperature, Cooling Fan Relay - T h i s relay is controlled by
oil pressure, intake manifold air temperature and the ECM which uses information from the coolant
coolant level. The monitoring alerts the operator of temperature sensor, the engine retarder and the
detected problems. Coolant temperature, intake air conditioning high pressure switch. The air
manifold air temperature, and oil pressure sensors conditioning high pressure switch is not always
are supplied by Caterpillar and monitored by the installed. The relay and the air conditioning high
ECM. The coolant level sensor is installed by pressure switch is supplied and installed by the
the vehicle OEM but still monitored by the ECM. OEM.
Aftermarket engine monitoring systems do not
interface with the Caterpillar electronic engine Crankshaft Position Sensor - Refer to Primary
control. Engine Speed/Timing Sensor.
Check Engine Lamp - The check engine lamp is Cruise Control Range - The cruise control range
sometimes referred to as the diagnostic lamp. The is the speed range that is monitored by the cruise
check engine lamp is used to alert the operator of control. This speed range is typically the anticipated
the presence of an active event. The lamp then speed range on the open road. The cruise control
flashes a diagnostic code. range can be programmed with the low cruise limit
and the high cruise limit.
Clutch Pedal Position Switch - T h e switch is
typically supplied and installed by the OEM. This Custom Data - Custom data is part of the fleet trip
switch is typically a limit switch that is mounted near data that is stored in the ECM This capability allows
the clutch pedal. The switch is usually adjustable. the vehicle owner to specify operating parameters
This switch is in the normally closed position when for monitoring purposes while the engine is in
the clutch pedal is released. Depressing the clutch service.
pedal will open the circuit.
Customer Specified Parameter - A Customer
Code - Refer to the Diagnostic Fault Code and the Specified Parameter is a value that can be set and
Diagnostic Event Code. changed by the customer. The parameters can be
protected by Customer Passwords.
18
Desired Engine Speed - T h e desired engine speed Electronic Engine Control - T h e electronic engine
is input to the electronic governor within the ECM. control is a complete electronic system. The
The electronic governor uses the signal from the electronic engine control monitors the engine
accelerator pedal position sensor, the engine operation under all conditions. The electronic
speed sensor, the cruise control, and the Customer engine control also controls the engine operation
Parameters in order to determine desired speed. under all conditions.
Desired RPM - T h e desired rpm is input to the Electronic Service Tool - Refer to "Caterpillar
electronic governor within the ECM. The electronic Electronic Technician" (Cat ET).
governor uses the signal from the accelerator pedal
position sensor, the engine speed sensor, the cruise Electronically Controlled Unit Injector - The
control, and the Customer Parameters in order to electronically controlled unit injector is an
determine desired rpm. injection pump which is a mechanically actuated,
electronically controlled unit injector. This unit
Diagnostic Event Code - These codes indicate an combines the pumping, electronic fuel metering
event that describes an abnormal engine condition and injecting elements in a single unit.
such as a high coolant temperature. These codes
are not necessarily an indication of problems within Engine Control Module (ECM) - The ECM is the
the electronic system. engine's control computer. The ECM provides power
to the electronics. The ECM monitors data that is
Diagnostic Fault Code - A diagnostic fault code input from the engine's sensors. The ECM acts as a
is sometimes referred to as a fault code. These governor in order to control engine rpm.
codes indicate an electronic system malfunction or
abnormal operating conditions. Engine Coolant Diverter - The engine coolant
diverter is a normally open valve that allows coolant
Diagnostic Flash Code - The diagnostic flash codes to flow through a radiator that cools the intake air.
are flashed on the check engine lamp. These flash The radiator is located after the turbochargers
codes indicate a malfunction in the electronic and before the air-to-air aftercooler. Energizing
system or an event that is detected by the ECM. the solenoid prevents the flow of coolant through
the radiator in order to prevent overcooling of the
Diagnostic Lamp - A diagnostic lamp is sometimes engine when cold ambient air temperatures exist.
called the check engine lamp. The diagnostic lamp
is used to warn the operator of the presence of an Engine Monitoring System - The Engine Monitoring
active diagnostic code. System is a programmable system that allows the
ECM to take actions if an engine parameter is out of
Digital Sensors - Digital sensors produce an ON a certain range. The actions are Warning, Derate,
or OFF type of signal. Some sensors vary the ON and Shutdown.
or OFF time which is referred to as Pulse Width
Modulation (PWM). Engine Oil Pressure Sensor - This sensor measures
engine oil pressure and the sensor sends a signal
Digital Sensor Return - T h e common line (ground) to the ECM.
from the ECM is used as a ground for the digital
sensors. Engine Retarder Solenoids - The engine retarder
solenoids are installed by Caterpillar and the
Digital Sensor Supply - T h e supply from the ECM is solenoids are driven by the ECM. These solenoids
used in order to power the digital sensors. are used in place of relays such as the auxiliary
brake that is installed by the OEM.
Direct Current (DC) - Direct current is the type of
current that flows consistently in only one direction. Engine Speed/Timing Sensor -This sensor provides
a variable amplitude and Pulse Width Modulated
DT, DT Connector, or Deutsch DT - This is a type of signal to the ECM. The ECM interprets this signal as
connector that is used on Caterpillar truck engines. the crankshaft position and the engine speed.
The connectors are manufactured by Deutsch.
Erasable Programmable Read Only Memory
Dual Coil Vehicle Speed Sensor - The dual coil (EPROM) - A n EPROM is a type of computer
vehicle speed sensor is a magnetic pickup that memory chip.
senses movement of the teeth on the output shaft
of the transmission. The sensor contains two coils. Estimated Dynamic Timing - The estimated dynamic
This sensor provides two differential output signals. timing is the estimate that is provided by the ECM
of the actual injection timing.
Duty Cycle - Refer to Pulse Width Modulation.
19
ET - Refer to "Caterpillar Electronic Technician" Flash Code (FC) - The flash codes are proprietary
(Cat ET). Caterpillar code numbers that are flashed on the
diagnostic lamp. The flash codes are flashed on the
Ether Relay - The ether relay is used in order to check engine lamp. These flash codes indicate a
actuate the ether injection system. The relay is malfunction in the electronic system or an event that
controlled by the ECM. is detected by the ECM.
Event -Events indicate an event that describes an Flash Programming - Flash programming is the
abnormal engine condition. These codes are not method of programming or updating an ECM with
necessarily an indication of problems within the Cat ET over the data link instead of replacing
electronic system. components. Flash programming installs the
specific Personality Module that is used to control
Exhaust Brake Relay - The brake solenoids are the engine. The Personality Module contains
driven by an OEM installed relay, which is driven specific performance maps and features for a
by the ECM. selected rating.
Failure Mode Identifier ( F M I ) - This Identifier Fleet Information Software (FIS) - FIS is a software
indicates the type of failure that has been program that operates on a personal computer
experienced by the component. The FMI has (PC). This program allows the user to review the
been adopted from the SAE practice of J1587 trip information. The program also allows the user
diagnostics. The FMI follows the PID in the to reset the trip information which includes the
descriptions of the fault code. The descriptions for Maintenance Indicator information.
the FMI's are shown in the following list:
Fuel Position - T h i s is an internal signal within
• 0 The data is valid but the data is above the the ECM. The signal comes from the electronic
normal operational range governor and the signal then goes to the fuel
injection control. The information that is gathered
• 1 The data is valid but the data is below the is based on the Desired RPM, the FRC Limit, the
normal operational range Rated Fuel Limit, and the actual engine rpm.
• 2 The data is erratic, intermittent, or incorrect. Fuel Ratio Control (FRC) - The FRC is a limit that
is based on the control of the fuel to air ratio. The
• 3 The voltage is above normal or the voltage is FRC is used for purposes of emission control. When
shorted high the ECM senses a higher boost pressure (more air
into the cylinder), the FRC increases the FRC Limit
• 4 The voltage is below normal or the voltage is (more fuel into the cylinder).
shorted low
Fuel Temperature Sensor - This sensor detects
• 5 The current is below normal or the circuit is the fuel temperature. The ECM monitors the fuel
open temperature and the ECM adjusts the calculated
fuel rate accordingly.
• 6 The current is above normal or the circuit is
grounded Full Load Setting (FLS) - T h e FLS is the number
that represents the fuel system adjustment. This
• 7 The mechanical system is not responding adjustment is made at the factory in order to help
properly ensure the maximum fuel delivery of the fuel system.
The correct value for this parameter is stamped on
• 8 Abnormal frequency, pulse width, or period the engine information ratings plate. This parameter
must be programmed. If the parameters are not
• 9 Abnormal update programmed, the diagnostic code that is 253-02
Check Customer or System Parameters will be
• 10 Abnormal rate of change active.
• 11 The failure mode is not identifiable Full Torque Setting (FTS) - The FTS is similar to
the Full Load Setting. This parameter must be
• 12 Damaged device or component programmed. If the parameters are not programmed
the diagnostic code that is 253-02 Check Customer
• 13 The device or the component is not calibrated or System Parameters will be active.
• 14 and 15 These locations are reserved for a Gear Down Protection - This feature consists of the
future assignment High Gear Limits that are programmable. High Gear
Limits are used in order to promote driving in higher
gears for increased fuel economy.
20
Harness - T h e harness is the bundle of wiring Injector Codes - The injector codes or injector trim
(loom) that connects all components of the codes are numeric codes or alphanumeric codes
electronic system. that are etched or stamped on individual injectors.
These codes are used to fine tune the fuel delivery.
Hertz (Hz) - Hertz is the measure of electrical
frequency in cycles per second. Injector Trim Files - Injector trim files are
downloaded from a disk to the ECM. The trim files
High Pressure Oil Manifold - T h e high pressure compensate for variances in manufacturing of the
oil manifold is an oil gallery that is added to the injector. The engine serial number must be know in
cylinder head in order to supply the unit injectors order to obtain the correct trim file.
with high pressure oil.
Intake Manifold Air Temperature Sensor - This
High Pressure Oil Pump - The high pressure oil sensor detects the air inlet temperature. The
pump is an axial piston pump that is driven by ECM monitors the inlet air temperature and other
gears. The high pressure oil pump is used to raise data in order to adjust injection timing and other
the engine oil pressure in order to activate the unit performance functions.
injectors. The amount of oil pressure that is required
to activate the unit injectors is called the actuation Intake Valve Actuation System Oil Pressure Sensor -
pressure. Monitors the pressure within the oil rail for the intake
valve actuator. The sensor can detect mechanical
Histogram - T h e histogram is a bar graph which problems with the intake valve actuation system
may indicate the relative frequency of vehicle such as leaking face seals.
operation in specific operating ranges. A histogram
can be used to show many relationships. Intake Valve Actuation System Oil Pressure
Solenoid - Solenoid mounted at the end of the oil
Hydraulically Actuated Electronically Controlled Unit rail for the intake valve actuator. The solenoid is
Injector (HEUI) - T h e HEUI is an injection pump normally closed to allow pressure to build up in
which is a hydraulically actuated, electronically the rail.
controlled unit injector. This injector uses hydraulic
forces to produce the high injection pressure. Intake Valve Actuator - An actuator that allows the
This unit combines the pumping, electronic fuel ECM to control the amount of time that the intake
metering, and injecting elements in a single unit. valve is open. The actuator traps engine oil in order
to hold the intake valve open. The ECM can vary
Idle rpm Limit - This is a programmable parameter the time that the intake valve is open in order to
which indicates the maximum allowable engine rpm optimize engine performance.
that is allowed when the engine rpm is set with the
cruise set/resume switch. Integrated Electronic Controls - The engine is
designed with the electronic controls as a necessary
Idle Shutdown Time - This programmable part of the system. The engine will not operate
parameter indicates a designated idle time in without the electronic controls.
minutes that is allowed before shutdown.
J1922 Data Link - This data link is an SAE
Idle/PTO Bump rpm -This programmable parameter diagnostic communications data link that is used to
indicates the amount of change to the engine rpm communicate between the electronic engine and
that will occur when the switch for acceleration is the power train components. Examples of power
toggled or the switch for deceleration is toggled. train components are the ABS/traction control
system and the transmissions. This allows the
Injection Actuation Pressure Control Valve - This is a power train component to control the engine during
dump valve that is controlled by an electrical signal reduced traction or transmission shifts.
that maintains high pressure for the high pressure
oil manifold. The ECM controls the pressure in J1939 Data Link - This data link is an SAE
the high pressure oil manifold by inputs from the diagnostic communications data link that is used to
other sensors. The control valve regulates the high communicate between the electronic engine, the
pressure oil to the hydraulic electronic unit injector transmission, instrument clusters, and/or the power
through the high pressure oil manifold. Proper fuel train controls.
injection pressure is necessary for desired engine
operation. Key Switch Input - When the input is energized, the
ECM is powered up.
Injection Actuation Pressure Sensor - An electrical
sensor on the high pressure oil manifold converts
oil pressure into an electrical signal for the ECM.
21
Kickout Switch - This term refers to the service Parameter Identifier (PID) - The PID is a two digit
brake switch and the clutch switch. These switches code or a three digit code which is assigned to
are used as an exit or a kickout for the cruise each component in order to identify data via the
control set speed, the idle speed setting, or the data link to the ECM.
PTO/Idle set speed.
Passive Magnetic Speed Sensor - This sensor is a
Latch Mode - T h i s is a programmable parameter speed sensor that does not require a power and a
for control of the exhaust brake. The exhaust ground connection. The sensor produces a signal
brake engages when the service brake pedal is that is based on the change in magnetic flux of a
depressed. The exhaust brake remains engaged ferrous metal gear near the sensing tip.
until the control detects a change in a control input.
Password - A password is a group of numeric
Logged Diagnostic Codes - Logged diagnostic characters or a group of alphanumeric characters
codes are codes which are stored in memory. that is designed to restrict access to parameters.
These codes are meant to be an indicator of The electronic system requires correct passwords
possible causes for intermittent problems. Refer to in order to change Customer Specified Parameters
the Diagnostic Fault Code for more information. (Customer Passwords) or certain engine
specifications (Factory Passwords). Passwords are
Maintenance Clear Switch - The maintenance also required to clear certain diagnostic codes.
clear switch is required to reset the "PM1 Interval"
diagnostic after maintenance on the engine Personality Module or Ratings Personality Module -
is performed. This reset is necessary for the This module is attached to the inside of the
maintenance indicator to function. ECM. The module contains all the instructions
(software) for the ECM and the module contains the
Maintenance Overdue Lamp - This lamp will turn on performance maps for a specific horsepower family.
when the Preventive Maintenance Interval occurs
such as "PM1 Interval". Power Cycled - Power cycled happens when
power to the ECM is cycled: on, off, and on. Power
Mechanically Actuated Electronically Controlled Unit cycled refers to the action of cycling the keyswitch
Injector (MEUI) - The MEUI is an injection pump from any position to the OFF position, and to the
which is a mechanically actuated, electronically START/RUN position.
controlled unit injector. Mechanical forces that are
produced from the camshaft are used to produce Power Take-Off (PTO) - The PTO operates with
the high injection pressures. This unit combines the the cruise control switches and the dedicated
pumping, electronic fuel metering, and injecting PTO On/Off switch. This mode permits the setting
elements in a single unit. of constant engine speeds or the mode permits
varying the speed with either the accelerator pedal
Messenger - Messenger is a digital display that in the cab or a remote accelerator.
can display the operating conditions for the engine.
Power Train Data Link - Refer to J1922 Data Link
Oil Pressure Sensor -This sensor measures engine or J1939 Data Link.
oil pressure and the sensor signals the ECM.
Powered Down - Powered down occurs when
Open Circuit - An open circuit is a condition that is power is removed from the ECM. Powered down
caused by an open switch, or an electrical wire or refers to the action of cycling the keyswitch from
a connection is broken. When this condition exists, any position to the OFF/RESET position.
the signal or the supply voltage can no longer reach
the intended destination. Powered Up - Powered up occurs when power
is applied to the ECM. Powered up refers to the
Original Equipment Manufacturer (OEM) - The action of cycling the keyswitch from the OFF/RESET
OEM is the manufacturer of a vehicle that uses a position to the START position.
Caterpillar engine for the power source.
Primary Engine Speed/Timing Sensor - Determines
Overspeed Verify - This feature is used to test the the position of the crankshaft for injection timing and
Overspeed Shutoff Circuit. The shutoff circuit is engine speed. The primary engine speed/timing
tripped at 75% of the Overspeed Shutoff Limit. sensor is primarily used after the engine has started.
Parameter - A parameter is a value or a limit that Pro-Link - Pro-Link is an electronic service tool that
is programmable. This helps determine specific is hand-held. The tool is manufactured by Micro
characteristics or behaviors of the engine and/or Processor Systems, Inc. (MPSI). This tool is supplied
vehicle. with a Caterpillar cartridge in order to service a
Caterpillar engine that is electronically controlled.
22
Progressive Shifting - T h i s is a method of quickly Remote Station Operation - This is a location that
upshifting through the lower gears without excessive is outside of the vehicle cab. The functions such
engine rpm in each gear. Shifts are made above as the engine speed control are typically used for
peak torque but below rated rpm. If the engine is some type of PTO operation that is for pumping
driven to an excessively high engine rpm before or for some other application that uses the engine
shifting to the next gear, fuel is wasted. When the power. These functions are controlled from the
excessively high engine rpm ranges are used, the remote station.
torque rise of the engine is not fully utilized. The
two steps LoGr 1 and LoGr 2 give the opportunity Retarder Enable Signal - The retarder enable signal
for progressive shifting. LoGr 1 is typically set at interfaces the ECM to the engine retarder. This
no lower than peak torque plus 200 rpm. LoGr 2 is will restrict operation of the engine brake during
typically set at a point that is midway between the undesirable engine operating conditions. One
LoGr 1 rpm limit and the Top Engine Limit. operating condition is at a time when the engine
is being fueled.
PTO Configuration - T h i s is a programmable
parameter that determines the best use of the ECM Retarder Solenoids - T h i s refers to the engine
input and the ECM output for PTO applications. retarder that is installed by Caterpillar. The solenoids
are driven directly by the Caterpillar ECM. The
Pulse Width Modulation (PWM) - The PWM is a solenoids are not driven through an OEM installed
signal that consists of pulses that are of variable relay such as the auxiliary retarder.
width. These pulses occur at fixed intervals. The
ratio of TIME ON versus total TIME OFF can be Secondary Engine Speed/Timing Sensor -
varied. This ratio is also referred to as a duty cycle. Determines the position of the camshaft during
start-up. The secondary engine speed/timing sensor
will be used if the signal from the primary engine
3111,0, TIME
speed/timing sensor is lost.
Sensor - T h e sensor is a device that is used

to detect a change in pressure, temperature, or
mechanical movement. The information that is
detected is converted into an electrical signal.
TIME
Service Brake Pedal Position Switch - This switch
o. ! is typically a pressure switch that is supplied and
OFF /Ill/ TIME

19o.~ installed by the OEM. This switch is normally closed
when the brake pedal is in the released position.
Depressing the brake will open the circuit.
g00284479
Ulustration 12 Service Program Module (SPM) - The service
program module is a software program that is used
Rated Fuel Limit - T h i s term indicates the maximum to adapt the electronic service tool to a specific
allowable fuel position (longest injection pulse). This engine application.
position will produce rated power for this engine
configuration. Short Circuit - A short circuit is a condition that has
an electrical circuit that is inadvertently connected
Reference Voltage - The Reference Voltage is a to an undesirable point. An example of a short
regulated voltage and a steady voltage that is circuit is a wire which rubs against a vehicle frame
supplied by the ECM to a sensor. The reference and this rubbing eventually wears off the wire
voltage is used by the sensor to generate a signal insulation. Electrical contact with the frame is made
voltage. and a short circuit results.
Remote Shutdown - T h e ECM disables the fuel Signal - T h e signal is a voltage or a waveform that
injection signal when the Remote Shutdown Switch is used in order to transmit information typically
is closed. This causes the ECM to shut down the from a sensor to the ECM.
engine. However, the ECM remains active. The air
shutoff solenoid is not activated when the remote Speed Burp - A Speed Burp is a sudden, brief,
shutdown switch is activated. unwanted change in the engine rpm.
Standard SAE Diagnostic Communications Data

Link - Refer to the ATA Data Link.
23
Starting Aid Switch - This switch is used for injection Total Tattletale - The Total Tattletale is the total
of a starting aid in cold weather. An example of a number of changes to all the Customer Specified
starting aid is ether. Parameters that are stored in the ECM.
Static Timing - Static timing is the basis for correct Transducer (Timing Calibration Probe) - This is
fuel timing and valve mechanism operation. Static a device that converts a mechanical signal to
timing is determined by the timing ring and the an electrical signal. This probe requires a power
alignment of the rear gear group. source in order to operate.
Subsystem - A Subsystem that is used in this Transmission Style - The "Transmission Style" is
application is a part of the electronic system that a programmable parameter that designates the
relates to a particular function. An example of a type of transmission in the vehicle and the various
subsystem is the throttle subsystem. circuits that are connected to the ECM The relay for
the transmission, cruise control, PTO/idle set speed,
Supply Voltage - The supply voltage is a constant and the operation of the exhaust brake are affected
voltage that is supplied to a component in order by this parameter setting.
to provide electrical power that is required for
the component to operate. The power may be Trip Recorder - T h e trip recorder is an aftermarket
generated by the ECM or the power may be battery device that is dedicated to recording the parameters
voltage that is supplied by the vehicle wiring. of the vehicle and the parameters of the operating
engine during the vehicle service. The trip recorder
Suspect Parameter Number (SPN) - The SPN is used to analyze the driving habits and the
is a three digit code which is assigned to each recorder is used in order to produce the logs of the
component in order to identify data via the data link driver.
to the ECM. This is used for J1939 diagnostics.
Variable Valve Actuation - Allows the engine to
System Configuration Parameters - System vary the closing of the valves in order to optimize
Configuration Parameters are Parameters that affect emissions and engine performance.
the power rating family or emissions.
Vehicle Speed Sensor - The vehicle speed sensor
T-Harness - The T-Harness is a test harness that is is an electromagnetic pickup that measures vehicle
designed to connect into the vehicle harness or the speed from the rotation of gear teeth in the drive
engine harness. This connection allows a normal train of the vehicle.
circuit operation and the connection simultaneously
provides a breakout T in order to measure the Wastegate Solenoid - Prevents pressurized air from
signals. reaches the turbocharger wastegate. Allows the
engine to build boost pressure beyond the preset
Terminating Resistor - T h i s is used to terminate wastegate setting.
the J1939 CAN data link. Refer to the installation
procedures.
i01921225
Theft Deterrent - This feature uses a four digit code Electronic Service Tools
in order to prevent the engine from starting. The
feature requires a password to be entered via the SMCS Code: 0785
CAT ID.
Caterpillar electronic service tools are designed
Timing Calibration - The timing calibration is the to help the service technician with the diagnosis
adjustment of an electrical signal. This adjustment and repair of electronic engines. Several tools are
is made in order to correct the timing error available to assist the service technician.
between the camshaft and the engine speed/timing
sensors or between the crankshaft and the engine
speed/timing sensors.
Top Center - This refers to the crankshaft position

when the engine piston position is at the highest
point of travel. The engine must be turned in the
normal direction of rotation in order to reach this
point.
Torque Limit - T h i s is a programmable parameter

that limits the maximum torque which is based on
the PTO configuration and PTO operation.
24
Required Service Tools • Flash programming
Table 1 • Set parameters

Part Number Description
• Copy the configuration for ECM replacement.
N/A 4 mm Allen Wrench
6V-2197 Transducer(Timing Calibration • Data logging
Probe)
• Snapshot recorder
7X- 1171 Transducer Adapter(Timing
Calibration Probe) The following components are required to use Cat
7X- 1695 Cable(Timing Calibration) ET to service the engine.
1U-5804 Crimp Too1(12 to 18 AWG) Table 2
1 U- 5805 Wire Removal Too1(14 AWG Wire) Required Electronic Service Tools for
the Use of Cat ET
151 - 6320 Wire Removal Tool(16 and 18 AWG
Wire) Part Description
Number
167 - 9225 Harness(Service Tool Adapter)
Caterpillar Electronic Technician
140- 2266 Cable(Seventy-Pin Breakout)
JERD2124 "Electronic Technician Program" (Cat ET)
9U- 7330 Digital Multimeter
or Digital Multimeter(RS-232) "Electronic Technician Truck Engine Data
146- 4080 JERD2125
Subscription"
190 - 8900 Connector Repair Kit or
"Electronic Technician Engine/Machine
JERD2129
Two short jumper wires are needed to check Data Subscription"
the continuity of some wiring harness circuits 171 -4400(1) Communication Adapter It Gp
by shorting two adjacent terminals together in
a connector. A long extension wire may also be (1) The 7X - 1700 Communication Adapter Gp may also be used.
needed to check the continuity of some wiring
harness circuits. 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
Caterpillar Electronic Technician (Cat ET) software.
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
25
Connecting Cat ET and the Communication Optional Service Tools

Adapter II
Table 3
Part Number Description
7X- 6370 Adapter Cable As(3 Pin DT Breakout)
8T-8726 Adapter Cable As(3 Pin Breakout)
5P - 7277 Voltage Tester
2
-.... 9U - 5103
7X- 1710
Socket(Slotted)
Multimeter Probe
1U-5718 VacuumPump
1U- 8757 Tube(FluidSampling)
169- 7372 Fluid Sampling Bottle
9S-9082 Engine Turning Tool
198- 4240 DigitalPressure Indicator
or
1U- 5470 Engine Pressure Group
I ll .... I
6V- 9130 Temperature Adapter
124 - 5643 Cable(ServiceTool Breakout)
125- 3662 Cable(Sensor Bypass)
157-4829 Cable Adapter(9 Pin J1939 Dash)
7X- 1403 AdapterCable As(9 Pin Navistar
Dash)
7X- 1686 Cable Adapter(6 Pin Dash)
(1) Personal computer (PC) Cable Adapter 0
(2) 196-0055 Adapter Cable As (PC Serial)
(3) 171 -4401 Communication Adapter II 139- 4166 Data Link Cable As(Eighteen Feet)
(4) 207-6845 Adapter Cable As
Note: Items (2), (3), and (4) are part of the i01905996
171 -4400 Communication Adapter II Gp.
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 Replacing the ECM with the Use of
the keyswitch is not placed in the OFF/RESET
position, the engine may start. the ECM Replacement Feature
2. Connect cable (2) between the "COMPUTER" . Ensure that the ECM is the problem by first
end of communication adapter (3) and the connecting a test ECM. This is a temporary
RS232 serial port of PC (1). connection. Hang the test ECM on the side of
the engine. Refer to Troubleshooting, "Test ECM
3. Connect cable (4) between the "DATA LINK" end Mode".
of communication adapter (3) and the service
tool connector. , If the test ECM repairs the problem, reconnect
the suspect ECM. Verify that the problem returns
4. Turn the keyswitch to the ON position. If when the suspect ECM is reconnected.
Cat ET and the communication adapter do
not communicate with the ECM, refer to , Select the ECM Replacement Feature under the
Troubleshooting, "Electronic Service Tool Will Not "Service/Copy Configuration" menu and load the
Communicate With ECM". parameters from the failed ECM.
, Temporarily connect the new ECM by connecting

both ECM connectors. Do not mount the ECM
on the engine yet.
26
5. Flash program the personality module into the C. Use the Troubleshooting, "Customer Specified
new ECM if the personality module is not already Parameters Worksheet" to record the customer
installed. The new ECM is shipped with a blank parameters.
personality module.
d. Record the injector codes. The injector
6. Use the ECM replacement feature on the codes can be found in the "Injector
Caterpillar Electronic Technician (Cat ET) in order Codes Calibration" in "Calibrations" under
to program the new ECM. the "Service" menu on Cat ET. Refer to
Troubleshooting, "Injector Code - Calibrate"
7. Enter the value for the "Rating Number" for more information.
parameter into the new ECM.
4. Record ECM lifetime totals.
8. Check for active codes. Program any required
parameters that have not been programmed. a. Use the Troubleshooting, "Customer Specified
Parameters Worksheet (Current Totals
Note: On initial powerup of a new ECM, the Worksheet)" in order to record the old "ECM
parameter "Rating Number" must be programmed Current Totals".
to avoid activating a 253-02 Check Customer Or
System Parameters. . Temporarily connect the new ECM by connecting
both ECM connectors. Do not mount the ECM to
9. If 22-13 Engine Speed Signal Calibration Not the engine until the timing calibration has been
Performed is not active, install the new ECM performed.
on the engine. Otherwise, perform a timing
calibration first. . Flash program the personality module into the
new ECM if the personality module is not already
Replacing the ECM without the Use installed. The new ECM is shipped with a blank
personality module.
of the ECM Replacement Feature
7. Obtain factory passwords when the passwords
1. Ensure that the ECM is the problem by first are required.
connecting a test ECM. This is a temporary
connection. Hang the test ECM on the side of the Note: The following parameters can be programmed
engine. Flash program the identical personality on a new ECM without factory passwords: "Full
module that was used in the suspect ECM into Load Setting (FLS)", "Full Torque Setting (FTS)",
the test ECM. Program any parameters that and "Engine Serial Number". System configuration
are necessary to use the ECM for the test. For parameters must be entered before the customer
example, vehicle speed parameters need to be specified parameters are entered. If customer
programmed to check the vehicle speed circuit. parameters are entered before the system
Program the parameters in the test ECM to be configuration parameters, the Total Tattletale will
equal to the parameters in the suspect ECM. change. It will then be necessary to obtain another
set of factory passwords in order to change system
2. If the test ECM repairs the problem, reconnect configuration parameters.
the suspect ECM. Verify that the problem returns
when the suspect ECM is reconnected. 8. Perform the following operations.
3. Obtain customer parameters from the failed a. Use the Troubleshooting, "Factory Passwords
ECM. Worksheet" to record the following information
from the engine information plate: "Full Load
a. Obtain the customer passwords and record Setting (FLS)", "Full Torque Setting (FTS)",
the customer passwords. If the customer and "Engine Serial Number".
(owner) has lost the passwords or if
the customer (owner) has forgotten the b. Record the mileage from the vehicle
passwords, proceed to Troubleshooting, odometer. Access the "Configuration" screen
"Customer Passwords, for more details. on Cat ET. When the screen for the "Factory
Passwords" appears, record the following
b. Access the "Configuration" screen on Cat ET information: "ECM Serial Number", "Engine
and record the customer parameters from Serial Number", "ET Serial Number", "Total
the ECM that is being replaced. If the ECM Tattletale", and "Reason Code".
does not communicate with Cat ET, obtain the
required parameter list from the OEM.
27
¢. Leave Cat ET on the screen for the "Factory i01907619

Passwords" and obtain the factory passwords.
Complete the Troubleshooting, "Factory Sensors and Electrical
Passwords Worksheet". Connectors
9. Program the new ECM. SMCS Code: 1900-NS; 7553-WW
Note: On initial powerup of a new ECM, the Table 4
following parameters must be programmed to avoid
Connector Function
activating 253-02 Check Customer Or System
Parameters: "Full Load Setting (FLS)", "Full Torque J1/P1 ECM Connector
Setting (FTS)", "Vehicle Speed Calibration" (ppm),
"Rating Number", "Engine Serial Number", and J2/P2 ECM Connector
"Injector Codes Calibration". JIOO/PIO0 Engine Coolant Temperature Sensor
a, Access the "Configuration" screen on Cat J103/P103 Intake Manifold Air Temperature
Sensor
ET. Enter the following parameters that are
recorded on the worksheet: "Full Load Setting J105/P105 Fuel Temperature Sensor
(FLS)", "Full Torque Setting (FTS)", and
J200/P200 Boost Pressure Sensor
"Engine Serial Number".
J201/P201 Engine Oil Pressure Sensor
b. Enter the customer specified parameters and
the original customer passwords that are J203/P203 Atmospheric Pressure Sensor
recorded on the worksheet. J300/P300 Injector Solenoid Harness
c, Use Cat ET to access current totals from the

J400/P400 Timing Calibration Probe
"Read/Change Current Totals" main menu. J401/P401 Primary Engine Speed/Timing
Record the information on the Troubleshooting, Sensor
"Factory Passwords Worksheet" in order to
J402/P402 Secondary Engine Speed/Timing
obtain the factory passwords. Enter the totals Sensor
from the original ECM that are recorded on
the worksheet. J403/P403 Accelerator Pedal Position Sensor
d. Program the injector codes on Cat ET. 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 Sensor - Calibrate" for
the proper procedure.
10. Install the new ECM on the engine.

28
~.
• .'= .=. .~. SAE J1587 Data Link
E'ectr°nic L~ f U
i) ~ ~ SAE J1922~l~DataLink
Control ]1
Module O~ SAE J1939 Data Unk
o ~
Y
3 Retarder Solenoids
BATTERIES
Cruise Control On/Off & Set/Resume Switches
Engine Retarder Level Switches

gg ~
Accelerator Pedal Position SensoJ
6 Electronic Unit Injectors

and Service Brake Switches
C~
Coolant Level Sensor
Check Engine & Warning Lamps

Primary Engine Speed/Timing Sensor
Speedometer & Ta___chometer
Secondary Engine Speed/Timing Senso
Cooling Fan
1.5A
Atmospheric Pressure Sensor
Vehicle Speed Sensor

Engine Oil Pressure Sensor
Boost Pressure Sensor A/C High Pressure Switch
Coolant Temperature Sensor Remote Accelerator Position Sensor
Fuel Tempera_tureSensor 2, 0.3A Outputs

Ignition Key
7 Switch Inputs
Intake Manifold Air Temperature Sensor
3, 1.0A Outputs
2 Passive Temperature
Sensor
3, 1.5A Outputs
29
Diagramof components
0-10 and C-12 Engines

Fuel Unit
Temperature Injector
Sensor Connector
Secondary
Engine
Speed/Timin,
Sensor
Primary
Engine .
Speed~Timing
Sensor
Engine Oil ECM ECM
Pressure Connector Connector
LEFT SIDE VIEW Sensor J2/P2 J1/P1
Left side view (typical example)

30
Engine Coolant Intake Manifold Boost

Temperature Air Temperature Pressure
Sensor Sensor Sensor
@
@@@
Atmospheric
Pressure
Sensor
TOP VTEW
Illustration 16
g00992610
Top view (typical example)
31
3406E Engine
Electronic Inteke
Boost Unit Monifold Air
Pressure
Injector Temperoture
Sensor Connector Sensor
Primory
Engine Enqine
Speed/Timing Control
Sensor '
Fuel J1/P1
Temperoh ECM
Sensor
@
Atmospher
Pressure
Sensor
Secondory
Engine ,
Speed/Timing
Sensor J2/P2 '
ECM
Connector
Left side view (typical example)

32
Engine
Cootont
Temperature
~Dne~r
iL
RIGHT SIDE VIEW FRONT VIEW
Right side and front views (typical example)
33
C-15, C-16 and C-18 Engines

Secondary Boost Unit Intake Manifold
Engine Pressure Injector Air Temperature
Speed/Timing Sensor
Sensor Sensor Connector
/
<
Atmospheric Engine Oil ECM ECM

Pressure Pressure Connector Connector
Sensor Sensor J2/P2 J1/P1
/ LEFT SiDE VIEW

Primary Fuel
Engine
Speed~Timing Temperature
Sensor
©
Sensor
©
1
Engine
Coolant
Temperature
Sensor '
FRONT VIEW
Left side view and top view (typical example)
34
i01907629
Engine Wiring Harness

Diagram
SMCS Code: 1408
35
ENGINE HARNESS CONNECTOR

P'2 J2
J300 p300
44( INJECTOR COMMON CYUNDERS 1 & 2
154 INJECTOR COMMON CYUNDERS3 & 4
INJECTOR COMMON C~UNDERS 5 & 6
554 INJECTOR CYLINDER6
54( INJECTOR CYLINDER5
39~ INJECTOR CYLINDER4
38~ INJECTOR CYLINDER3
37< fN,JECTOR CYLinDER 2
36< LNJECTOR CYLINDER 1
I0( RETARDER SOLENOID MEDIHI
It ( RETARDER SOLENOID LOWIHI
~NJECTOR INJECTOR INJECTOR RETARDER SOLENOIDCOMMON
CYLINDER CYLINDER CYUNDER CYLINDER CYUNDER CYLINDER
NO.1 NO.2 NO3 NO.6
Air Inlet SPlutoffOutput
ENGINE RETARDER ENGINE RETARDER ENGINE RETARDEF

SOLENOID CYLINDERS SOLENOID CYUNDERS SOLENOIDCYLINDEF
1&2 NOTEH 5 & 6 NOTEH 3 & 4 NOTEH
J520 P520
G884 YL iNPUT #17

ENGINE BOOST PRESSURE f GN A746PK A?46-PK ENGINE BOOST PRESSURE
A747-GY ENGINE ATM PRESSURE
994~Y ENGINE OIL PRESSURE
C-~9GN ENGINE PRESSURESENSORCOMMON

Ga28 WH ENGINE PRESSURESENSOR+SV
PRESSURESENSOR ENGINE PRESSURESENSOR COMMON
ENGINE PRESSURESENSOR +5V
PRIMARYSPEED/'rlMINCT~ ' ~ ] ~ E 9 6 3 BK ~ E 9 6 3 - B K
"3R'E%/%,".~'S"~NSOR PRIMARYSPEED/TIMING+f--)2 I)~.~ EgSzFWH E~H
=RIMARYENGINE SPEED/TIMING-
PRIMARYENGINE SPEED/rIMING +
J401 P401
"~ECONDARYENGINE SPEED/TIMING
SECONDARY ENGINE SPEED/TIMING+
J402 P402
ENGINE COOLANT [ ~ ENGINE COOLANT TEMPERATURE ~22- " ~ 995-BU 995-BU :ENGINE COOLAkiTTEMPERATURE
TEMPERATUPJ!: SEt,,ISO~ ENGINE TEMPERATURESENSOR COMMON GB33-PK Cg67-BU iENGINE INTAKEMANIFOLDA)R TEPERATURE
A751-YL ENGINE FUEL TEMPERA~JRE
J100
I") 2P100
[F~"
C-~33-PK ENGINE TEMPERATURESENSORCOMMON
G&32-OR INPUT SENSOR COMMON #4
'~TAKE MAN'PO~ A,R ~ ENG'NS'NTAKE MAN,EO,~ A,R TEMPERATURE ~ C~-BU G827-BU INPUT SENSORCOMMON #3
TEMPERATURESENSOR I L~ ENGINETEMPERATURESENSOR COMMON G833-PK
J103 FI(~
ENGINE TIMING CAUBRA13ON PROBE POSITIVE F - ' f - T ) ] , ~ / v , - - , ~ G856-WH IENGINE TIMING CALIBRATIONPROBE POSITIVE
ENGINE TIMING CAUBRATION PROBE NEGATIVE I 2 I)1 /'~'/~ G857-YL ENGINE TIMING CALIBRATIONPROBE NEGATtVE
FUEL TEMPERATURE I - - ~ 1 ~ ENGINE FUEL TEMPERATURE ~ - ' 2 : ~ A751-YL J400 P400
SENSOR ENGINE TEMPERATURESENSOR COMMON G833-PK G883-GN INPLq" #16
J105 P105
P1 Jt
NOTE J: ENGINE BLOCK MUST HAVEA DIRECTWIRE CONNECTION EUMINATION OF ANY COMPONENTSS ~ N WILL DISABLECERTAIN
TO BA1TERY(-).THIS CONNECTION CAN BE MADE AT THE ENGINE FEATURES,CONTACTCATERPILLARENGINEERINGWHEN
STARTER(-) TERMINALOR MAIN FRAMEGROUND LUG CONSIDERING COMPONERT REMOVAL ~ . / f ~ N D STRA1
NOTE K: SEE SAE J1939H1 FOB WIRING GUIDELINES ALL SWITCHES ARE SHOWN IN THE OFF POSITION
UNLESS OTHEFNVISESPECIFIED:
NOTE L: SENSOR COMMON CONNECTION FOR INPUTS #1 THROUGH #8 ALL WIRES TO BE 18 AWG OR LARGERSAE Jl128 TYPE SXL
AND #'11CAN BE MADE TO EITHERJ15 OR J1-18, J1-18 OFt EOUIVALENT,FOR "I3NISTECPAIRSPECIFICATIONSEE SAE J1701~
IS FOR BODY BUtLDER/AFTERMARKETINSTALLATIONS ~CT=,NG _~
NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES BOLT
NOTE M: J1922 AND J1939 DATA LINKS MUST BE PROGRAMMEDFOR ECMTO WITHOUT CATERPILLARENGINEERINGAPPROVAL
INTERACT ON DATA LINK, J19~9 MUST NOT BE PROGRAMMEDUNLESS
USED, IF PROGRAMMEDWITHOUT PROPERCONNECTION A DIAGNOSTIC
CODE WILL RESULT
36
i01248643
Vehicle Wiring Harness

Diagram
SMCS Code: 1408
37
CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

TO +BAT, ( . . - - . - - - - - -
N/O
RELAY
CHECK ENGINE LANPC~L994_YL~
CHECK ENGINE LAMP

WARRING LAMP(~_~_65B_pK 0.3A CURRENT LIMIT WARNING LAMP
KS9~-BU- OUTP°T
OUTPUT
1~
IGNTT[ON KEY SWITCH
NOTE B vo~,~v- INPUT ~12
G882-WH- INPUT ~3
SPEEUOMETER~ ¥74-PU'~ CB74-PB~ SPEEDOMETERPOSITIVE
NOTE E ~ ~C973-GN- SPEEDOMETERNEGATIVE
NOTE H ~ ~B73-GN E71D--PK-
EBBI-DY. +OT f!
OUTPUT
NOTE B OB3S-WR- OUTPUT
T A ~ T E R {~f'[GNA'~"ASO-YL~ I 4SO-YL-
NOTE E TACHOMETER POSITIVE
rACROMETER HEOATIVE
CAB DIAGNOSTIC TOOL CONNECT^~u.
I NOTE H ~SIDNAL-~-ASI-BR ~ 45'-~"
GB37-YL-
~
+BAT.~
-BAT.
/ GBlB-BR-
COOLING TAN SOLENOID G839-BO-
°~T"°T ti
OUTPUT
OUTPUT
~ OB4O-PU~
J1587 OL NEGAT[VE BU 1~'nA ETS3-BU" JISB7 DATA LINK NEGATIVE
JISB70L POSITIVE~E794-E794-YL ~ ~ ~ ~lOOmA E794-YL- JI587 DATA L[flK POSITIVE
TO J1939 DATA L~TK-CONNECTOR(
TO JI939 DATA LINK CONNECTOR( V~" N T H A24B'-BK- JIgSg DATA LINK $HIELU (i~TE K & NOTE M)
~x/-'ORE"-KBRO-GN" J1939 DATA LINK NEOATIVE (NOTE K & NOTE M/
TO JI93~ DATA LINK CONNECTOR( ," ~v "~ v
~ ~v~
. . . . ,. v ~. . . ~O~-H--K
--KBOD-TL" J1939 DATA LINK POSITIVE INOTE KI& NOTE M
TO JIBZ2 DATA LINK CONNECTOR - - '-~ --£721-WH- JIBE2 DATA LINK POSITIVE NOTE
I.°,. I
BLOCK
TO JI922 DATA LENK C O N N
~
E C T O R ~ T 2 0
l~ ,wD DXL
AWG GXL
- P K -
,U,-RO
IOI-RD.
JIgZZ DATA LINK NEGATIVE NOTE M
UNSWITCHEB ~BATTERY
NOTE
ON$WITCHED ~BATTERY INOTEII
14 AWD GXL 22B-EK" -BATTERY
-BATTERY
0933-YL" INPUT 9
INPUT BID
SET/RESUME ENPUT SENSOR COMMON~2
INPUT !14
H795_px~B78_BR §,~mA SET
979-0R~,~ mA RESUME
CRUISE CONTROL ON/OFF KRDS-GN- INPUT ~1 ~NOTE L)
KgDU-PK- INPUT ~2 (NOTE L)
H795-PK-~)-G975-WH§,Pm~ CRTB-WN- CRUISE CONTROL ON/OFT SWITCH
KDBE-YL" INPUT 3 NOTE L
SERVICE BRAKE PEDAL POSITION N/D GBAI-GN-
CDB2-PU-
INPUT I, INOTELI
SERVICE BRAKE PEDAL POSITION SWITCH
(PEOACB~.EAsEo~)-1-'£~ ''2-~ LDOI-GT - INPUT SENSORCOMMON~1
CLUTCH PEDAL POSIT[ON N/C
OB42-GY-
GB4~-OR-
[RPOTf! INOTE
INPUT NOTE
G844-RK- INPUT NOTE
H7qS-RKc..~r-"~_C$77.BU §,~mA CgTT-DU- CLUTCH PEDAL POSITION SWITCH
(PEDAL RELEASED POSITION) ~ "
~ ~716-GY E716-GY : RETARO[R SOLENOID LOW/HI SWITCH
HTBS-'~- _~.'...~-.~] ENGINE RETARDER GB79-OR- +5V
ENGINE RETAROER O SOLEflO[OSELECTOR SWITCH C~3-WH- ENGINE COOLANT LEVEL NORMAL (NOTE G)
Cg84-YL - ENGINE COOLANT LEVEL LOW (NOTE O)
SOLENOIO
A/C HIGH PRESS. SWITCH ON/OFF SWITCH I + ~qj-"'-GN E7t7-GN - RETKI~R SOLENOm MEU/H[ SWITCH
N/C
N.SmA NOTE H ~ r- NOTE
- N
H7RS-PK --I E971GN ER7t-GN" INPUT l i t (NOTE L )
G834-PU" PUT !15 POSZTEVE
t PASSIVE O835-0R. INPUT ~15 NEGATIVE
NOTE MAGNETIC OBO8-BU. VEHICLE SPEED IN POSITIVE (NOTE F)
ROTE VEHICLESPEED GDOB-GN. VEHICLE SPEED IN MEGAT[VE
~ ACCELERATORPEDAL SENSOR/SWITCHSENSORC O M M O N ~ B K ~ 7 9 5 - P K
,CCELENNTONPEDALPOS[~O~ 'DE ~:~
J +Ore^
5mA
SENSOR
GBAS-PU-
t1795-PK-
INPUT ~B (NOTE L)
ACCELERATOR PEDAL ~ENSOR/SW[TCH SENSOR COMMON
+BY
ACCELERATOR PEDAL POSITION
J403J403 IP÷03
ACCELERATOR PEDAL JP÷
POSITION SENSOR OEOl VEHICLE HARNESS CONNECTOR
COMPONENTS WITHIN THIS AREA ARE OATERPILLAR PROVE
NOTE B: FOR SI~EDOMETERSOR TACHOMETERSWITH A S[NOLE SIGNAL [N~T NOTE E: THE ECM SPEEDOMETERAND TACHOMETEROUTPUT SIGNAL LINE NOTE F: IF AN ELECTRONIC SIGNAL IS PROVIDED IN PLACE OF A PASSIVE
TERMINAL. EITHER ONE OP THE TWO SIGNAL OUTPUT LINES PROM VOLTAGES ARE ZERO-GROSSING SQUARE WAVES, THE SPEEDOMETER MAGNETIC SENSOr, CONNECT THE ELECTRONIC SIGNAL INPUT TO
THE ECM CAN BE USEO. LEAVE THE REMAINING LINE O[SCONNECTED, SIGNALS AT JI-37 AND JI-SB ARE COMPLEMENTSOF EACH OTHER. THE +SIGNAL PIN. THE -SIGNAL PEN SHOULD NOT BE CONNECTED
DO NOT CONNECT TO GROUND THE TACHOMETERSIGNALS AT JI-3B AND J1-Sg ARE COMPLEMENTS OR GROUNDEDWITH ELECTRONIC SIGNAL INPUTS
OF EACH OTHER, MAXIMUM SIGNAL AMPLITUDE OF Jt-35, Jl-S7,
NOTE C: "SINGLE" WENDING MAGNETIC PICKUP SENSORR[COMIdERDEO JI-SB. AND dr-JR IS ~/0 VOLTS. AMPLITUDE WILL ~E '5 VOLTS
OR GREATER IF LOAO CURRENT IS LESS THAN OmA NOTE H: THIS IS AN OPTIONAL FEATURE ROT AVAILABLE ON ALL SYSTEMS
NOTE D: THESE CONNECTIONS ARE UNSWETCHED,DIRECT CONNECTION
TO THE BATTERY IS NOT REOUIRED
(SEE OTHER PAGE FOR AOB[TIONAL NOTES)
CATERPILLAR
PROGRAMMING PARAMETERS
TABLE OF CONTENTS
DESCRIPTION PAGE
PROGRAMMING PARAMETERS ......................................................................................................................................... 38
TEST ECM MODE................................................................................................................................................................ 38
CUSTOMER PASSWORDS .................................................................................................................................................. 39
ECM DATE/TIME STAMPED INFORMATION........................................................................................................................ 39
ECM SNAPSHOT ................................................................................................................................................................. 40
FACTORY PASSWORDS ..................................................................................................................................................... 42
FACTORY PASSWORDS WORKSHEET .............................................................................................................................. 42
FLASH PROGRAMMING ..................................................................................................................................................... 43
SERVICE INFORMATION REPORT...................................................................................................................................... 44
38
Programming Parameters i01795655
Test ECM Mode

i01815884
SMCS Code: 1901
Programming Parameters
"Test ECM Mode" is a feature in the software that
SMCS Code: 1901 can be used to help troubleshoot an engine that
may have a problem with the ECM. This feature
Many programmable parameters affect the engine allows a standard ECM to be used as a test ECM.
operation. These parameters may be changed with This feature eliminates the need to stock a test ECM.
the electronic service tool. The parameters are
stored in the ECM. The parameters are not stored 1. Use the "Copy Configuration" feature on the
in the personality module. Any parameter can be electronic service tool to copy the parameters
read. However, passwords protect parameters from from the suspect ECM.
unauthorized changes.
Note: If the "ECM Replacement" feature can not
Two categories contain various parameters, System be used, record the programmed values into the
Configuration Parameters and Customer Specified "Customer Specified Parameters Worksheet". Also
Parameters. System Configuration Parameters can record the System Configuration Parameters.
be altered with the electronic service tool only if the
proper factory passwords are obtained. 2. Disconnect the suspect ECM. Temporarily
connect the test ECM to the engine. Do not
Customer Specified Parameters can be changed mount the test ECM on the engine.
with the electronic service tool only if the
proper customer passwords are used. Refer 3. Use the "Copy Configuration" feature on the
to Troubleshooting, "Customer Passwords" and electronic service tool to program the test ECM.
Troubleshooting, "Factory Passwords" for additional
information. Note: If the "ECM Replacement" feature can not be
used, program the test ECM with the values from
the "Customer Specified Parameters Worksheet"
Programming a New ECM and the values from the System Configuration
Parameters.
The Engine Control Module or the ECM is the
brain of the system. So when a problem occurs, 4. Start the "Test ECM Mode" on the electronic
it is easy to assume that the ECM is responsible. service tool. Access the feature through the
This is usually the wrong assumption. Most failures
"Service" menu. The electronic service tool will
occur at the wiring and connectors or at a sensor
display the status of the test ECM and the hours
input or sensor output. Follow the procedures in
that are remaining for the "Test ECM Mode".
the Troubleshooting Guide, and do not replace
an ECM on an assumption. However, when your Note: "Test ECM Mode" can only be activated if
troubleshooting indicates that a failure has in fact the engine serial number has not already been
occurred in the ECM, refer to Troubleshooting,
programmed during normal operation of the ECM.
"Replacing the ECM". If the engine serial number is programmed and the
ECM is not in "Test ECM Mode", the ECM can never
Note: If a replacement for the ECM is required, the be used as a test ECM.
customer parameters and the timing calibration
can be transferred from the suspect ECM to the When the "Test ECM Mode" is activated, an internal
replacement ECM. Timing calibration will not be timer sets a 24 hour clock. This clock will count
necessary. This feature requires the electronic down only while the ECM is powered and the key
service tool and this feature is only possible if the switch is in the ON position. After the ECM has
suspect ECM can communicate with the electronic counted down the 24 hour period, the ECM will
service tool. exit the "Test ECM Mode". The parameters, the
accumulated mileage, and the engine serial number
will be set.
39
Once an ECM has been activated in the "Test ECM i01179887

Mode", the ECM will stay in the "Test ECM Mode"
until the timer times out. If the ECM is used as a ECM Date/Time Stamped
test ECM for more than one engine, the "Test ECM
Mode" must be reactivated. Anytime prior to the
Information
"Test ECM Mode" timing out, the ECM can be reset SMCS Code: 0785
to 24 hours.
The date/time clock indicates the month, the day,
i01778706
the year and the time of day. This clock is used to
time stamp the following Diagnostic Event Codes:
Customer Passwords
• 84-00 Vehicle Overspeed Warning
SMCS Code: 0785
• 84-14 Quick Stop Occurrence
If Customer Passwords have been entered, then
the Customer Passwords are required to change • 100-11 Very Low Oil Pressure
ANY customer parameter. Customer Parameters
are those parameters that affect the vehicle speed • 110-11 Very High Coolant Temperature
limits, the power rating within an engine family
and the PTO operation. Refer to Troubleshooting, • 111-11 Very Low Coolant Level
"Customer Specified Parameters" for more detail on
parameters that are customer programmable. • 190-00 Engine Overspeed Warning
The Caterpillar Electronic Technician (Cat ET) may The following types of ECM data are also time
change Customer Parameters. To obtain customer stamped information:
passwords, contact the owner of the vehicle. If the
owner has lost the owner's passwords, customer • Diagnostic snapshots
passwords may be read by using Cat ET.
• Snapshots that are triggered by using the
Note: Factory passwords are required in order to Set/Resume switch
read customer passwords.
• Quick Stop snapshots
Use the following procedure in order to read
customer passwords with Cat ET: Adjustment of ECM Date/Time
1. Use Cat ET to access the "Utilities" menu. Then Clock
access "View Passwords" under the "Utilities"
menu. Before adjusting the ECM Date/Time Clock on
a vehicle, ask the owner/operator if the time
2. When the Factory Password screen appears, stamped information should be recorded. After the
record the information that is listed on the Factory time stamped information is recorded, clear this
Passwords Worksheet. Refer to Troubleshooting, information before adjusting the ECM Date/Time
"Factory Passwords Worksheet". Clock. This is a very important step if the adjustment
of the clock is a big adjustment. This will prevent
3. Obtain the factory passwords. The information unnecessary confusion if someone else views the
that is recorded on the Factory Passwords information at a later date.
Worksheet must be provided. When the factory
passwords are obtained, a permanent record of Occurrence of Time Stamped
the access is generated at Caterpillar.
Information
4. From the Factory Password screen, enter the
Factory Passwords. When the time stamped information is being viewed,
remember that the vehicle may be based in a
5. When the "Read Customer Passwords" screen different time zone. Also remember the following
appears, record the Customer Passwords. The two possibilities:
Customer Passwords may then be used to
change Customer Parameters. • Someone may have incorrectly set the clock.
• No one ever set the clock.

40
Compare the electronic control module's current i01778708

time of day to the time stamped information in the
ECM in order to determine the amount of time ECM Snapshot
that has passed since the occurrence of the time
stamped event. DO NOT REPLACE AN ECM SMCS Code: 0785
BECAUSE OF AN INCORRECT TIME OF DAY. The
following example indicates the proper use of the The engine ECM can record a snapshot of the
clock. engine parameters and vehicle parameters. The
snapshot records the parameters for a period of
13 seconds that surrounds the event. The event is
Proper Use of ECM Date/Time either a diagnostic code or an external trigger.
Stamped Information
Use Of Snapshot
The Electronic Service Tool indicates that a
diagnostic code occurred. The 190-00 Engine Use Snapshots ONLY to help determine
Overspeed Warning occurred on 19 November engine/vehicle operating conditions when an
1998 at 10:30:46. The Electronic Service Tool also intermittent problem occurs. If an intermittent
indicates that the current time of day in the ECM is diagnostic code is causing problems, use the
24 November 1998 at 11:20:58. This indicates that snapshot data. Snapshot data can be used to
the problem occurred in the past (approximately determine whether the problem seems to occur
one week and 50 minutes), under specific circumstances. The following list of
conditions is an example of some of the specific
Do not compare the electronic control module's circumstances:
time of day to the current time of day at your
location. If the electronic control module's time of • Engine rpm
day differs significantly from the current time of
day (wrong month), ensure that the important time • Ranges of vehicle speed
stamped information is recorded. After recording
the information, clear the code or the snapshot, and • Ranges of Coolant temperature
then adjust the clock.
Use this data to attempt to duplicate these
ECM Diagnostic Clock conditions with the vehicle and get the code to
reoccur.
The Diagnostic Clock should not be confused
with the ECM Date/Time clock. The Diagnostic
Clock records the actual hours of the ECM under
power. The information from the diagnostic clock
is used in order to log occurrences of diagnostic
code and occurrences of event c o d e . 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. The Diagnostic Clock does
not represent actual Engine Hours. The clock
increments any time of the ECM under power. This
happens when the engine is running or when the
engine is not running. Actual Engine Running hours
(Total Time) can be obtained from the menu for
Current Totals of Electronic Technician (ET).
41
Replacement of electronic components should

not be based on the Snapshot data alone. When
the snapshot information is triggered externally, the
snapshot information is stored in frames during
every 0.24 seconds. When the snapshot information
is triggered by a diagnostic code, the snapshot
information is stored in frames during every 0.48
seconds. Frequently, the parameters are changing
at a rate that is different from 0.24 seconds. If
too much emphasis is put on this information, the
result could be a misdiagnosed problem. Also
when snapshot information 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 g00627693
the reason that the Sensor value suddenly jumps Illustration 22
to a specific value at the trigger point and the (1) OFF position
Sensor value remains there for the rest of the (2) SET position
(3) RESUME position
snapshot frames. DO NOT attempt to interpret
the information and DO NOT attempt to analyze
1. Toggle the switch quickly from the OFF position
the reason that the engine is operating from this
(1) to the SET position (2).
historical information. Incorrect diagnoses will occur
by looking at this information under a microscope.
2. Toggle the switch quickly from the SET position
Incorrect diagnoses will occur because some of
(2) to the RESUME position (3).
the parameters will not be set to the values that
are expected. Even though the parameters are not
3. Toggle the switch quickly from the RESUME
related to the problem that is under investigation,
position (3) back to the OFF position (1).
the parameters can lead to incorrect diagnoses.
Note: The switch must be toggled within a one
Snapshot Information That Is second time period in order to take a snapshot of
Triggered By A Diagnostic Code the engine parameters. The procedure can also be
performed in the reverse order.
When a diagnostic code occurs the ECM records
many of the status parameters that are available on On Cat ET, the snapshot can be triggered from the
the Caterpillar Electronic Technician (Cat ET). The Snapshot Recorder Tool. Refer to the instructions on
ECM records this information for approximately 9 the screen or the system's documentation for help.
seconds before the code occurs, and approximately
4 seconds after the code. Quick Stop Snapshot
Snapshot Information That Is A snapshot can also be stored for a Quick Stop
event if the Customer Parameter is programmed.
Triggered Externally The ECM stores the number of occurrences of the
Quick Stop Event and a snapshot of the latest
A snapshot can be triggered externally with either occurrence.
the Cruise Control Set/Resume Switch, or with Cat
ET. Use the following procedure in order to trigger One data record is kept for the most recent Quick
the snapshot with the Cruise Control Set/Resume Stop event. The previous record is replaced by the
Switch: 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 following the Quick Stop event.
Each frame is separated by 1.0 second. Each frame
of the Quick Stop record stores the following data:
• Engine RPM
• Throttle Position
• Clutch Switch
42
• Vehicle Speed If the owner loses the owner's customer

passwords, the owner will not be able to
• Cruise Status program customer parameters. By using factory
passwords, one can read customer passwords.
• Brake Switch Then use those customer passwords to program
customer parameters.
Storage of Snapshots In The ECM = Clear certain diagnostic codes.
The ECM can store a maximum of two snapshots
that are triggered by a Diagnostic Code, two 5. Unlock a customer parameter that is locked.
snapshots that are triggered externally, and one
Quick Stop Snapshot. The snapshots are stored in If a customer parameter has been locked
a circular buffer. The newest snapshot will replace out, factory passwords are required to unlock
the oldest snapshot. the parameter. Also if a customer parameter
has been locked out, factory passwords are
The ECM stores the snapshots in memory. The required to change the parameter. Refer
memory is maintained through the Unswitched to Troubleshooting, "Customer Specified
Parameters" for additional information.
battery connections. If the Unswitched + battery
pins are disconnected, or if the vehicle batteries
are disconnected, the snapshot information is 6. Enable certain customer parameters.
maintained by the internal battery in the ECM.
• "ECM Wireless Communication Enable"
Also, the snapshots can be cleared manually by
using Cat ET. Snapshots are automatically cleared NOTICE
by the ECM after 100 hours of operation. Snapshots Operating the engine with a Personality Module not
are similar to Diagnostic Codes in this characteristic. designed for that engine will damage the engine. Be
sure the Personality Module is correct for your engine.
i01914316
Certain other codes require customer passwords.
Factory Passwords The majority of logged codes do not require
passwords to be cleared. Since the factory
SMCS Code: 0785 passwords contain alphabetic characters, the
electronic service tool may perform these functions.
Factory passwords are required to perform each of In order to obtain the factory passwords, proceed
the following six functions: as if you already have the password. At some
point, if the factory passwords are actually needed,
1. Change the System Configuration Parameters. the electronic service tool will request the factory
passwords and the electronic service tool will
When an ECM is replaced, the System display the information that is required to obtain the
Configuration Parameters must be programmed passwords.
into the new ECM. A new ECM will allow these
parameters to be programmed once without Note: The "Customer Parameter Lockout" may
Factory Passwords. After the initial programming, restrict changing some customer parameters unless
these parameters are protected by factory factory passwords are obtained. If changing a
passwords. customer parameter indicates that the factory
passwords are required, the parameter has been
2. Rerate to another engine family locked out. Refer to Troubleshooting, "Customer
Specified Parameters" for additional information.
This requires changing the personality module
code, which is protected by factory passwords.
i01180795
This includes changing from a non-multitorque
personality module to a multitorque personality Factory Passwords Worksheet
module.
SMCS Code: 0785
3. Read customer passwords
Note: A mistake in recording these parameters will
result in incorrect passwords.
43
Table 5 4. Select "WinFlash" from the "Utilities" menu on the

Dealer Code electronic service tool.
Customer's Name Note: If "WinFlash" will not communicate with the

Address
ECM, refer to Troubleshooting, "Electronic Service
Tool Will Not Communicate with ECM".
5. Program the flash file into the ECM.

Telephone Number a. Select the engine ECM under the "Detected
Information From Engine Information Plate ECMs".
Engine Serial Number b. Press the "Browse" button in order to select
Full Load Setting the part number of the flash file that will be
programmed into the ECM.
Full Torque Setting
Information From Vehicle Odometer ¢. When the correct flash file is selected, press
the "Open" button.
Engine's Miles (km)
Information From Factory Password Entry d. Verify that the "File Values" match the
Screen on ET application. If the "File Values" do not match
the application, search for the correct flash
Electronic Service Tool file.
Serial Number
Engine Serial Number e. When the correct flash file is selected, press
the "Begin Flash" button.
ECM Serial Number
Total Tattletale f. The electronic service tool will indicate when
flash programming has been successfully
Reason Code completed.
From Interlock(~)
6. Start the engine and check for proper operation.
To Interlock0)
Factory Passwords a. Program any parameters that were not
programmed in the old flash file if a 253-02
Factory Password (No. 1) Check Customer Or System Parameters is
Factory Password (No. 2) active.
(1) This parameteris required when the engine is being rerated. b. The following parameters must be
This parameter is only displayed when the engine is being
rerated. programmed on a new ECM to prevent
a 253-02 Check Customer Or System
Parameters:
i01850081
• "FLS"
Flash Programming
• "FTS"
S M C S Code: 1901-591
• "Vehicle Speed Calibration"
1. Obtain the part number for the new flash file.
• "Rating Number"
a. If the part number is not available, use
the "Flash File Search" tool on the Service • "Engine Serial Number"
Technician Workbench (STW) or on SIS Web.
• "Injector Codes Calibration"
Note: The engine serial number must be obtained in
order to use the "Flash File Search".
2. Connect the electronic service tool to the data

link connector.
3. Turn the key switch to the ON position. Do not

start the engine.
44
"WinFlash" Error Messages Be as specific as possible.
If you receive any error messages during flash Repair Procedure

programming, click on the "Cancel" button in order
to stop the process. Access the information about Comments on the Repair Procedure should include
the "ECM Summary" under the "Information" menu. the following types of information:
Make sure that you are flashing the correct file for
your engine. • The wiring harness was repaired.
i01183143
• The FLS was changed per the factory's
instructions.
Service Information Report
SMCS Code: 0336
After verifying the correct repair has been performed

on the vehicle it is critical to provide brief, detailed
information. This information helps Caterpillar better
serve you and the Customer.
Recommendations
Customer's Complaint
Provide a copy of the Troubleshooting, "Driver
Questionnaire". Include comments in as many
categories as possible. The following information is
of particular importance:
• Indicate whether the Check Engine Lamp was

ON continuously or whether the Check Engine
Lamp was ON intermittently.
• Indicate the symptoms of vehicle operation that

are present.
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.
CATERPILLAR
CUSTOMER SPECIFIED PARAMETERS
TABLE OF CONTENTS
DESCRIPTION PAGE
CUSTOMER SPECIFIED PARAMETERS .............................................................................................................................. 45
CUSTOMER SPECIFIED PARAMETERS TABLE.................................................................................................................. 72
CUSTOMER SPECIFIED PARAMETERS WORKSHEET ....................................................................................................... 78
45
Customer Specified A locked out parameter also provides an audit

trail. The audit trail can be used to determine the
Parameters following information:
• Time of change
i01914146
• Operator during change
Customer Specified
Parameters The following Customer Parameters are available
for Lockout:
S M C S Code: 1901
• "Multi-Torque Ratio"
Customer Specified Parameters allow the vehicle
owner to influence the operating technique of • "Vehicle Speed Calibration"
a driver. Some parameters may affect engine
operation in a way that would not be expected by • "Vehicle Speed Cal (J1939 - Trans)"
an inadequately trained driver. These parameters
may lead to power or performance complaints • "Vehicle Speed Cal (J1939 - ABS)"
even though the engine's performance is within the
engine's specification. • "Vehicle Speed Limit"
Customer parameters may be changed repeatedly • "VSL Protection"

as a customer's operation changes or as new
drivers are assigned to a truck. Customer Passwords • "Soft Vehicle Speed Limit"
are required to change these parameters.
• "Low Speed Range Axle Ratio"
The following information is a brief description of
the Customer Specified Parameters. The following • "High Speed Range Axle Ratio"
parameter values are included with the descriptions:
• "Low Cruise Control Set Speed Limit"
• Minimum
• "High Cruise Control Set Speed Limit"
• Maximum
• "Top Engine Limit"
• Default
• "Transmission Style"
The tables show values in an approximate range for
metric units that is followed by the metric conversion • "Top Gear Ratio"
to English units. The exact range of the parameter
in metric units depends on the service tool that is • "Top Gear Minus One Ratio"
being used. Each tool may use slightly different
conversion factors. • "Top Gear Minus Two Ratio"
• "A/C Switch Fan On-Time"

Customer Parameter Lockout
• "Engine Retarder Delay"
The Customer Parameter Lockout is available in
order to restrict access to changing some of the
• "Engine Monitoring Lamps"
available parameters. Locking out a parameter
requires Customer Passwords (if used). Once a
• "Driver Reward Enable"
parameter is locked out, Factory Passwords are
required to change the parameter. Also, once a
• "Fan Control Type"
parameter is locked out, Factory Passwords are
required to unlock the parameter.
When an attempt to change a locked out parameter
occurs, the Factory Password screen will come up.
If a Iockable parameter is not locked out, Factory
If changing the parameter is required, follow the
Passwords are not required. A locked out parameter
instructions on ET.
restricts the parameter from being changed directly
by the operator. This helps vehicle owners that
Factory Passwords are also required to change a
are encountering problems with operators that are
parameter from a locked parameter to an unlocked
obtaining Customer Passwords and altering some
parameter. If more than one parameter is locked
of these parameters.
out, and each one needs to be unlocked, one
Factory Password is required.
46
"Selected Engine Rating"

"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:
• 324 kW (435 hp) at a Governed Engine Speed of

1800 rpm
• 324 kW (435 hp) at a Governed Engine Speed of

2100 rpm
Both ratings will be displayed for Multi-Torque

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 "Multi-Torque"
feature also helps to reduce wear. The trip point
is determined by a ratio of engine speed versus
vehicle speed. The three programmable options
represent the different trip point values that are
listed below.
Table 6
Programmable Option Turn On Ratio (RPM to MPH) Gear Range
MT-4 71.5 Top 4 Gears
MT-2 37.6 Top 2 Gears
MT-1 27.9 Top 1 Gear
Note: This feature is not used with standard engine

ratings. This feature is only available for muttitorque
ratings.
Table 7
Type of Engine Rating Alternatives Default
Standard Ratings Unavailable Unavailable
Multitorque Ratings MT-2, MT-1 MT-4
47
"ECM Identification Parameters" The "Vehicle Speed Cal (J1939-Trans)" is used

when the ECM is configured to use the speed of
"Vehicle ID" the transmission output shaft in order to calculate
vehicle speed. The "Vehicle Speed Input" parameter
"Vehicle ID" is the identification of the vehicle that must be programmed to "Vehicle Speed Cal
is assigned by the customer. "Vehicle ID" is used J1939-Trans". This value represents the revolution
only for the customer's reference. "Vehicle ID" is of the transmission output shaft as revolutions per
not required by the ECM. kilometer (revolutions per mile). This parameter
must be programmed. If this parameter is not
programmed, the diagnostic code 253-02 that is
"Security Access Parameters" Check Customer or System Parameters (56) will be
active. This parameter affects the cruise control and
"ECM Wireless Communication Enable" the ECM speedometer signal. Also, this parameter
can affect the PTO operation, extended idle and
The "ECM Wireless Communication Enable" trip totals.
determines if the ECM will transfer information
over the data link through remote communications Table 10
systems for customers. Minimum Maximum Default
The parameter will default out of Caterpillar to no 0 65000 Not Programmed
access. The parameter can only be enabled by
getting Factory Passwords. This feature can only "Vehicle Speed Cal (J1939-ABS)"
be enabled after the truck has been delivered to
the customer. Refer to Troubleshooting, "System NOV01 and newer software
Overview" for additional information.
Table 8
Note: This parameter is not available on engine
serial numbers WlA1-Up, MDP1-Up, and MEP1-Up.
Alternative Default
Yes No The "Vehicle Speed Cal (J1939-ABS)" is used to
calculate vehicle speed by the use of the input from
the wheel speed. The data from the wheel speed
"Vehicle Speed Parameters" is transmitted via the J1939 data link. The "Vehicle
Speed Input" parameter must be programmed to
"Vehicle Speed Calibration"
"Vehicle Speed Cal J1939-ABS". The manufacturer
of the ABS system must transmit tire revolutions per
The "Vehicle Speed Calibration" is the value that is mile that is based on the tire size. If the tire size is
changed from the tire size that is programmed in the
used by the ECM in order to translate the vehicle
ABS system, the "Vehicle Speed Cal (J1939-ABS)"
speed signal into kilometers per hour (miles per
must be changed. The value that is contained in
hour). This parameter is programmed in pulses per
kilometer (PPKM) or pulses per mile (PPM). This the "Vehicle Speed Cal (J1939-ABS)" parameter is
parameter must be programmed. If the "Vehicle a ratio. If the actual tire size is equal to the tire size
that is programmed in the ABS system, the "Vehicle
Speed Calibration" parameter is not programmed,
Speed Cal (J1939-ABS)" parameter will be "1". The
253-02 Check Customer or System Parameters (56)
will be active. This parameter affects the cruise ratio can be found by dividing the tire revolutions
per mile that is transmitted by the ABS system by
control and the ECM speedometer signal. Also, this
the actual tire revolutions per mile. Contact the
parameter can affect the PTO operation, extended
idle and trip totals. manufacturer of the ABS system in order to verify
that this message is supported.
Table 9
If the "Vehicle Speed Input" parameter is
Minimum Maximum Default programmed to "Vehicle Speed Cal J1939-ABS",
2485 PPKM 93226 PPKM 8696 PPKM this parameter must be programmed. If this
(4000 PPM) (150000 PPM) (14000 PPM) parameter is not programmed, the diagnostic
code 253-02 that is Check Customer or System
Parameters (56) will be active. This parameter
"Vehicle Speed Cal (J1939-Trans)" affects the cruise control and the ECM speedometer
signal. Also, this parameter can affect the PTO
NOV01 and newer software operation, extended idle and trip totals.
48
Table 11 Table 14
Minimum Maximum Default Minimum Maximum Default
0 6.550 Not Programmed 12.0 PPR 500,0 PPR 113.0 PPR
"Vehicle Speed Limit" (VSL) "Soft Vehicle Speed Limit"

The "Vehicle Speed Limit" (VSL) is the maximum The "Soft Vehicle Speed Limit" operates in
vehicle speed that is allowed by the ECM. The ECM conjunction with the "Vehicle Speed Limit". The
will shut off fuel above this speed. An inexperienced "Soft Vehicle Speed Limit" limits the vehicle speed
driver may think that something is wrong with the within the following range:
engine because the ECM will not fuel the engine
above this vehicle speed limit. Vehicle speed • The minimum value is 4 km/h (2.5 mph) below the
limiting allows the implementation of a gear fast/run programmed "Vehicle Speed Limit" at full load.
slow specification for the truck. The gear fast/run
slow specification for the truck improves fuel • The maximum value is 4 km/h (2.5 mph) above
economy while the parameter for the vehicle speed the selected "Vehicle Speed Limit" at no load.
limit limits the maximum vehicle speed of the truck.
Table15
Note: The Driver Incentive Feature can be used Alternative Default
to automatically adjust the VSL according to the
driver's operating techniques. Yes No
Table 12
"Low Speed Range Axle Ratio"
Minimum Maximum Default
The "Low Speed Range Axle Ratio" must be
48 km/h (30 mph) 204 km/h 204 km/h
(127 mph) (127 mph) 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
"VSL Protection" used, the change in gear ratios from the high
speed range to the low speed range alters the
The "VSL Protection" is the maximum engine rpm calibration of the vehicle speed signal. Since the
when there is a problem with the vehicle speed vehicle speed signal has been altered, a calibration
signal that is detected by the ECM. The ECM limits adjustment is required to ensure that the ECM driven
the engine to this engine rpm when the ECM senses speedometer and the information that is stored in
no vehicle speed signal, and a load on the engine. the ECM correctly reflect the actual vehicle speed.
This is a feature that is used to prevent tampering by This parameter should be programmed to the "Low
running without a Vehicle Speed input to the ECM. Speed Range Axle Ratio". This parameter only
requires programming when the "Two-Speed Axle
Note: When this parameter is programmed to 2120 Switch" parameter is enabled. The "Two-Speed Axle
rpm, the ECM disables 84-01 Loss Qf Vehicle Switch" Parameter is enabled when the parameter
Speed Signal (31) and 84-10 Vehicle Speed Rate is programmed to J1/P1:7, J1/P1:47, J1/P1:6, or
of Change (36) and the "VSL Protection" may be J1/P1:46.
exceeded by disconnecting the Vehicle Speed
Sensor. Table 16
Table 13
Maximum Default 1.00 19.99 1.00
Minimum
1300 rpm 2120 rpm 2120 rpm
"Tachometer Calibration"
The "Tachometer Calibration" is used by the ECM
to translate the engine speed signal into revolutions
per minute for a tachometer. The "Tachometer
Calibration" is programmed in pulses per revolution
(PPR). The programmable range is from 12.0 PPR
to 500.0 PPR in 0.1 PPR increments.
49
"High Speed Range Axle Ratio" "Engine Retarder Mode"

The "High Speed Range Axle Ratio" must be "Engine Retarder Mode" determines the operation
programmed when a "Two-Speed Axle On/Off of the Auxiliary Retarder Output and the Exhaust
Switch" is used by the ECM to adjust the "Vehicle Retarder Output while the cruise control On/Off
Speed Calibration". When a two-speed axle is switch is in the ON position but the engine is not
used, the change in gear ratios from the high in cruise control. This does not determine engine
speed range to the low speed range alters the retarder operation while the engine is in cruise
calibration of the vehicle speed signal. Since the control. Also, this does not allow engine retarder
vehicle speed signal has been altered, a calibration operation while the engine is in cruise control.
adjustment is required to ensure that the ECM driven
speedometer and the information that is stored in The following modes are allowable options:
the ECM correctly reflect the actual vehicle speed.
This parameter should be programmed to the "High • Coast
Speed Range Axle Ratio". This parameter only
requires programming when the "Two-Speed Axle • Latch
Switch" parameter is enabled. The "Two-Speed Axle
Switch" parameter is enabled when the parameter • Manual
is programmed to J1/P1:7, J1/P1:47, J1/Pl:6, or
J 1/P1:46. When the "Engine Retarder Mode" is programmed
to the Coast mode, the engine retarder is enabled
Table 17 only while the service brakes are being applied.
Minimum Maximum Default When the ECM is programmed to the Latch mode,
the engine retarder stays enabled after the service
1.00 9.99 1.00 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
"Cruise Control Parameters" in the ON position until the accelerator pedal is
depressed.
"Low Cruise Control Speed Set Limit"
When the ECM is programmed to the Manual mode,
The "Low Cruise Control Speed Set Limit" sets the cruise control switch is not required to be in the
the lowest vehicle speed that will allow the cruise ON position. When the ECM is programmed to the
control to be set. Programming this parameter to Manual mode, the engine retarder will activate when
the maximum value disables cruise control. all of the following conditions are met:
Table 18 • The engine retarder switch is in the ON position.
• The engine rpm is greater than 800 rpm.
204 km/h 204 krn/h
24 km/h (15 mph) (127 mph) (127 mph)
• The engine is not being fueled.
Table 20
"High Cruise Control Speed Set Limit"
Alternative Default
The "High Cruise Control Speed Set Limit" sets Coast or Latch Manual
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 19
48 km/h (30 mph) 204 km/h 204 km/h

(127 mph) (127 mph)
50
The following diagram illustrates the Engine

Applied Retarder operation for both options of the "Engine
Retarder Minimum VSL Type". The Engine Retarder
parameter is programmed to MANUAL and the
Service Broke Released parameter for the Engine Retarder Minimum Vehicle
ON Speed is programmed to 48 km/h (30 mph).
Engine Retarder OFF

"Coast" hgine I~etarder Operation
Applied
Vehicle Speed
z
o.
60 . . . . . . . . .
30
~/ Retarder
1 Minimum
Vehicle
Speed
Service Broke IReleosed o

ON Eno Retarder
(Hard Limit) ON
Engine Retarder
OFF
"Latch" Engine Retarder Operation
Ena Retarder ON
g00631045 (Soft Limit)
Illustration23
OFF I
Coast and latch of engine retarder mode
"Engine Retarder Minimum VSL Type" "Hard Limit/Saft Limit" Engine Retarder Operotian
The "Engine Retarder Minimum VSL Type" defines g00631048

the use of the "Engine Retarder Minimum Vehicle Illustration 24
Speed" parameter. The "Engine Retarder Minimum
VSL Type" provides the following two options: Note: When the vehicle speed drops below the
Engine Retarder Minimum Vehicle Speed and the
• Hard Limit parameter is programmed to the Hard limit, the
engine retarder turns off. When the vehicle speed
• Soft Limit drops below the Engine Retarder Minimum Vehicle
Speed and the parameter is programmed to the
If the "Engine Retarder Minimum VSL Type" is Soft limit, the Engine retarder remains on.
programmed to the Hard Limit, the engine retarder
will turn off when the value that is programmed If the Engine Retarder Minimum Vehicle Speed
into the Engine Retarder Minimum Vehicle Speed has been programmed to 0 km/h (0 mph), the
is reached. programming of the parameter for the "Engine
Retarder Minimum VSL Type" does not affect the
If the "Engine Retarder Minimum VSL Type" is operation of the Engine Retarder.
programmed to the Soft Limit, the engine retarder
will remain on and the retarder will have a value that Table 21
is below the value that is programmed in the Engine Alternative Default
Retarder Minimum Vehicle Speed. The engine
Soft Limit Hard Limit
retarder wilt 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.
51
"Engine Retarder Minimum Vehicle "Auto Retarder in Cruise Increment"

Speed"
"Auto Retarder in Cruise Increment" requires
Engine Retarder Minimum Vehicle Speed determines the "Auto Retarder in Cruise" parameter to be
the minimum vehicle speed limit for the engine programmed above zero. "Auto Retarder in Cruise
retarders to turn ON. Below this vehicle speed, the Increment" determines the increment in kilometers
ECM will not turn on the engine retarder unless the per hour (km/h) or miles per hour (mph) when the
vehicle is stationary. If the vehicle is stationary, the Medium level of engine retarder will activate. "Auto
vehicle speed is 0 km/h (0 mph). If the vehicle Retarder in Cruise Increment" also determines the
speed signal was not being read by the ECM, the increment in kilometers per hour (km/h) or miles per
vehicle could be moving but the vehicle speed hour (mph) when the High level of engine retarder
signal would be 0 km/h (0 mph). If Engine Retarder will activate. Programming the parameter to zero
Minimum Vehicle Speed is programmed to 0 km/h will allow the retarder to come on in the High mode
(0 mph) the engine retarder will operate at all when the programmed "Auto Retarder in Cruise"
vehicle speeds. This parameter affects both the speed is reached. The "Auto Retarder in Cruise"
engine retarder and any auxiliary retarder such as speed must be set above the cruise set speed.
a BrakeSaver. This parameter affects the engine while the cruise
control is activated. The actual level of braking is
Table 22 limited by the settings of the retarder switch. For
example, the retarder will not come on if the retarder
is switched off.
204 km/h
0 km/h (0 mph) (127 mph) 0 km/h (0 mph) Table 24
"Auto Retarder in Cruise" 0 km/h (0 mph) 8 km/h (5 mph) 3 km/h (2 mph)
The "Auto Retarder in Cruise" determines the

vehicle speed in kilometers per hour (km/h) or "Cruiselldle/PTO Switch Configuration"
miles per hour (mph) above the cruise set speed
when the engine retarder will be activated. The "Cruise/Idle/PTO Switch Configuration" defines the
engine retarder switch must be in the ON position function of the Set/Resume Switch for "ACCEL"
and the cruise control must be set for this feature mode and "DECEL" mode. This parameter affects
to operate. Programming the "Auto Retarder in cruise control mode, idle mode and PTO mode.
Cruise" parameter to zero disables this feature.
This parameter affects the engine while the cruise Table 25
control is activated. Alternative Default
Set/DeceI-Res/Accel Set/AcceI-Res/Decel
Note: This parameter only affects the Factory
installed engine retarder (compression brake). This
parameter does not affect an auxiliary braking "Soft Cruise Control"
device or Brakesaver.
"Soft Cruise Control" provides a 8 km/h (5 mph)
The actual level of braking is limited by the settings operating range around the cruise control set speed
of the retarder switch. For example, the retarder will in order to provide a smoother cruise control. "Soft
not come on if the retarder is switched off. Cruise Control" controls the cruise speed within the
following range:
If Soft Cruise Control is programmed to YES, the
retarder will not come on until the vehicle speed • 4 km/h (2.5 mph) below the set vehicle speed
is 5 km/h (3 mph) above the cruise set speed. An at full load
Electronic Service Tool will change an attempt to
program 2 km/h (1 mph) or 3 km/h (2 mph) for this • 4 km/h (2.5 mph) above the set vehicle speed
parameter to 5 km/h (3 mph) if Soft Cruise Control at no load
is programmed to YES.
Table 23
0 km/h (0 mph) 16 km/h (10 mph) 0 km/h (0 mph)
52
"Idle Parameters"
(Smph) "Idle Vehicle Speed Limit"
8km/h
The "Idle Vehicle Speed Limit" is the maximum
Off vehicle speed for setting or maintaining a set
100% -- 7 O
1
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 On/Off switch is in the ON position. If the vehicle
v speed signal exceeds this value, the engine will not
CL
"r maintain the set engine rpm.
Table 28
S ~ e ~ruise 2 km/h (1 mph) 24 km/h (15 mph) 2 km/h (1 mph)

Speed
Or VSL
Vehicle Speed "Idle RPM Limit"
Illustration 25 g00670797 The "Idle RPM Limit" is the maximum engine rpm in
idle mode. The idle mode occurs if the engine rpm
Table 26 is set by the use of the Cruise Control On/Off switch
and the Set/Resume switch. Refer to "Idle Vehicle
Alternative Default Speed Limit". The actual high limit of this parameter
No Yes is determined by the programmed Top Engine Limit.
The lower limit is determined by the programmed
"Low Idle Engine rpm".
"Adaptive Cruise Control Enable"
Programming this parameter to 600 rpm will prevent
Adaptive cruise control reduces the need to the engine from idling at a constant rpm above the
manually cancel cruise control when you approach programmed Low Idle rpm.
a slower vehicle. The system responds by
decreasing the cruise control set speed until a Table 29
following distance is obtained. If the slower vehicle Minimum Maximum Default
speeds up, the cruise control set speed will be
adjusted in order to maintain the following distance. 600 rpm TEL rpm TEL rpm
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
"ldle/PTO RPM Ramp Rate"
the cruise control set speed above the original
The "ldle/PTO RPM Ramp Rate" determines the
setting. If the vehicle is approaching the target too
rate of increase or decrease of engine rpm. This
rapidly, the ECM will turn off the cruise control.
parameter determines rates of increase or decrease
Table 27 in engine rpm for the following functions:
Alternative Default • Idle rpm
Enabled Disabled
• 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 the use of the Cruise Control On/Off
switch and the Set/Resume switch. The PTO mode
occurs if the engine rpm is set by the use of the
"PTO On/Off" switch and the Set/Resume switch.
53
Table 30 • Cruise Control Switches

If the ECM is programmed to "Remote Throttle", the
5 rpm/sec 1000 rpm/sec 50 rpm/sec 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
"ldlelPTO Bump RPM" "PTO On/Off" circuit is ON.
The "ldle/PTO Bump RPM" determines the Table 32
increment or the decrement in engine rpm when
Alternative Default
the ACCEL switch or the DECEL switch is briefly
toggled. The "ldle/PTO Bump RPM" also pertains to Cab Switches
the dedicated PTO and idle. If a "PTO Engine RPM Remote Switches Off
Set Speed" has been programmed, the "ldle/PTO Remote Throttle
Bump RPM" pertains only to the control of the
engine rpm that is initiated by the use of the "Cruise
Control On/Off" input circuit. If a PTO Engine rpm "PTO Top Engine Limit"
Set Speed has been programmed, the "ldle/PTO
Bump RPM" also pertains to the control of the The "PTO Top Engine Limit" is the top engine limit
engine rpm that is initiated by the use of the "PTO that is available by the use of a "PTO On/Off" circuit
On/Off" circuit. that is connected to Input 1 of ECM Connector
J1/P1.
Table 31
Note: The "PTO Configuration" must be programmed
to Cab Switches, Remote Switches, or Remote
5 rpm 500 rpm 20 rpm Throttle before this parameter can be programmed.
Table 33
"Dedicated PTO Parameters" Minimum Maximum Default
600 TEL rpm TEL rpm
"PTO Configuration"
The "PTO Configuration" determines the features "PTO Engine RPM Set Speed (0 = Off)"
that are available for Dedicated PTO applications
and the input signals that are used for Dedicated This parameter allows automatic ramping to the
PTO applications. When the "PTO Configuration" is preset rpm when the PTO is engaged. "PTO to
turned off, the application does not use the PTO. Set Speed" must be programmed to "Yes" for this
The remaining PTO programmable options require a parameter to function. When the PTO is engaged
"PTO On/Off" circuit that is connected to ECM Input the rpm will change according to the programmed
1. A PTO Switch On Lamp can also be connected "PTO Ramp Rate". This parameter is only available
to Output 1 (ECM J1/P1:30). when the "PTO Configuration" is programmed to
"Cab Switches", "Remote Switches", or "Remote
If the ECM is programmed to the Cab Switches, Throttle".
the ECM will use the signals from the following two
switches for PTO Control and Cruise Control: Table 34
• Cab Set switch (J1/P1:35)
Low Idle PTO TEL rpm 0
• Resume switch (J1/P1:44)
If the ECM is programmed to "Remote Switches", "PTO Engine RPM Set Speed A"
the ECM will monitor programmed signals such as
the Remote Set switch and the Remote Resume NOV99 and newer software
switch. Signals from the cab controls will be ignored
when the "PTO On/Off" circuit is on. The following
components are cab controls:
• Brake Switch
• Clutch Switch
• Accelerator
54
The ECM controls this engine rpm. This control The ECM controls this engine rpm. This control
occurs when the "PTO ON/OFF" circuit is on and occurs when the "PTO ON/OFF" circuit and the
the "PTO Engine RPM Set speed Input A" switch "PTO Engine RPM Set Speed Input B" switch is on
is on. The RPM can be programmed to operate and the "PTO Engine RPM Set Speed A" switch is
from Low Idle up to the PTO Top Engine Limit RPM. off. The RPM can be programmed to operate from
While the engine is operating at this set speed, Low Idle up to the "PTO Top Engine Limit" RPM.
all other inputs for speed control are ignored. The While the engine is operating at this set speed, all
inputs for speed control that are ignored include the other inputs for speed control are ignored except
Cab Throttle switch, the Remote Throttle switch, the for the "PTO Engine RPM Set Speed A". The inputs
Set/Accel switch, and the Resume/Decel switch. for speed control that are ignored include the Cab
This feature can also be used in conjunction with Throttle switch, the Remote Throttle switch, the
the "PTO to Set speed" feature and the "PTO Engine Set/Accel switch, and the Resume/Decel switch.
RPM Set Speed B" feature for multiple speed PTO This feature can also be used in conjunction with
operation. This feature can also override the "PTO the "PTO to Set speed" feature for multiple speed
to Set speed" feature and the "PTO Engine RPM Set PTO operation. This feature can also override the
Speed B" feature for multiple speed PTO operation. "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 is on and the The engine will only operate at this programmed
"PTO Engine RPM Set Speed Input A" switch is on. speed when the "PTO ON/OFF" circuit and the
The engine will operate at the programmed speed "PTO Engine RPM Set Speed Input B" switch is on
unless a condition that causes PTO operation and the "PTO Engine RPM Set Speed A" switch
kickout occurs. The conditions that will cause is off. The engine will operate at the programmed
PTO operation kickout include the depression speed unless a condition that causes PTO operation
of the brake pedal, the depression of the clutch kickout occurs. The conditions that will cause
pedal, and the "PTO Vehicle Speed Limit" that is PTO operation kickout include the depression
exceeded. The engine will return to low idle if the of the brake pedal, the depression of the clutch
PTO operation is kicked out. pedal, and the "PTO Vehicle Speed Limit" that is
exceeded. The engine will return to low idle if the
Note: The "PTO Configuration" parameter must be PTO operation is kicked out.
programmed to Cab Switches, Remote Switches,
or Remote Throttle and the "PTO Engine RPM Set Note: The "PTO Configuration" parameter must be
Speed Input A" parameter must be programmed programmed to Cab Switches, Remote switches,
to a dedicated switch input (J1/P1:6, J1/P1:46, or Remote Throttle and the "PTO Engine RPM Set
J1/P1:58, or J1/P1:60) for this feature to function. Speed Input B" parameter must be programmed
to a dedicated switch input (J1/P1:6, J1/P1:46,
Table35 J1/P1:58, or J1/P1:60) for this feature to function.
Table36
Low Idle rpm PTO TEL rpm 0 rpm Minimum Maximum Default
Low Idle rpm PTO TEL rpm 0 rpm
" P T O E n g i n e R P M S e t S p e e d Input B"
NOV99 and newer software " P T O to S e t S p e e d "
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 Remote Switches before this parameter
can be programmed.
Note: This parameter is not available for "PTO

Configuration Remote Throttle".
Table 37
Alternative Default
Yes No
55
"Maximum PTO Enable Speed" "PTO Kickout Vehicle Speed Limit" (VSL)
NOV01 and newer software This is the maximum vehicle speed for setting or
maintaining a set engine rpm in PTO mode. PTO
Note: This parameter is not available on engine mode is entered if the "PTO On/Off" Switch is on.
serial numbers WlA1-Up, MDP1-Up, and MEP1-Up. (This uses Input 1.) If the vehicle speed signal
exceeds this value, the engine will not maintain the
This parameter specifies the maximum engine set engine rpm.
speed for the engagement of the PTO mode. The
PTO mode will engage when the engine rpm is Table 40
equal to the programmed limit or less than the Minimum Maximum Default
programmed limit. This parameter is only available
when the "PTO Configuration" is programmed to 204 km/h
2 km/h (1 mph) (127 mph) 2 km/h (1 mph)
"Cab Switches", "Remote Switches", or "Remote
Throttle".
Table 38
"Torque Limit"
Torque Limit
Low Idle rpm TEL rpm TEL rpm
"PTO Cab Controls RPM Limit"

¢P
This determines the engine rpm limit of the cab O" Pr °gr °n~?rned T°rque /
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.
Engine Speed(rpm)
• If the parameter is programmed to Low Idle, the
Cab Controls are ignored.
Operation of Torque limit
• If the parameter is programmed to "Top Engine (1) Programmed torque limit
Limit" (TEL), the engine will operate to the
programmed "Top Engine Limit". The parameter for the "Torque Limit" defines the
maximum torque output of the engine during
• If the parameter is programmed to "PTO TEL", Dedicated PTO operation. This parameter provides
the engine will operate to the programmed "PTO temporary protection of equipment. The Torque
Top Engine Limit". limit of the engine is active when the circuit for the
Torque Limit Switch is on. The maximum value is the
Note: "PTO Configuration" must be programmed Rated Torque of the engine. The "Torque Limit" is
to Cab Switches for this parameter to take effect. programmable to N.m (Ib ft) of torque. Programming
If "PTO Configuration" is programmed to Remote a value higher than the Rated Torque is limited
Switches or Remote Throttle, the ECM will always by the ECM to Rated Torque. The torque limit is
ignore the Cab Throttle when the "PTO On/Off" indicated by the dashed line in Illustration 26.
circuit is on.
Table 41
Table 39
Alternative Default
270 N.m 3400 N.m 3400 N-m
Low Idle (200 Ib ft) (2500 Ib ft) (2500 Ib ft)
TEL TEL
PTO TEL
56
"PTO Shutdown Time" "PTO Activates Cooling Fan"

The "PTO Shutdown Time" sets the amount of idle This parameter requires the use of the ECM cooling
time before the PTO shuts down. The time begins fan circuit. When this parameter is programmed to
when the "PTO On/Off" circuit is on and there is no Continuous Mode, the ECM will signal the cooling
vehicle speed. The PTO Shutdown Timer will not fan to run continuously when the "PTO On/Off"
begin counting if the engine is in Cold Mode. This circuit is on. The cooling fan runs continuously
parameter requires the "PTO Configuration" to be in order to reduce changes in the load while
programmed to Cab Switches, Remote Switches or the engine is being used for dedicated PTO
Remote Throttle for the timer to function. applications. When this parameter is programmed
to the normal mode, the operation of the fan is
Note: This feature does not shut down the vehicle's based on coolant temperature, inlet air temperature
power. The ECM and the vehicle remain powered. or air conditioning high head pressure. The "PTO
Configuration" must be programmed to "Cab
Table 42 Switches", "Remote Switches" or "Remote Throttle"
Minimum Maximum Default before this parameter can be programmed. The
"Fan Control Type" must be programmed to the
3 minutes 1440 minutes 0 minutes "On/Off" setting or the "Three-Speed Fan Setting".
Table 44
"PTO Shutdown Timer Maximum RPM"
Alternative Default
O C T 9 9 and newer software Continuous Normal
This parameter can be used to reset the PTO
Shutdown Timer if engine speed goes above the " E n g i n e / G e a r Parameters"
programmed "PTO Shutdown Timer Maximum RPM".
Programming this parameter to 2120 rpm disables "Lower Gears Engine RPM Limit"
this feature. If this parameter is programmed to a
value below 2120 rpm and the PTO Shutdown Timer The engine will accelerate at a slower rate when this
is used, the timer will be reset when the engine limit is exceeded under normal driving conditions.
RPM exceeds the programmed value. This parameter is used to encourage the driver to
shift to the next highest gear.
Table 45
1100 rpm TEL rpm TEL rpm
"Lower Gears Turn Off Speed"

PTO Shutdown
Timer Reset The "Lower Gears Turn Off Speed" parameter is
Engine the vehicle speed which turns off the "Lower Gears
RPM Engine RPM Limit". This must be matched with the
Progrommed
PTO Shutdown Timer "Lower Gears Engine RPM Limit" to the specific
Moximim RPM drive train for best performance.
PT0 Shutdown
Timer Counting Table 46
5 km/h (3 mph) 48 km/h (30 mph) 5 km/h (3 mph)
Illustration 27 g00671143 "Intermediate Gears Engine RPM Limit"

"PTO Shutdown Timer Maximum RPM" Graph
This parameter is similar to the "Lower Gears
Table 43 Engine RPM Limit". The engine will accelerate at
a slower rate when this limit is exceeded under
normal driving conditions. This parameter is
600 rpm 2120 rpm 2120 rpm typically programmed to a slightly higher rpm than
the "Lower Gears Engine RPM Limit".
57
Table 47 Table 51
1100 rpm TEL rpm TEL rpm This value is
1600 rpm 2120 r p m 0 ) dependent on
the Engine
"Intermediate Gears Turn Off Speed" Rating.
(t/ A limitednumberof special ratings have a "Top Engine Limit"
This parameter is similar to the "Lower Gears Turn of 2150 rpm.
Off Speed". This parameter is typically programmed
to a slightly higher vehicle speed than the "Lower
Gears Turn Off Speed".
"Top Engine Limit with Droop"
Table 48 O C T 9 9 and older software
Minimum Maximum Default When the "Top Engine Limit with Droop" is selected,
8 km/h (5 mph) 80 km/h (50 mph) 8 km/h (5 mph) the engine can exceed the TEL with a partial load.
The rpm limit increases as load decreases to 150
rpm above the selected limit for no load.
"Gear Down Protection RPM Limit"
Note: NOV99 and newer software do not allow the
This parameter is the Engine RPM Limit when the droop option to be selected.
vehicle speed is above the "Gear Down Protection
Turn On Speed". This is a hard limit. The ECM will Table 52
not allow fuel to the engine above this limit. This Alternative Default
parameter is used to encourage the driver to shift
into overdrive or top gear. Yes No
Table 49
"Low Idle Engine RPM"
1300 rpm TEL rpm TEL rpm The "Low Idle Engine RPM" is the minimum engine
rpm.
"Gear Down Protection Turn On Speed" Table 53

This parameter is the Vehicle Speed when the
"Gear Down Protection RPM Limit" is turned on. 600 rpm 750 rpm 600 rpm
This must be matched to the specific drive train for
best performance. Above this vehicle speed limit, "Transmission Style"
the engine rpm will be limited by the "Gear Down
Protection RPM Limit". This parameter indicates the type of transmission
Table 50 configuration that is installed in the vehicle to the
ECM. This parameter is used by the ECM to read
Minimum Maximum Default the signals from the following devices:
204 km/h 204 km/h
48 km/h (30 mph) (127 rnph) (127 mph) • Brake switch (No. 2)
• Clutch Switch
"Top Engine Limit" (TEL)
• Neutral switch
OOT99 and older software
If an automatic transmission is installed, this
This parameter is the maximum engine rpm when parameter should be programmed to one of the
the engine is under load. The engine will still following options:
achieve Rated rpm under no load conditions.
• Automatic Option 1
the TEL to be adjusted. • Automatic Option 2
58
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 54
"Transmission Style" Use of Switch
Parameter Setting Service Brake No. 1 Service Brake No. 2 Clutch Neutral
Manual Option 1 X X
Automatic Option 1 X
Automatic Option 2 X X
Automatic Option 3 X X X
Automatic Option 4 X X
Eaton Top 2 X X
Table 55 "Eaton Top 2 Override with Cruise

Alternative Default Control Switch"
Automatic Option 1 If this parameter is programmed to "YES" the Cruise
Automatic Option 2 Control On/Off switch can be used to disable Top 2
Automatic Option 3 Manual Option 1
Automatic Option 4 mode. If the Cruise Control On/Off switch is turned
Eaton Top 2 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.
59
Table 56 Note: This parameter must be precisely programmed

Alternative Default to three decimal places to ensure the proper
operation of the Eaton Top 2 and Caterpillar engine
Yes No drive train in the top two gears.
Table 59
"Top Gear Ratio"
The "Top Gear Ratio" identifies the highest gear 0.000 3.750 0,000
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 "Gear Ratios for Eaton Top 2
to 3.750 in 0.001 increments. The default is 0.000. Transmission"
Refer to "Gear Ratios for Eaton Top 2 Transmission"
for programmable values for each Eaton Top 2 Table 60
transmission. Transmission Top Top Top
Model Gear Gear Gear
Note: This parameter must be precisely programmed Minus Minus Ratio
to three decimal places to ensure the proper Two One
operation of the Eaton Top 2 and Caterpillar engine Ratio Ratio
drive train in the top two gears.
RTLO-XX610B-T2 1.352 1.000 0.741
Table 57 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" Note: The XX that appears in the model number
of the transmission refers to the Nominal Torque
The "Top Gear Minus One Ratio" identifies the Capacity. XX times 100 equals the Nominal
second highest gear ratio for an Eaton Top 2 Torque Capacity. For example, RTLO-14613A has
Transmission. For example, ninth gear for an Eaton a Nominal Torque Capacity of 14 times 100 or
Super 10 Top 2 transmission is Top Gear Minus 1900 N.m (1400 Ib ft).
Qne. The programmable range is 0.000 to 3.750
in 0.001 increments. The default is 0.000. Refer The model designation of the transmission and
to "Gear Ratios for Eaton Top 2 Transmission" other information are stamped on a tag on the
for programmable values for each Eaton Top 2 transmission. The tag is located on the lower left
transmission. side near the front of the transmission.
Note: This parameter must be precisely programmed "Governor Type"

to three decimal places to ensure the proper
operation of the Eaton Top 2 and Caterpillar engine NOV01 and newer software
drive train in the top two gears.
Table 58
0.000 3.750 0.000 This parameter determines the type of governor that
controls the engine. Select "Full Range" for manual
transmissions and for electronically shifted manual
"Top Gear Minus Two Ratio" transmissions. Select "Min/Max" for automatic
transmissions.
The "Top Gear Minus Two Ratio" identifies the third
highest gear ratio for an Eaton Top 2 Transmission. Table 61
For example, eighth gear for an Eaton Super Alternative Default
10 Top 2 transmission is Top Gear Minus Two.
Min/Max Full Range
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.
60
"Timer Parameters" In order to override the timer under the following

conditions, depress the clutch or the service
"Idle Shutdown Time" brake if the parameter is programmed to "Outside
Temperature Based" or "J 1587 Outside Temperature
The "Idle Shutdown Time" is the time (minutes) of Based" and the driver alert is activated. Depression
engine idle before shutting down. The engine will of the clutch or the service brake will override the
only shut down if the ECM senses low engine load timer:
and no vehicle speed. The Idle Shutdown Timer will
not begin counting if the engine is in Cold Mode. If • The outside temperature is below the programmed
this parameter is programmed to zero, this feature is "Minimum Idle Shutdown Outside Temperature".
disabled and the engine will idle until the keyswitch
for the ignition is in the OFF position. • The outside temperature is above the" Maximum
Idle Shutdown Outside Temperature".
Note: This feature does not shut down the vehicle's
power. The ECM and the vehicle remain powered. Note: When the timer is overridden, the engine will
not shut down.
Table 62
If the outside temperature is between the "Minimum
Idle Shutdown Outside Temperature" and the
3 minutes 1440 minutes 0 minutes "Maximum Idle Shutdown Outside Temperature",
the timer is not overridden and the engine will
shut down. If the Outside Temperature Based
"Idle Shutdown Timer Maximum RPM" option is programmed, an Air Temperature Sensor
must be installed in order to measure the outside
NOV99 and newer software temperature. If the sensor is not installed, a
171-03 Outside Air Temp Sensor Open Circuit
This parameter can be used to reset the "Idle diagnostic code will be active. If the J1587 Outside
Shutdown Timer" if engine speed goes above Temperature Based option is programmed and a
the programmed "Idle Shutdown Timer Maximum 171-11 No Ambient Air Temperature Data active
RPM". Programming this parameter to 2120 rpm diagnostic code exists, the idle shutdown timer will
disables this feature. By disabling this feature, be disabled.
the "Idle Shutdown Timer" can not be overridden
by increasing the engine rpm. If this parameter Table 64
is programmed to a value below 2120 rpm and
Alternative Default
the "PTQ Shutdown Timer" is used, the timer
will be reset when the engine RPM exceeds the No
programmed value. Outside Temperature
Based Yes
Table 63 (J1587) Outside
Temperature Based
600 rpm 2120 rpm 2120 rpm
"Minimum Idle Shutdown Outside
Temperature"
"Allow Idle Shutdown Override"
This parameter determines the lower outside
This parameter determines if the clutch or the temperature limit when the "Allow Idle Shutdown
service brake can be used to override the idle Override" is programmed to one option of the
shutdown timer during the driver alert. The driver options that follow:
alert is the last 90 seconds when the Check Engine
Lamp begins flashing. This parameter requires the • "Outside Temperature Based"
"Idle Shutdown Time" to be programmed to 3 or
more minutes for the parameter to be enabled. • "J1587 Outside Temperature Based"
When the "Idle Shutdown Time" is programmed to
0, the parameter is turned off. Table 65
-40 °C (-40 °F) 49 °C (120 °F) 49 °C (120 °F)
61
"A/C Switch Fan On-Time"

The input 11 to the ECM can be used for the
;Idl .e..S.hut .do.w.8~///////~11 connection of a normally closed high pressure A/C
:0verride A'llowed~//////~l Moximum Idle switch. The ECM has a built-in timer. The timer is
....... .......
s.ut do w n 0u t s d, used to prevent excessive cycling of the cooling fan
clutch due to successive cycling of the A/C switch.
Override Not Allowed ] Minimum Idle Programming this parameter to 0 disables the
..... -i/~ . . . . . . . . . . . . . . . . . . . . . Shui<]o;n - ()ut Side function. Programming depends on the refrigerant,
~.l.d.le $hutdown~Z/////L,~
, -~m -ve r o , u , , and the design of the air conditioning system as
:O'~"~.rri'd'e"
"A'ni; ;'edY/////~ well as the use of the signal input. Program the
timer to 1 second for the connection of this input to
0 9O another system. Programming the timer to 1 second
Time(seconds) also provides a time delay. This feature requires the
"Fan Control Type" to be programmed to the On/Off
or the "Three-Speed Fan".
The "Allow Idle Shutdown Override" is programmed to the "Outside
Temperature Based" option or the "Outside Temperature Based Table 67
(J1587)" option.
"Maximum Idle Shutdown Outside 1 second 600 seconds 0 seconds

Temperature"
"Fan with Engine Retarder in High Mode"
This parameter determines the upper outside
temperature limit when the "Allow Idle Shutdown This parameter determines whether the Cooling
Override" is programmed to one option of the Fan will turn on when the Engine Brake has been
options that follow: active for at least two seconds. This feature requires
the "Fan Control Type" to be programmed to the
• "Outside Temperature Based" On/Off or the "Three-Speed Fan". An On/Off or a
"Three-Speed Fan" must be installed in order for
• "J1587 Outside Temperature Based" this parameter to function.
Illustration 28 indicates that the "Allow Idle Table 68
Shutdown Override" is allowed in the final 90
Alternatives Default
seconds of the timer's countdown. During the final
90 seconds, one of the following conditions must Yes No
exist in order for the engine to be shut down:
• The outside temperature is below the programmed "Engine Retarder Delay"

"Minimum Idle Shutdown Outside Temperature".
This parameter provides a programmable delay
• The outside temperature is above the "Maximum after provisions to turn on the engine retarder or
Idle Shutdown Outside Temperature". the engine brake are met.
Table 66 Table 69
- 4 0 °C (-40 °F) 49 °C (120 °F) 49 °C (120 °F) 0 seconds 3 seconds 0 seconds
"Smart Idle Parameters"

"Battery Monitor and Engine Control Voltage"
OCT99 and newer software
62
This parameter is used to determine the voltage trip This parameter determines the lamp requirements
point. Below this trip point, the Battery Monitor and for the Engine Monitoring System. If this parameter
the Engine Speed Control System will automatically is programmed to the Warning Lamp option,
elevate engine idle in order to maintain ideal battery J1/P1:29 is available for the connection of a red
system voltage. This feature is used to promote Warning Lamp. The Warning Lamp is used to alert
additional battery life. The engine idle will only the operator that an engine problem is occurring.
be increased if the vehicle is stopped and the The Warning Lamp also indicates when the engine
transmission is out of gear. If these conditions is being derated or the lamp will indicate that
are not met, the engine idle will not be adjusted. shutdown will take place.
This feature will not function when the engine is
operating in dedicated PTO mode ("PTO On/Off" If this parameter is programmed to Option 1, there
switch in the ON position). will be up to three discrete lamp outputs that
are available for use to indicate specific engine
The recommended setting is 12.2 Volts for a 12 Volt problems. "Option 1" configures J1/P1:29 for the
system, and 24.5 Volts for a 24 Volt system. connection of a Low Oil Pressure Lamp and "Option
1" also configures J1/P1:31 for the connection of a
Note: This feature requires the installation of a High Coolant Temperature Lamp. If the parameter
Neutral Switch on J1/PI. This is terminal 62 (Input for the Coolant Level Sensor is programmed to the
12). Engine speed will only be elevated when the 4 Pin option, then J1/P1:30 will also be available
transmission is in Neutral. for the connection of a Low Coolant Level Warning
Lamp. If the parameter for the Coolant Level Sensor
Table 70 is programmed to Off, then J1/P1:30 can be used
Minimum Maximum Default to connect a PTO Switch On Lamp.
0 Volts 25,5 Volts 0 Volts Table 72
Alternative Default
"Engine Monitoring Parameters" Option 1 Warning Lamp
"Engine Monitoring Mode" Note: The Engine Monitoring System must be

programmed to one of the following items for the
This parameter determines the level of action that Warning Lamp to function.
will be taken by the ECM in response to a condition
that has the capability to damage the engine. The • Warning
ECM reads the Caterpillar Coolant Temperature, Oil
Pressure and Inlet Manifold Air Temperature. If the • Derate
ECM has been programmed to monitor the OEM
Installed Coolant Level Sensor, the ECM will read • Shutdown
that sensor.

"Coolant Level Sensor"
the "Engine Monitoring Mode" to be programmed
This parameter determines if the ECM monitors
to "Off" except on engine serial numbers WlA1-Up,
the input signal of the Coolant Level Sensor. This
MDP1-Up, and MEP1-Up.
feature requires the Engine Monitoring Mode to be
Table 71 programmed to one of the following modes:
Alternative Default • Warning
Derate Off
Shutdown Warning(1) • Derate
(1) This is for NOV01and newer software except engine serial
numbers WlA1-Up, MDP1-Up,and MEP1-Up. • Shutdown
Table 73
"Engine Monitoring Lamps" Alternative Default
NOV99 and newer software 4 pin No
2 wire Float Sensor
63
"Maintenance Parameters" Table 77

"Maintenance Indicator Mode"
Refer to Table
19 L (20 qt) 57 L (60 qt) 78.
The ECM records data that is related to the
vehicle's maintenance. If Distance is selected, all
maintenance indications on the service tool will Table 78
be displayed in distance. Typical maintenance Engine Model Default
indications are PM 1, PM 2 and the Cooling System
Clean/Flush. C-10 and C-12 34 L (36 qt)
3406E, C-15, C-16
If Hour is selected, all maintenance indications on and C-18 38 L (40 qt)
the service tool will be displayed in Hours. Typical
maintenance indications are PM 1, PM 2 and the 3406E, C-15, C-16 and
Cooling System Clean/Flush. The ECM provides C-18 with a Rear Sump 38 L (40 qt)
BreakSaver
PM 1 maintenance interval and last maintenance
information. 3406E, C-15, C-16 and
C-18 with a Front Sump 38 L (40 qt)(~)
Table 74 BreakSaver
Alternative Default (0 The 3406E, C-15, C-16 and C-18 Engineswith a Front Sump
BrakeSavershould be programmed to 49 L (52 qt).
Manual Distance
Manual Hours
Automatic Distance Off "Trip Parameters"
Automatic Hours
"Fuel Correction Factor"
"PM 1 Interval" (Manual Maintenance The "fuel correction factor" is available to fine tune
Indicator Mode) all fuel data that will be stored in the future by
the ECM. Caterpillar recommends changing this
The "PM 1 Interval" allows a maintenance interval factor only after a significant operating interval that
(PM 1) to be specified by the user. This parameter includes a comparison of actual tank fuel economy
("PM 1 Interval") must be programmed only when to the fuel economy that is recorded in the ECM.
the Maintenance Indicator Mode is programmed to The operating interval should also reflect a typical
a Manual Mode (Distance or Hours). route. The "Fuel Correction Factor" is a percentage
that is programmable in 0.5 percent increments.
Table 75
Manual Distance Table 79
8050 km 56325 km 24140 km -63.5 +63.5 0

(5000 miles) (35000 miles) (15000 miles)
"Calculating Fuel Correction Factor"
Table 76
Manual Hours The following formula should be used to determine
the new Fuel Correction Factor (NEW FCF).
1O0 750 300
ERROR = ( E C M - TANK) / TANK
"Engine Oil Capacity" (Automatic
Maintenance Indicator Mode)
NEW FCF = ((100 + OLD FCF) ERROR) + OLD FCF
The "PM 1 Interval" can be determined by the
ECM. The ECM bases the "PM 1 Interval" on Illustration 29 g00629908
fuel usage. This parameter ("PM 1 Interval") must
be programmed only when the Maintenance OLD FCF - Fuel Correction Factor in ECM
Indicator Mode is programmed to an Automatic
Mode (Distance or Hours). Capacity of the sump TANK - A c t u a l Fuel Economy
influences the maintenance interval.
ECM - Fuel Economy in ECM Stored Trip Data
64
Refer to Illustration 30 as an example. The Actual Table 81

TANK fuel economy is 7.1 mpg. The Fuel Economy Alternative Default
in the ECM Stored Trip Data is 7.0 mpg over the
same distance with an OLD FCF of -2.5. Yes No
"Fleet Trip Reset"

ERROR = (7.0 -7.1) / 7.1 = -0.0141 This parameter determines the driver's access for
resetting the Fleet Trip Segment.
NEW FCF,,((100+-2.5)X[-0.0141])+(-2.5)--3.9 Table 82

Alternative Default
-3.9 ROUNDED OFF TO THE NEAREST 0.5,
Yes No
NEW F C F = - 4 . 0 "State Selection"
g00629939 Program this parameter to NO to disable this

Illustration 30 function of the Cat ID. The Cat ID will not show
"State Selection" as an option to the driver. If this
"Dash Display Access Parameters" parameter is programmed to "YES" (default) the Cat
ID will provide the feature of "State Selection".
The following parameters establish a security
access for the Caterpillar Driver Information Display: Programming this parameter to "NO" eliminates
"State Selection". Therefore, the storage of the trip
• "Change Fuel Correction Factor" data ("State Selection") is eliminated.
• "PM 1 Reset" Table 83

Alternative Default
• "Fleet Trip Reset"
No Yes
• "State Selection"
"Theft Deterrent System Control"
These parameters require a Caterpillar Driver
Information Display for access. When this parameter is used with a "Theft Deterrent
Password", this parameter prevents the engine from
"Change Fuel Correction Factor" starting unless the password has been entered via
the dash display of the CAT ID. Before the operator
This parameter allows the driver to adjust the "Fuel can use the feature of Theft Deterrent of the CAT
Correction Factor". An owner/operator would want ID, the system must be turned on. In order to turn
the driver to be able to change this information, but on the theft deterrent, a service tool must be used
a fleet operation might not want the driver to be to program the parameter for the theft deterrent to
able to change this information. "YES". The operator must first enter the password
before the engine is shut off. This will enable the
Table 80 system. Enabling the system prevents the engine
Alternative t Default from starting without re-entering the password on
the next attempted start.
Yes No
Table 84
"PM 1 Reset" Alternative Default

Yes, Auto-EnableO) No
This parameter determines the driver's access for
resetting the PM 1 (Maintenance) after the PM 1 (1) NOV99 and newersoftware
has been performed. Maintenance Indicator Mode
cannot be programmed to "OFF" for the "PM 1
Reset" parameter to take effect.
65
"Theft Deterrent Password" Note: Programming the "Quick Stop Rate" too low
will cause an excessive number of Quick Stop Event
The "Theft Deterrent Password" is the password Codes. A vehicle without a load or a trailer will be
that is required by the ECM before the feature of able to stop much more quickly than a vehicle with
Theft Deterrent is enabled. After the Theft Deterrent a heavy load. If too many Quick Stop Event Codes
is enabled, the "Theft Deterrent Password" is the are being logged, the "Quick Stop Rate" should be
password that is required to restart the engine. All increased. This will improve the detection of the
of the characters must be in the upper case. exceptions when the exceptions occur.
Table 85
"Vehicle Activity Report"
Alternative Default
Four Characters "Minimum Idle Time"
A through Z 0000
0 through 9 OCT99 and newer software
The "Vehicle Activity Report" provides a

"Quick Stop Rate" chronological order log of engine operation. This
report records the following items: "vehicle starts",
This parameter determines the rate of vehicle speed "vehicle stops", "idle time", "driving time", and "PTO
change that is used by the ECM to record a Quick time". The "Minimum Idle Time" parameter can
Stop Event Code and a Quick Stop Snapshot. This be used to adjust the recorded idle time. This is
parameter is programmable from 5 kilometers per done in order to remove the time for the following
hour per second (3 miles per hour per second) to 24 occurrences: stopped in traffic, switching into PTO
kilometers per hour per second (15 miles per hour mode and switching out of PTO mode, and idling
per second). This parameter is also programmable for other brief periods of time. If the "Minimum Idle
to 0, which is the default value. Programming this Time" is programmed to a value above 0 minutes
parameter to 0 will disable this feature and no (default), the previous mode of operation will be
Quick Stop Events will be logged. Each Quick logged until the idle time exceeds the programmed
Stop Snapshot contains 60 frames of information. limit.
The no. 45 Frame is the "Quick Stop occurrence".
The Quick Stop Snapshot also contains 44 frames Table 88
before the "Quick Stop occurrence" and 15 frames
after the "Quick Stop occurrence". Each frame is Minimum Maximum Default
separated by 1.0 second. 0 Minutes 1440 Minutes 0 Minutes
Table 86
ECM Snapshot Frame Data "Driver Reward"
Engine rpm Vehicle Speed
Throttle Position Cruise Status "Driver Reward Enable"
Clutch Switch Brake Switch
M A R 9 9 and newer software
The most recent Quick Stop Snapshot is stored in "Driver Reward" is a feature that allows a truck
the ECM memory. When a Quick Stop Event occurs owner to place emphasis on certain factors
the ECM replaces the old Quick Stop Snapshot for desired operating habits. If the vehicle is
with the new Quick Stop Snapshot. The ECM also operated in a manner that exceeds the owner's
logs a diagnostic event code for each "Quick Stop specifications, the maximum vehicle speed limit can
Occurrence". The ECM stores a maximum of 255 be automatically increased to a specified value as
occurrences. a reward to the driver. The "Driver Reward Enable"
parameter provides a means in order to disable
Table 87
the "Driver Reward" feature. This parameter also
Alternative Default provides a means in order to lock out the "Driver
5 kilometers per hour Reward" feature. An Electronic Service Tool is used
per second ( 3 miles per for those areas with regulations that require a fixed
0 kilometers per hour maximum Vehicle Speed Limit.
hour per second) to 24
per second (0 miles per
kilometers per hour per
hour per second)
second (15 miles per
hour per second)
66
Table 89 "Torque Limit Switch"

The Input 4 to the ECM can be used to connect
Disabled Enabled the "Torque Limit Switch" in order to limit the
engine torque to a programmable value. This
should only be used for temporary protection of
"Input Selections" equipment. The "Torque Limit Switch" parameter
cannot be programmed if the "PTO Configuration"
"Fan Override Switch" is programmed to "OFF". If the "PTO Configuration"
is programmed to "OFF", the ECM will ignore the
Four input connections can be used in order to "Torque Limit Switch". This parameter ("Torque Limit
connect the "Fan Override Switch". The "Fan Switch") must be programmed to J1/P1:7 to enable
Override Switch" can be programmed to the this feature.
following ECM pins:
Table 92
• J1/P1:7 (Input 4) Alternative Default
• J1/P1:47 (Input 5) J1/P1:7 None
• J1/P1:6 (Input 6) "Diagnostic Enable"

• J1/P1:46 (Input 7) The J1939 data link and input 7 can be used
to connect the "Diagnostic Enable". Diagnostic
The J1939 data link can also be used to control flash codes can be prompted by the use of the
the "Fan Override Switch" on NOV01 and newer "Diagnostic Enable". To initiate the flash codes,
software. depress the momentary "Diagnostic Enable" until
the Check Engine Lamp begins to flash. Refer to
This switch will allow the operator to turn on the Troubleshooting, "Diagnostic Codes" for additional
cooling fan at any time for improved retarding and information regarding flash codes.
braking of the engine. This will also allow better
engine cooling. Table 93
Table 90 Alternative Default

Alternative Default J1/P1:46
J1939 - Body Controller
J1/P1:7 None
J1939 - Cab Controller
J1/P1:47 J1939 - instrument Cluster
J1/P1:6
J1/P1:46 None
J1939 - Body Controller "PTO On/Off Switch"
J 1939 - Instrument Cluster NOV01 and newer software
"Ignore Brake/Clutch Switch" Note: This parameter is not available on engine

serial numbers W1A1-Up, MDP1-Up, and MEP1-Up.
The Input 5 to the ECM can be used to connect
an "Ignore Brake/Clutch Switch". The "Ignore This parameter allows the connection of a "PTO
Brake/Clutch Switch" is used for applications that On/Off Switch" using either the J1939 data link or
require the mobile use of the vehicle with a set PTO J1/P1:56.
engine set rpm that does NOT require the Brake or Table 94
the Clutch to disengage the engine's PTO operation.
This parameter ("Ignore Brake/Clutch Switch") must Alternative Default
be programmed to J1/P1:47 to enable this feature. J1939 - Body Controller
J1939 - Cab Controller J1/P1:56
Table 91 J1939 - Instrument Cluster
Alternative Default
J1/P1:47 None
67
"Remote PTO Set Switch" "PTO Engine RPM Set Speed Input B"
The J1939 data link and input 2 can be used NOV99 and newer software
to connect the "Remote PTO Set Switch". The
"Remote PTO Set Switch" is used when the "PTO The "PTO Engine RPM Set Speed Input B" switch
Configuration" is programmed to Remote Switches can be connected to any one of the following
and the "PTO On/Off" switch is in the ON position. locations: J1/P1:6, J1/P1:46, J1/P1:58, J1/P1:60,
and Jlg39 data link. If the "PTO Engine RPM Set
Table 95 Speed Input B" parameter is programmed to the
Alternative Default corresponding switch input option, the switch is
used to control engine speed during PTO operation.
J1939 - Body Controller The "PTO Configuration" parameter must be
J1939 - Cab Controller programmed to Cab Switches, Remote Switches or
J1939 - Instrument Cluster J1/P1:58
None
Remote Throttle and the "PTO Engine RPM Speed
Input B" parameter must be programmed to a valid
speed.
"Remote PTO Resume Switch"
Table 98
The J1939 data link and input 3 can be used to Alternatives Default
connect the "Remote PTO Resume Switch". The
J1/P1:6
"Remote PTO Resume Switch" is used when the J1/P1:46
"PTO Configuration" is programmed to Remote J1/P1:58 None
Switches and the "PTO On/Off" switch is in the ON J1/P1:60
position.
Table 96 "Starting Aid On/Off Switch"

Alternative Default
OCT99 and newer software
J 1939 - Body Controller
J1939 - Cab Controller J1/P1:60 The "Starting Aid On/Off Switch" can be connected
J1939 - Instrument Cluster
to either of the following locations: J1/P1:6, J1/P1:7,
None
J1/P1:46, and J1/P1:47. The Starting Aid System
does not require a switch for Automatic operation. A
"PTO Engine RPM Set Speed Input A" switch can be installed in order to allow the operator
to disable the Automatic Starting Aid. If a switch
NOV99 and newer software is installed and the "Starting Aid On/Off Switch"
parameter is programmed to the corresponding
The "PTO Engine RPM Set Speed Input A" switch switch input, the switch will control the Starting Aid
can be connected to any one of the following system. When the switch is in the ON position, the
locations: J1/P1:6, J1/P1:46, J1/P1:58, J1/P1:60, Starting Aid System will automatically enable the
and J1939 data link. If the "PTO Engine RPM Set Starting Aid Output when conditions require the
Speed Input A" parameter is programmed to the use of a starting aid. When the switch is in the Off
corresponding switch input option, the switch is position, the Starting Aid System will not function.
used to control engine speed during PTO operation.
The "PTO Configuration" parameter must be Table 99
programmed to Cab Switches, Remote Switches or Alternatives Default
Remote Throttle and the "PTO Engine RPM Speed
Input A" parameter must be programmed to a valid J1/P1:6
J1/P1:7
speed. J1/P1:46
None
J1/P1:47
Table 97
J1/P1:6
J1/P1:46
J1/P1:58
J1/P1:60 None
68
"Two-Speed Axle Switch" • Enable the Diagnostic Flash Codes on the Check
Engine Lamp.
The J1939 data link and input 6 to the ECM is used
to connect the "Two-Speed Axle On/Off Switch". When the "PTO Configuration" is programmed to
When a two-speed axle is used, the change in Cab Switches, the "Cruise Control Set/Resume
gear ratios from the high speed range to the low Switch" is also used with the "PTO On/Off" switch to
speed range alters the calibration of the vehicle control the engine rpm in PTO Mode.
speed signal. When this parameter is programmed
to J1/P1:6 or J1939 and the switch is in the ON Table 102
position the ECM automatically adjusts the vehicle Alternative Default
speed calibration. This will ensure that the ECM
driven speedometer and the information that is J1939 - Body Controller
stored in the ECM correctly reflect the actual J1939- Cab Controller J1/P1:35 & 44
vehicle speed. The "High Speed Range Axle Ratio" J1939 - Instrument Cluster
and "Low Speed Range Axle Ratio" must also be
programmed for this feature to function correctly. "Cruise Control Pause Switch"
Table 1O0
NOV01 and newer software
Alternative Default
J1/P1:6
J1939 - Body Controller serial numbers WlA1-Up, MDP1-Up, and MEPI-Up.
None
J1939 - Instrument Cluster 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.
"Cruise Control On/Off Switch"
Table 103
The "Cruise Control On/Off" input circuit is available Alternative Default
for the connection of a "Cruise Control On/Off
Switch" to ECM Connector J1/Pl:59 or the J1939 J1939 - Body Controller
data link. This switch is used to enable Cruise J1939 - Cab Controller None
Control when the vehicle is moving. Also, this switch J1939 - Instrument Cluster
is used to control the engine idle rpm when the
vehicle is stationary. "Clutch Pedal Position Switch"
Table 101
The Input for the "Clutch Pedal Position Switch"
Alternative Default is available for the connection of a Clutch Pedal
J1939 - Body Controller Position Switch to ECM Connector J1/P1:22 or
J1939 - Cab Controller J1/P1:59 the J1939 data link. This input is used when
J1939 - Instrument Cluster the "Transmission Style" is programmed to the
Manual Mode. When the "Transmission Style" is
programmed to the Manual Mode, an input that is
"Cruise Control Set/Resume Switch" used to determine the position of the clutch pedal
is required.
The "Cruise Control Set/Resume" input circuits
are available for the connection of a cruise Table 104
control set/resume switch. This parameter can be Alternative Default
programmed to J1/P1:35 & 44 or J1939. If the
parameter is set to J1/P1:35 & 44, the Set input J1939 - Body Controller
should be connected to J1/P1:35 and the Resume J1939 - Cab Controller J1/P1:22
input should be connected to J1/P1:44. This switch J1939 - Instrument Cluster
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.
69
"Retarder Off~Low/Medium~HighS w i t c h " "Vehicle Speed Input"
The input for the "Retarder Solenoid Low/Hi Switch" NOV01 and newer software
and the input for the "Retarder Solenoid Med/Hi
Switch" are available for the connection of a selector Note: This parameter is not available on engine
switch for the engine retarder solenoid. The Retarder serial numbers WlA1-Up, MDP1-Up, and MEPI~Up.
Switch can be connecting by the use of the J1939
data link or using J1/P1:23 & 40. If J1/Pl:23 & 40 The ECM has an input circuit that can be used to
is used, the Low/Hi Input should be connected to receive vehicle speed information. The ECM input
ECM Connector J1/P1:23 and the Med/Hi Input can receive the vehicle speed information in either
should be connected to ECM Connector J1/P1:40. of the following ways:
This switch controls the operation of the Engine
Retarder Solenoids. • A vehicle speed sensor can be connected to the
input.
Table 105
Alternative Default • A signal wire from an electronic control can be
connected to the input.
J1939 - Cab Controller J1/P1:23 & 40 The "Vehicle Speed Input" parameter must be
J1939 - Instrument Cluster programmed to "J1/P1:32 & 33" to use this option.
" S e r v i c e B r a k e P e d a l P o s i t i o n S w i t c h 1" The ECM can also be configured to receive vehicle

speed information from an Electronic Transmission
The Input for "Service Brake Pedal Position Switch Control Unit via the J1939 data link. The transmission
1" is available for the connection of a Service must be capable of supporting the "J1939 ETC1
Brake Pedal Position Switch. The "Service Brake Broadcast Message". The "Vehicle Speed Input"
Pedal Position Switch 1" can be connected by the must be programmed to "J 1939-Trans".
use of the J1939 data link or by the use of ECM
connector J1/P1:45. The input is used to determine The ECM can also be configured to receive vehicle
the position of the service brake pedal. The position speed information from the ABS system via the
of the service brake pedal can affect the following J1939 data link. The ABS system must be capable
functions: of supporting the "J1939 High Resolution Wheel
Speed Broadcast Message". The "Vehicle Speed
• Cruise Input" must be programmed to "J1939-ABS".
• Idle Note: The "J 1939-ABS" option is only available with

NOV01 and newer Personality Modules. This option
• PTO is not available for engine serial numbers WlA1-Up,
MDP1-Up, and MEP1-Up.
• Idle Shutdown
Table 108
Table 106 Alternative Default
Alternative Default J 1939 - ABS
J1939 - Trans
J1/Pl:32 & 33
J1939 - Cab Controller JI/P1:45
"Accelerator Pedal Position"
The Input for the "Accelerator Pedal Position" is

available for the connection of an Accelerator Pedal
Position Sensor. The Sensor's 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 107
Alternative Default
J1/P1:66
70
"Output Selections" Table 111

Alternative Default
"Engine Running Output" J1/P1:12 None
The Output 2, Output 3, or Output 4 is available
for the connection of an Engine Running Output "Starting Aid Output"
Relay that is used to prevent engagement of the
starter while the engine is running. The "Engine N O V 9 9 and newer software
Running Output" can be programmed to J1/P1:10,
J1/P1:12 or J1/P1:13. The "Engine Running Output" Output 2, Output 3 or Output 4 is available
comes on when the engine is running. The "Engine for the connection of the Starting Aid Output
Running Output" turns off when the engine rpm is Relay/Solenoid. If a Starting Aid Switch is not used,
0. The relay is normally closed so cranking can be the "Starting Aid Output" will turn on automatically
achieved immediately at powerup. During cranking, when operating conditions require the use of a
the ECM energizes the "Engine Running Output" Starting Aid. If the "Starting Aid On/Off Switch"
once engine low idle rpm has been achieved. The parameter is programmed and a switch connected
relay is de-energized when the engine speed falls to the corresponding switch input, the "Starting Aid
by 100 rpm below the programmed low idle. The Output" will not function when the switch is in the
programmed low idle range is 600 rpm to 750 rpm. OFF position.
Table 109 Table 112
Alternative Default Alternatives Default
J1/P1:10 J1/P1:10
J1/P1:12 None J1/P1:12 None
J1/P1:13 J1/P1:13
"Engine Shutdown Output" "Air Inlet Shutoff Relay Control"

The Output 2, Output 3 or Output 4 is available for The Air Inlet Shutoff is available for certain engine
the connection of an Engine Shutdown Output Relay ratings that operate in areas with large amounts of
that is used to shut down the vehicle electrical combustible gases. The air inlet shutoff will protect
system after the idle timer has expired. The "Engine the engine from an engine overspeed when these
Shutdown Output" can be programmed to J 1/P1 : 10, gases are present. If this option is installed, the
J1/P1:12 or J1/P1:13. The "Engine Shutdown "Air Inlet Shutoff Relay Control" cannot be turned
Output" comes on after the engine runs for more off. J1/P1:62 must be connected to the +Battery in
than 3 seconds. The "Engine Shutdown Output" order for the air inlet shutoff to operate.
turns off when the engine rpm is at least 100 rpm
below the low idle rpm for more than 3 seconds. Table 113
Table 110 Alternatives Default
Alternative Default Unavailable
J1/P1:10
J1/P1:12 None "Fan Control Type"
J1/P1:13
If the ECM is used to operate the cooling fan,
this parameter must be programmed to "On/Off",
"Auxiliary Brake" "Three-Speed Fan", or "Variable Speed Fan
The Auxiliary Brake Output is for use with a Option S". Options are "None" (default), "On/Off",
"Three-Speed Fan", and "Variable Speed Fan
BrakeSaver or other Aftermarket braking devices.
Option S". This parameter should be programmed
The Output 3 is available for the connection of an
to "None" if the ECM is not connected to the cooling
auxiliary Brake Relay. This parameter ("Auxiliary
fan relay or the cooling fan solenoid. Also, this
Brake") must be programmed to J1/P1:12.
parameter should be programmed to "None" if
Operation of the auxiliary brake and the relay
the ECM is not operating the cooling fan relay or
is inhibited during undesirable engine operating
the cooling fan solenoid. When this parameter is
conditions. The time period of fueling the engine is
programmed to "None", the service technician can
an undesirable engine operating condition.
use an Electronic Service Tool to determine that the
ECM is not connected to the fan circuit.
71
Table 114 Injector Codes

Alternative Default
Injector Codes are etched on each injector. The
On/Off Injector Codes can be viewed from the electronic
Three-Speed Fan service tool and the injector codes can be changed
None
Variable Speed Fan from the electronic service tool. The technician must
Option S select the Service screen, the Calibration screen
and the Injector Codes Calibration screen in order
"PTO Active Output" to view the injector codes. Also, the technician must
select the Service screen, the Calibration screen
NOV01 and newer software and the Injector Codes Calibration screen in order
to change the injector codes. The injector code
Note: This parameter is not available on engine must match the code on the corresponding injector.
serial numbers WlA1-Up, MDP1-Up, and MEP1-Up. When an injector is replaced, reprogram the new
code for the new injector.
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 115
Alternative Default
J1/P1:19 None
Data Link Parameters

"Power Train Data Link"
This parameter ("Power Train Data Link") determines
if the ECM will communicate to a power train device
by the use of the SAE J1922 data link or the J1939
data link. If the vehicle is not using the data link
for communication to the power train systems, this
parameter should be programmed to "None". The
following systems are examples of power train
systems:
• Traction control systems
• Anti-lock brake systems
• Electronically controlled transmissions
Note: In addition, the J1939 data link is sometimes

used for instrument cluster communications.
Table 116
Alternative Default
J1922
J1939 None
J1922 and J1939
72
i01907620
Customer Specified
Parameters Table
SMCS Code: 1901
Table 117
Table for Customer Specified Parameters
/
"Parameter" | AvailableRange or Options | Default
"Rating Number" Dependent on engine power Unavailable

"Multitorque Ratio" Unavailable (Standard Ratings)
"MT-1 ~, "MT-2", or "MT-4~ "MT-4" (Multi-Torque)
(Multi-Torque Ratings)
"Vehicle ID" 17 Digits 1

Available characters are dependent t all zeroes
on the service tools.
"ECM Wireless Communication Enable. . . . Yes" "No"

"No"
"Vehicle Speed Calibration" 2485 to 93226 PPKM

8696 PPKM (14000 PPM)
(4000 to 150000 PPM)
"Vehicle Speed Cal (J1939 - Trans)" 0 to 6500 Not Programmed
"Vehicle Speed Cal (J1939 - ABS)" 0 to 6.550 Not Programmed
"Vehicle Speed Limit" 48 to 204 km/h (30 to 127 mph) 204 km/h (127 mph)
"VSL Protection" 1300 to TEL rpm TEL rpm
"Tachometer Calibration" 12.0 to 500.0 pulses per revolution 113.0 pulses per revolution
"Soft Vehicle Speed Limit" "Yes" "No"
"No"
"Low Speed Range Axle Ratio" 1.00 to 19.99 1.00
"High Speed Range Axle Ratio" 1.0 to 9.9 1.00
"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)
"Engine Retarder Mode" "Coast"
"Latch. . . . Manual"
"Manual"
"Engine Retarder Minimum VSL Type. . . . Hard Limit" "Hard Limit"
"Soft 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 to 16 km/h (0 to 10 mph) 0 km/h (0 mph)

"Auto Retarder in Cruise Increment" 0 to 8 km/h (0 to 5 mph) 3 km/h (2 mph)
(continued)
73
Table 117, contd)

"Parameter" Available Range or Options Default
"Cruise/Idle/PTO Switch Configuration" "Set/AcceI-Reset/Decer'
"Set/Accel- Reset/Decel"
"Set/DeceI-Reset/Accer'
"Soft Cruise Control" "Yes"
"Yes"
"No"
"Adaptive Cruise Control Enable. . . . Disabled" "Disabled"

"Enabled"
"Idle Vehicle Speed Limit" 2 to 24 km/h (1 to 15 mph) 2 km/h (1 mph)

"Idle RPM Limit" 600 rpm to TEL rpm TEL rpm
"ldle/PTO RPM Ramp Rate" 5 to 1000 rpm/sec 50 rpm/sec
"ldle/PTO Bump RPM" 5 to 500 rpm 20 rpm

•ii.::i~i~:::::::::::::::::::::::
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'ii'ii:i"i~i'i~i~i~"~
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................. ~iii 'i"'~";"!''ii~iiii'!""~;i!i!!'i'i'ii~i~'i;i~'il;i
"PTO Configuration. . . . Off'

"Cab Switches" "Off"
"Remote Switches"
"Remote Throttle"
"PTO Top Engine Limit" 600 to TEL rpm TEL rpm
"PTO Engine RPM Set Speed (0 = Off)" Low Idle to PTO TEL rpm 0
"PTO Engine RPM Set Speed A" Low Idle rpm to PTO TEL rpm 0
"PTO Engine RPM Set Speed B" Low Idle rpm to PTO TEL rpm 0
"PTO to Set Speed . . . . Yes" "No"

"No"
"Maximum PTO Enable Speed" Low Idle to TEL rpm TEL rpm
"PTO Cab Controls RPM Limit. . . . Low idle rpm"
"TEL rpm" "TEL rpm"
"PTO TEL rpm"
"PTO Kickout Vehicle Speed Limit" 2 to 204 km/h (1 to 127 mph) 2 km/h (1 mph)
"Torque Limit" 270 N.m (200 Ib ft) to Rated Torque 3400 N.m (2500 Ib ft)
"PTO Shutdown Time" 3 to 1440 minutes 0
"PTO Shutdown Timer Maximum RPM" 600 to 2120 rpm 2120 rpm
"PTO Activates Cooling Fan" "Normal"
"Continuous" "Normal"
"Lower Gears Engine RPM Limit" 1100 to TEL rpm TEL rpm
"Lower Gears Turn Off Speed" 5 to 48 km/h (3 to 30 mph) 5 km/h (3 mph)

"Intermediate Gears Engine RPM Limit" 1100 to TEL rpm TEL rpm
"Intermediate Gears Turn Off Speed" 8 to 80 km/h (5 to 50 mph) 8 km/h (5 mph)
"Gear Down Protection RPM Limit" 1300 to TEL rpm TEL rpm
"Gear Down Protection Turn On Speed" 48 to 204 km/h (30 to 127 mph) 204 km/h (127 mph)
"Top Engine Limit (TEL)" 1600 to 2120 rpm Dependent on the engine rating
"Top Engine Limit with Droop . . . . Yes"
"No"
"No"
(continued)
74
Table 117, contd)

"Low Idle Engine RPM" 600 to 750 rpm 600 rpm
'%ransmission Style" "Manual Option 1"
"Automatic Option 1"
"Manual Option 1"
"Eaton Top 2"
"Eaton Top 2 Override with Cruise "Yes"
Switch . . . . No" "No"
"Top Gear Ratio" 0.000 to 3.750 0.000
"Top Gear Minus One Ratio" 0.000 to 3.750 0.000
'q-op Gear Minus Two Ratio" 0.000 to 3.750 0.000
"Governor Type. . . . Min/Max"
"Full Range" "Full Range"
"Idle Shutdown Time" 3 to 1440 minutes 0 minutes

"Idle Shutdown Timer Maximum RPM" 600 to 2120 rpm 2120 rpm
"Allow Idle Shutdown Override . . . . Yes"
"No"
"Yes"
"Outside Temperature Based"
"J1587 Outside Temperature Based"
"Minimum Idle Shutdown Outside
Temperature" -40 ° to 49°C (-40 ° to 120°F) 49 °C (120 °F)
"Maximum Idle Shutdown Outside -40 ° to 49°C (-40 ° to 120°F) 49 °C (120 OF)
Temperature"
"A/C Switch Fan On-Time" 1 to 600 seconds 0 seconds
"Fan with Engine Retarder in High "Yes" "No"
Mode. . . . No"
"Engine Retarder Delay" 0.0 to 3.0 seconds 0.0 seconds
Voltage"'BatteryMonitor and Engine Control 0 to 25.5 volts 0 volts
"Engine Monitoring Mode" "Warning"

"Derate" "Warning"
"Shutdown"
"Engine Monitoring Lamps" '~Varning Lamp"
"Option 1" "Warning Lamp"
"Coolant Level Sensor" "No"

"4-pin . . . . No"
"2-wire Float Sensor"
(continued)
75
Table 117, contd)

"Maintenance Indicator Mode" "Off"
"Manual Distance"
"Manual Hours" "Off"
"Automatic Distance"
"Automatic Hours"
"PM 1 Interval (Manual Maintenance 8050 to 56325 km
24140 km (15000 miles)
Indicator Mode)" (5000 to 35000 miles)
300 hours
100 to 750 hours
"Engine Oil Capacity" (Automatic C-10:34 L (36 qt)
Maintenance Indicator Mode) 19 to 57 L (20 to 60 qt) C-12:34 L (36 qt)
3406E, C-15, C-16, C-18:38 L (40 qt)
"Fuel Correction Factor" -63.5 to 63.5 0

"Dash-Change Fuel Correction Factor" "Yes"
"No . . . . No"
"Dash-PM 1 Reset . . . . Yes"

"No" "No"
"Dash-Fleet Trip Reset . . . . Yes"

"No" "No"
"Dash-State Selection" "Yes" "Yes"

"No"
"Theft Deterrent System Control . . . . Yes"
"No . . . . No"
"Auto-Enable"
"Theft Deterrent Password" Four Characters 0000
"Quick Stop Rate" 5 to 24 km/h per second ( 3 to
0 km/h second (0 mph per second)
15 mph per second)
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~g.~ ........... ~" "~7~i:"~:"> "~"" " " ~ " ' ~~.-~ 7.......... :~!7~7~.-c..~
~'~!~7~t'~i~!~
~ i
"Minimum Idle Time" 0 to 1440 minutes 0 minutes
"Driver Reward Enable" "Disabled"

"Enabled" "Enabled"
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"Fan O v e r r i d e Switch . . . . None"

" J1/P1:7"
"J1/P1:47"
"J1/P1:6"
"None"
"J1/P1:46"
"J1939 - Body Controller"
"J1939 - Cab Controller"
"J1939 - Instrument Cluster"
"Ignore Brake/Clutch Switch" "None" "None"
"J1/P1:47"
'q-orque Limit Switch" "None" "None"
"J1/P1:7"
(continued)
76
Table 117, contd)

"Diagnostic Enable" "None"
"JI/P1:46"
"J1939 - Body Controller" "None"
"PTO On/Off Switch" "J1/P1:56"

"J1/P1:56"
"Remote PTO Set Switch" "None"

"J1/P1:58"
"J 1939 - Body Controller" "J1/P1:58"
"J 1939 - Instrument Cluster"
"Remote PTO Resume Switch" "None"

"J1/P1:60"
"J1939 - Body Controller" "J1/P1:60"
"PTO Engine RPM Set Speed Input A" "J1/P1:6"

"J1/P1:46"
"J1/P1:58"
"J1/P1:60" "None"
"PTO Engine RPM Set Speed Input B" "J1/P1:6"

"J1/P1:46"
"None"
"J1/P1:58"
'M1/P1:60"
"Two-Speed Axle Switch" "None"

"J1/P1:6"
"J1939 - Body Controller" "None"
"Cruise Control On/Off Switch" "J1/P1:59"

"J1/P1:59"
"J1939 Instrument Cluster"
"Cruise Control Set/Resume Switch" "J1/P1:35 & 44"

"J1/P1:35 & 44"
"Cruise Control Pause Switch" "None"

"None"
"Clutch Pedal Position Switch" "JI/P1:22"

"J1/P1:22"
(continued)
77
Table 117, contd)

"Retarder Off/Low/Medium/High Switch" "J1/P1:23 & 40"
"J1/P1:23 & 40"
"Service Brake Pedal Position Switch 1" "J1/P1:45"
"J1/P1:45"
"Accelerator Pedal Position. . . "J1/P1:66" . J1/P1:66"
"Vehicle Speed Input" "J1/P1:32 & 33"
"J1939 - Trans" "J1/P1:32 & 33"
"J1939 - ABS"
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"Engine Running Outpuf' "None"

"J1/P1:10" "None"
"J1/P1:12"
"J1/P1:13"
"Engine Shutdown Output" "None"
"J1/P1:10" "None"
"J1/P1:12"
"J1/P1:13"
"Auxiliary Brake . . . . None" "None"

"J1/P1:12"
"Starting Aid Output" "J1/P1:10"
"J1/P1:12" "None"
"J1/P1:13"
"Air Inlet Shutoff Relay Control . . . . None" "None"
"J2/P2:13"
"Fan Control Type. . . . None"
"On/Off" "None"
"Three-Speed Fan"
"Variable Speed Fan Option S"
"PTO Active Output. . . . None"
"J1/P1:19" "None"
"Customer Password (1)" 8 Digits

Available characters are dependent
"Customer Password (2)" on the service tools.
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!ii!iii~ ®i ~!~i i i i liiiiii®iiiii iiiiii ii~i ii! !®®ii~iii i i~i~i®iiii~ili i i i Ji iii ®~®®ili ii~®~®!iiiiiii~ ®i,!i!i!~ii i !ii i !i!i !i i ! iiii i
"Power Train Data Link" "None"
"J 1922" "None"
"J 1939"
"J1922 and J1939"
78
i01762595 Table 122
Customer Specified Cruise Control Parameters
Parameters Worksheet "Low Cruise Control Speed

Set Limit"
SMCS Code: 1901 "High Cruise Control
Speed Set Limit"
Table 118
"Engine Retarder Mode"
Selected Engine Rating
"Engine Retarder Minimum
"Rating Number" VSL Type"
"Multitorque Ratio" "Engine Retarder Minimum
Vehicle Speed"
Table 119 "Auto Retarder in Cruise"
ECM Identification Parameters "Auto Retarder in Cruise
"Vehicle ID" I Increment"
"Cruise/Idle/PTO Switch
Table 120 Configuration"
Security Access Parameters "Soft Cruise Control"
"ECM Wireless "Adaptive Cruise Control
Communication Enable" Enable"
Table 121 Table 123

Vehicle Speed Parameters Idle Parameters
"Vehicle Speed Calibration" "Idle Vehicle Speed Limit"
"Vehicle Speed Cal (J1939 "Idle RPM Limit"
- Trans)"
"ldle/PTO RPM Ramp
"Vehicle Speed Cal (J1939 Rate"
- ABS)"
"ldle/PTO Bump RPM"
"Vehicle Speed Limit"
(VSL)
"VSL Protection"
"Tachometer Calibration"
"Soft Vehicle Speed Limit"
"Low Speed Range Axle
Ratio"
"High Speed Range Axle
Ratio"
79
Table 124 Table 125

Dedicated PTO Parameters Engine/Gear Parameters
"PTO Configuration" "Lower Gears Engine rpm
Limit"
"PTO Top Engine Limit"
"Lower Gears Turn Off
"PTO Engine RPM Set Speed"
Speed (0 = Off)"
"Intermediate Gears
"PTO Engine RPM Set Engine RPM Limit"
Speed"
"Intermediate Gears Turn
"PTO Engine RPM Set Off Speed"
Speed A"
"Gear Down Protection
"PTO Engine RPM Set RPM Limit"
Speed B"
"Gear Down Protection
"PTO to Set Speed" Turn On Speed"
"Maximum PTO Enable "Top Engine Limit" (TEL)
Speed"
"Top Engine Limit with
"PTO Cab Controls RPM Droop"
Limit"
"Low Idle Engine RPM"
"PTO Kickout Vehicle
Speed Limit" "Transmission Style"
"Torque Limit" Eaton Top 2 Override with
Cruise Switch
"PTO Shutdown Time"
'q'op Gear Ratio"
"PTO Shutdown Timer
Maximum RPM" 'q-op Gear Minus One
Ratio"
"PTO Activates Cooling
Fan" "Top Gear Minus Two
Ratio"
"Governor Type"
Table 126
Timer Parameters
"Idle Shutdown Time"
"idle Shutdown Timer
Maximum RPM"
"Allow Idle Shutdown
Override"
"Minimum Idle Shutdown
Outside Temp"
"Maximum Idle Shutdown
Outside Temp"
"A/C Switch Fan On-Time"
"Fan with Engine Retarder
in High Mode"
"Engine Retarder Delay"
Table 127
Smart Idle Parameters
"Battery Monitor and
Engine Control Voltage"
80
Table 128 Table 133

Engine Monitoring Parameters Input Selections
"Engine Monitoring Mode" "Fan Override Switch" 1
F
"Engine Monitoring Lamps" "Ignore Brake/Clutch

Switch"
"Coolant Level Sensor"
"Torque Limit Switch"
Table 129 "Diagnostic Enable"
Maintenance Parameters "PTO On/Off Switch"
"Maintenance Indicator "Remote PTO Set Switch"
Mode"
"Remote PTO Resume
"PM 1 Interval" (Manual Switch"
Maintenance Indicator
Mode) "PTO Engine RPM Set
Speed Input A"
"Engine Oil Capacity"
(Automatic Maintenance "PTO Engine RPM Set
Indicator Mode) Speed Input B"
"Starting Aid On/Off
Table 130 Switch"
Trip Parameters "Two Speed Axle Switch"
"Fuel Correction Factor" "Cruise Control On/Off
"Dash - Change Fuel Switch"
Correction Factor" "Cruise Control
"Dash - PM 1 Reset" Set/Resume Switch"
"Dash - Fleet Trip Reset" "Cruise Control Pause

Switch"
"Dash - State Selection"
"Clutch Pedal Position
"Theft Deterrent System Switch"
Control"
"Retarder Off/Low/
"Theft Deterrent Password" Medium/High Switch"
"Quick Stop Rate" "Service Brake Pedal
Position Switch #1"
Table 131 "Accelerator Pedal
Position"
Vehicle Activity Report
"Vehicle Speed Input"
"Minimum Idle Time" I
i
"able 134
Table 132
Output Selections
Driver Reward
"Driver Reward Enable" "Engine Running Output"
"Engine Shutdown Output"
"Auxiliary Brake"
"Starting Aid Output"
"Air Inlet Shutoff Relay
Control"
"Fan Control Type"
"PTO Active Output"
81
Table 135
Customer Passwords
"Customer Password #1"
"Customer Password #2"
Table 136
Data Link Parameters
"Power train Data Link"
Injector Codes
Table 137
Injector Codes
Injector Code (1)
Injector Code (2)
Injector Code (3)
Injector Code (4)
Injector Code (5)
Injector Code (6)
Lifetime Totals Worksheet

Table 138
Lifetime Totals Worksheet
Total Time
Total PTO Time
Total Idle Time
Total Distance
Total Fuel
Total PTO Fuel
Total Idle Fuel
Total Maximum Fuel
Average Load Factor
CATERPILLAR
SYSTEM CONFIGURATION PARAMETERS
TABLE OF CONTENTS
DESCRIPTION PAGE
SYSTEM CONFIGURATION PARAMETERS ......................................................................................................................... 82
82
System Configuration When a personality module is replaced this code

must match the code that is stored in the ECM. If
Parameters the personality module code does not match the
code that is stored in the ECM, both of the following
situations will exist:
i01182873
System Configuration • The engine will only run at low idle.
Parameters • A 253-02 Check Customer Or System Parameters

(56) Diagnostic Code will also be generated.
SMCS Code: 1901
Note: The flash programming of a personality
System Configuration Parameters affect the module replaces the personality module.
emissions of the engine or the power of the engine.
System Configuration Parameters are programmed When the engine is being rerated, programming
at the factory. System Configuration Parameters this code to 0 will prompt the ECM to read the
would never need to be changed through the stored code and programming this code to 0 will
life of the engine normally. System Configuration prompt the ECM to match the stored code to the
Parameters must be reprogrammed if an ECM is Personality Module Code. This code does not need
replaced. Unless the engine rating has changed, to be programmed when a personality module is
System Configuration Parameters do not need to replaced under both of the following conditions:
be reprogrammed when the Personality Module
is replaced. Proper values for these parameters • The new personality module is from the same
are stamped on the engine information ratings family.
plate. The engine information ratings plate is
located on the valve cover or the air inlet manifold. • The new personality module is from the same
Factory Passwords are required to change emission year.
these parameters. The following information is a
description of the System Configuration Parameters. If the Personality Module is from a different family,
the following components may need to be changed:
pistons, injectors, and other components. The
"Full Load Setting" engine information ratings plate must also be
changed in order to reflect the new rating.
"Full Load Setting" is a number that represents the
adjustment to the fuel system that was made at
Some vehicle systems such as the cooling system
the factory in order to fine tune the fuel system.
or the transmission may also require changes when
The correct value for this parameter is stamped on
the engine is rerated. Please contact the local OEM
the engine information ratings plate. A new ECM
dealer for further information.
requires this parameter to be programmed to avoid
generating a 253-02 Check Customer Or System
Parameters (56) Diagnostic Code. "Engine Serial Number"
The "Engine Serial Number" should be programmed
"Full Torque Setting" to match the engine serial number that is stamped
on the engine information plate. When a new ECM
"Full Torque Setting" is similar to "Full Load Setting".
is delivered, the engine serial number in the ECM
This parameter must be programmed to avoid
is not programmed.
generating a 253-02 Check Customer Or System
Parameters (56) Diagnostic Code.
"Personality Module Release Date"
Personality Module Code This parameter is defined by the Personality
Module and this parameter is not programmable.
The Personality Module Code is a code that
The "Personality Module Release Date" is used to
prevents the use of an incorrect personality module
provide the version of the software. The Customer
for this engine. Each horsepower family and each
parameters and the software change levels can be
emission certification has a different code that
monitored by this date. The date is provided in the
is associated with the horsepower family or the
month and the year (NOV99). NOV is the month
emission certification.
(November). 99 is the year (1999).
CATERPILLAR
TROUBLESHOOTING WITHOUT A DIAGNOSTIC CODE
TABLE OF CONTENTS
DESCRIPTION PAGE
CAN NOT REACH TOP ENGINE RPM .................................................................................................................................. 83
CAN NOT REACH VEHICLE SPEED LIMIT .......................................................................................................................... 84
CHECK ENGINE LAMP OR WARNING LAMP IS MALFUNCTIONING ................................................................................... 86
COOLING FAN IS ALWAYS ON........................................................................................................................................... 87
CRUISE CONTROL, IDLE, OR PTO CAN NOT BE SET ........................................................................................................ 89
DRIVER QUESTIONNAIRE .................................................................................................................................................. 91
DRIVER QUESTIONNAIRE RESPONSE............................................................................................................................... 92
ECM WILL NOT ACCEPT FACTORY PASSWORDS ............................................................................................................. 93
ELECTRONIC SERVICE TOOL WILL NOT COMMUNICATE WITH ECM ............................................................................... 94
ENGINE CRANKS BUT WILL NOT START ........................................................................................................................... 95
ENGINE MISFIRES, RUNS ROUGH OR IS UNSTABLE ........................................................................................................ 98
ENGINE RETARDER (COMPRESSION BRAKE) WILL NOT TURN ON ................................................................................. 99
ENGINE VIBRATION.......................................................................................................................................................... 100
ENGINE WILL NOT CRANK ............................................................................................................................................... 102
EXCESSIVE BLACK SMOKE............................................................................................................................................. 103
EXCESSIVE FUEL CONSUMPTION ................................................................................................................................... 104
EXCESSIVE WHITE SMOKE.............................................................................................................................................. 105
INTERMITTENT CRUISE CONTROL, IDLE, OR PTO KICK-OUT ......................................................................................... 106
INTERMITTENT ENGINE SHUTDOWN............................................................................................................................... 108
INTERMITTENT LOW POWER OR POWER CUTOUT......................................................................................................... 109
LOW POWER/POOR OR NO RESPONSE TO THROTTLE.................................................................................................. 111
POOR ACCELERATION OR RESPONSE........................................................................................................................... 113
83
Troubleshooting without a • "Vehicle Speed Limit"
Diagnostic Code • "Lower Gears Engine RPM Limit"
• "Intermediate Gears Engine RPM Limit"

i01891617
• "Gear Down Protection Engine RPM Limit"
Can Not Reach Top Engine
RPM • "Top Engine Limit"
SMCS Code: 1915-035 • "VSL Protection"
• "PTO Top Engine Limit" with the PTO On/Off

Probable Causes Switch turned ON.
Note: If this problem occurs under load, refer to • "PTO Vehicle Speed Limit" with the PTO
Troubleshooting, "Low Power/Poor or No Response On/Off Switch turned ON.
to Throttle".
d. Set each parameter to the parameter's
The probable root causes are listed in order below: 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
a. Monitor the electronic service tool in order to
• Accelerator pedal position sensor verify that the engine has progressed from
Cold Mode.
• Vehicle speed signal
"Cold Mode" is indicated in the upper corner
• Fuel supply of any status screen.
• Power train data link 4. Check the accelerator pedal position sensor.
• Air intake and exhaust system a. Use the Cruise/Idle On/Off Switch to put the
engine in idle mode.
Recommended Actions
b. Vary the engine rpm with the Set/Resume
1. Check for diagnostic codes. switches.
a. Connect the electronic service tool to the data If both of the following conditions are met,
link connector. monitor the status of the accelerator pedal
position sensor.
b. Check for active diagnostic codes and/or
logged diagnostic codes. • The engine is stable by using idle mode to
control the engine rpm.
Certain diagnostic codes will limit the engine
speed. • The engine is unstable by using the
accelerator pedal position sensor.
¢. Troubleshoot all active diagnostic codes
before continuing with this procedure. If the status of the accelerator pedal position
sensor is unstable, refer to Troubleshooting,
2. Check customer specified parameters. "Accelerator Pedal (Throttle) Position Sensor
Circuit - Test".
a. Verify that the complaint is not normal
operation (programmed parameter). 5. Monitor the vehicle speed signal. Ensure
the accuracy of the vehicle speed signal by
b. Access the "Configuration" screen on the comparing the vehicle speed signal to the actual
electronic service tool. vehicle speed.
¢. Check the following parameters:

84
If the vehicle speed is greater than the VSL, the i01891622

engine rpm is limited to the programmed "VSL
Protection". If a problem is discovered, refer to Can Not Reach Vehicle Speed
Troubleshooting, "Vehicle Speed Circuit - Test". Limit
6. Check the fuel supply. S M C S C o d e : 7463-035
a. Monitor the exhaust for smoke while the

engine is being cranked. Probable Causes
If no smoke is present, there may be a The probable root causes are listed in order below:
problem with the fuel quality or there may be
a problem with the fuel supply. • Diagnostic codes
b. Check the fuel quality. Refer to Testing and • Customer specified parameters (normal
Adjusting, "Fuel Quality - Test". Also refer operation)
to the Truck Performance and Driveability
Diagnostic Guide, LEBT3477. • Cold mode
¢. Check the fuel pressure. Refer to Testing and • Electronic system problem
Adjusting, "Fuel System Pressure - Test".
• Fuel supply
d. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, "Fuel System • Air intake system or exhaust system
- Prime".
• Leakage in Air-to-Air Aftercooler Core
e. Check for fuel supply lines that are restricted.
Recommended Actions
f. Check the fuel filters.
1. Check for diagnostic codes.
g. If the temperature is below 0 °C (32 °F), check
for solidified fuel (wax). a. Connect the electronic service tool to the data
link connector.
h. Check for air in the fuel system. Refer to
Testing and Adjusting, "Air in Fuel - Test". b. Turn the key switch to the ON position.
7. Check the "Powertrain Data Link". Ensure that ¢. Check for active diagnostic codes and logged
the power train data link is not limiting the power. diagnostic codes.
a, Monitor the "Powertrain Data Link" status Certain diagnostic codes will limit the vehicle
screen while the vehicle is experiencing speed to 45 mph.
problems.
d. Troubleshoot all diagnostic codes before
If the "Powertrain Data Link" status screen continuing with this procedure.
indicates that the "Powertrain Data Link" is
limiting the power or the rpm, verify that this 2. Check customer specified parameters.
is not normal operation. If this is not normal
operation, refer to the vehicle OEM for repairs. a. Verify that the complaint is not due to normal
operation (programmed parameter).
8. Air intake and exhaust system
b. Access the "Configuration" screen on the
a. Clean plugged air filters or replace plugged electronic service tool.
air filters. Refer to the Operation and
Maintenance Manual. ¢. Check the following parameters:
b. Check the air intake and the exhaust system • "Vehicle Speed Limit"
for restrictions and/or leaks. Refer to Testing
and Adjusting for more information. • "Soft Vehicle Speed Limit"
• "Lower Gears Engine RPM Limit"

85
• "Intermediate Gears Engine RPM Limit" a, When the engine is OFE turn the key switch
to the ON position. Check the boost pressure
• "Gear Down Protection Engine RPM Limit" on the electronic service tool.
• "VSL Protection" When the engine is OFE the boost pressure

should be 0 kPa (0 psi).
• "Top Engine Limit"
b. Monitor the status of the accelerator pedal
• Incorrect programming of the Vehicle Speed position sensor. Operate the engine at high
calibration (ppm). idle with the vehicle in Neutral.
• "PTO Top Engine Limit" with the PTO On/Off If the engine can not reach the programmed
Switch turned ON. "Top Engine Limit", check the duty cycle
for the accelerator pedal position sensor in
• "Maximum PTO Vehicle Speed" with the order to ensure that the duty cycle is within
PTO On/Off Switch turned ON. calibration (75 to 90 Percent at high idle).
d. Set each parameter to the parameter's If the accelerator pedal position is unstable,
maximum value one at a time and determine check the duty cycle of the accelerator pedal
whether the problem is corrected. position sensor. Check the duty cycle by
slowly operating the accelerator pedal in
Note: The "Soft Vehicle Speed Limit" will not allow order to verify that the duty cycle is within
the vehicle to achieve the programmed VSL under calibration. The accelerator pedal position
all engine load conditions. Programming the "Soft sensor is within calibration when both of the
Vehicle Speed Limit" to NO may be required to following conditions are met:
eliminate the complaint.
• 10 to 22 percent at low idle
3. Check cold mode operation.
• 75 to 90 percent at high idle
Note: This is normal operation if the problem occurs
only after start-up in cold weather. Also, ensure that the duty cycle changes as
the pedal position changes.
a. Check the status screen on the electronic
service tool. If a problem with the accelerator pedal
position sensor is suspected, refer to
"Cold Mode" is indicated in the upper corner Troubleshooting, "Accelerator Pedal (Throttle)
of any status screen when cold mode is Position Sensor Circuit - Test".
active.
Note: If the engine exceeds the "Top Engine Limit",
4. Check for an electronic system problem. the "Top Engine Limit with Droop" is programmed
to YES.
a. Monitor the fuel position, the "Rated Fuel
Limit", and the "FRC Fuel Limit". 6. Monitor the vehicle speed signal. Ensure
While the vehicle is operating under full load, comparing the vehicle speed signal to the actual
the parameters should meet the following vehicle speed.
conditions:
If the vehicle speed is greater than the VSL, the
• The fuel position is equal to the "Rated Fuel Power is limited. If a problem is discovered, refer
Limit". to Troubleshooting, "Vehicle Speed Circuit - Test".
• The fuel position is less than the "FRC Fuel 7. Check the "Powertrain Data Link". Ensure that
Limit". the SAE J1939 Powertrain Data Link is not
limiting the power.
If the fuel position is equal to the "Rated Fuel
Limit" and the fuel position is less than the a. Monitor the "Powertrain Data Link" status
"FRC fuel Limit", the electronics are operating screen while the vehicle is experiencing
correctly. Go to Step 6. problems.
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:
86
If the "Powertrain Data Link" status screen • Intermittent Diagnostic Codes

indicates that the "Powertrain Data Link" is
limiting the power or the rpm, verify that this • Burned out bulb
operation, refer to the vehicle OEM for repairs. • Problem with Lamp circuit (Vehicle)
8. Check the fuel supply. • The Lamp does not come on.
a. Monitor the exhaust for smoke while the • Short in Set/Resume Switch Circuit
engine is being cranked.
• Short in Vehicle Harness
If no smoke is present, there may be a
a problem with the fuel supply.
Recommended Actions
Perform the following diagnostic procedures in
b, Check the fuel quality. Refer to Testing and order:
Adjusting, "Fuel Quality - Test". Also refer
1. Check for logged diagnostic codes and active
Diagnostic Guide, LEBT3477. diagnostic codes with an Electronic Service Tool.
¢. Check the fuel pressure. Refer to Testing and . In order to check the Check Engine Lamp, turn
the ignition key to the ON position while the
engine is OFE
d. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, "Fuel System The Check Engine Lamp should turn on. Then,
- Prime".
the Check Engine Lamp should turn off. The
Check Engine Lamp will flash if there is an Active
Diagnostic Code.
f. Check the fuel filters. a, If the Check Engine Lamp does not operate
correctly remove the Check Engine Lamp
g. If the temperature is below 0 °C (32 °F), check (terminal 28) from the ECM connector (seventy
for solidified fuel (wax). terminal).
h, Check for air in the fuel system. Refer to Connect the Check Engine Lamp (terminal
b.
Testing and Adjusting, "Air in Fuel - Test". 28) to the Ground Stud. Turn the ignition key
switch to the ON position.
9. Check the air intake system for restrictions
or leakage. Check the exhaust system for
¢. Observe the Check Engine Lamp.
restrictions or leakage. Refer to Testing and
Adjusting, "Air Inlet and Exhaust System - If the Check Engine Lamp comes on,
Inspect". check the power connection and the
ground connection of the ECM. Refer to
10. Check for leakage in the Air-to-Air Aftercooler Troubleshooting, "Check Engine Lamp Circuit
Core. Refer to Testing and Adjusting, "Aftercooler - Test" for additional information.
- Test".
If the lamp does not come on, check the lamp
i01186789 in order to ensure that the lamp is not burned
out. Also, check the wiring in order to ensure
Check Engine Lamp that there is not an open circuit.
or Warning Lamp Is 3. In order to check the Warning Lamp, start the
Malfunctioning engine.
SMCS Code: 7431-035 The Warning Lamp should come on for at least 2
seconds. Then, the Warning Lamp should turn
off. The Warning Lamp will remain on or flash if
Probable Causes there is a problem with the engine.
The probable root causes are listed in order below:
87
a, If the Warning Lamp does not operate • PTO Mode

correctly remove the Warning Lamp (terminal
29) from the ECM connector (seventy • A/C High Pressure Switch circuit
terminal).
• Manual Fan Override Switch
b. Connect the Warning Lamp (terminal 29) to
the Ground Stud. Turn the ignition key switch Recommended Actions
to the ON position.
¢. Observe the Warning Lamp.
order:
If the Warning Lamp comes on, check the
1. Check for OEM Vehicle component failure.
power connection and the ground connection
of the ECM. Refer to Troubleshooting, a. Inspect the ECM Vehicle Harness Connector
"Warning Lamp Circuit - Test" for additional J1/P1. Check for a wire that goes into terminal
information.
13 (Output 4) and/or terminal 11 (Output 5).
If the lamp does not come on, check the lamp If a wire is not connected to terminal 13
in order to ensure that the lamp is not burned
(Output 4) and/or terminal 11 (Output 5), the
out. Also, check the wiring in order to ensure
ECM is not connected to the Cooling Fan
that there is not an open circuit. System. The problem is in the OEM Vehicle
system.
4. Connect an Electronic Service Tool. Observe the
status screen for the Cruise Control Set/Resume
If a wire is connected to the ECM Vehicle
Switch.
Harness Connector J1/P1, proceed to Step
4.b.
If the status screen indicates that the switch is
ON and the switch is not in the ON position, the
b, Turn the ignition key to the ON position while
switch is shorted out. Refer to Troubleshooting, the engine is OFE
"Cruise Control Switch Circuit - Test".
C. Connect the Caterpillar Electronic Technician
5. Monitor the Check Engine Lamp while the Check (ET).
Engine Lamp (terminal 28) is removed from the
ECM connector (seventy terminal). Also, the
d. Access the parameter for the "Fan Control
technician could monitor the Check Engine Lamp
Type".
while the ECM Connector (P1) is disconnected.
Ensure that the parameter for the "Fan Control
If the lamp remains on and the pin has been
Type" is programmed to On/Off control for
removed from the ECM, there is a short circuit to
an On/Off fan or ensure that the parameter
ground in the vehicle harness.
for the "Fan Control Type" is programmed to
Three-Speed Fan control for a three-speed
6. Monitor the Warning Lamp while the Warning
fan.
Lamp (terminal 29) is removed from the ECM
connector (seventy terminal). Also, the technician If the fan is an On/Off fan, proceed to Step
could monitor the Warning Lamp while the ECM 1.e.
Connector (P1) is disconnected.
If the fan is a three-speed fan, proceed to
If the lamp remains on and the pin has been
Step 1 .h.
removed from the ECM, there is a short circuit to
ground in the vehicle harness.
e, Access the "On/Off Cooling Fan" test.
i01661891 f. Ensure that any fan override switches on the

dash are in the OFF position.
Cooling Fan Is Always ON
g. Listen for the solenoid and/or the relay to click
S M C S Code: 1350-035 as the test is activated and deactivated.
Probable Causes If the solenoid and/or the relay is clicking, the

ECM and the circuit to the solenoid and/or the
The probable root causes are listed in order below: relay are operating correctly.
• OEM Vehicle component failure

88
If the solenoid and/or the relay are not clicking, C, Start the engine. Allow the engine to idle.
refer to Troubleshooting, "Cooling Fan Circuit Watch the Electronic Service Tool Status
and A/C High Pressure Switch Circuit - Test". screen that indicates the status of the "A/C
Fan Input".
h, Access the "Three-Speed Fan Slip Output"
test. If the status screen indicates OFF at any
time and the fan is still ON, the A/C High
i. Listen for the Slip Solenoid to click as the test Pressure Switch circuit is operating correctly.
is activated and deactivated. The problem is in the OEM Vehicle system.
If the Slip Solenoid is clicking, the ECM and If the status screen indicates ON and/or
the circuit to the Slip Solenoid are operating COUNTING, the ECM is turning the fan ON
correctly. because the A/C High Pressure Switch circuit
is open. Refer to Troubleshooting, "Cooling
If the Slip Solenoid is not clicking, refer to Fan Circuit and A/C High Pressure Switch
Troubleshooting, "Cooling Fan Circuit and A/C Circuit - Test".
High Pressure Switch Circuit - Test".
4. Check the Manual Fan Override Switch.
2. Check the "PTO Activates Cooling Fan"
parameter. a. Connect ET to the cab data link connector.
Note: If the problem occurs in PTO mode, continue b. Access the parameter for the "Fan Override
with this step. If the problem does not occur in PTO Switch".
mode, skip this step.
¢. Check the parameter for the "Fan Override
a. Connect ET to the cab data link connector. Switch". Ensure that the Fan Override Switch
is programmed to one of the options for Input
b. Access the configuration parameters on ET. Selections.
¢. Check the "PTO Activates Cooling Fan" If the parameter is programmed to one of the
parameter. four available outputs, check the input for
the Fan Override Switch. The four available
d. If the parameter is programmed to options for Input Selections are the following
"Continuous" the cooling fan will run connections:
continuously while the engine is in PTO mode.
• J1/P1:6
3. Check the A/C High Pressure Switch circuit.
• J1/P1:7
a. Connect ET to the cab data link connector.
• J1/P1:46
b. Access the status screen for the "A/C Fan
Input". • J1/P1:47
If the status screen for the "A/C Fan Input" d. Access the status screen for the "Fan
indicates that the "A/C Fan Input" is Disabled, Override Switch".
the ECM is not programmed to use the signal
input for the A/C High Pressure Switch. The If the status is ON, either the Manual Fan
ECM will not turn the fan ON because of a Override Switch is ON or there is a short in
high A/C Pressure. The problem is in the OEM the circuit for the "Fan Override Switch". Refer
Vehicle system. to Troubleshooting, "Cooling Fan Circuit and
A/C High Pressure Switch Circuit - Test".
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.
89
i01764266 Note: If the vehicle speed exceeds the "High Cruise

Control Set Speed Limit" and the driver attempts to
Cruise Control, Idle, or PTO set a cruise control speed, the cruise set speed will
Can Not Be Set be the "High Cruise Control Set Speed Limit". If the
vehicle speed is below the "Low Cruise Control Set
SMCS Code: 1915-035 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
Probable Causes rpm the Idle engine rpm will be the Idle rpm Limit. If
the driver attempts to set an Idle engine rpm and the
The probable root causes are listed below: vehicle speed exceeds the Idle Vehicle Speed Limit,
the Idle will not activate. Refer to Troubleshooting,
• Customer Specified Parameters (normal "Cruise Control Switch Circuit - Test".
operation)
. Connect Cat ET to the data link connector. Check
• Cruise Control Pause Switch the status screen for the following kickouts:
• On/Off switch for Cruise Control and Idle Control • Cruise Kickout
• PTO On/Off Switch If the cruise control pause switch was the cause
of the last kickout, the cruise control pause
• Set/Resume Switch switch may be preventing normal operation of
the cruise control.
• Circuit for Service Brake Switch
a, Check the position of the cruise control pause
• Transmission Neutral Switch Circuit switch. If the switch is in the ON position, the
switch will prevent normal operation of the
• Clutch Switch Circuit cruise control. Change the switch to the OFF
position. Verify that the repair eliminates the
• Vehicle Speed Circuit problem.
• Adaptive Cruise Control b. If the cruise control pause switch is in the
OFF position and the switch is still causing
Recommended Actions the cruise kickout, the switch is bad or the
wiring is shorted.
order: C, Check the switch for proper operation. If
the switch is bad, replace the switch. If the
1. When the Cruise Control or the Idle Control is set switch is working, the wiring is probably
with the Cruise Control On/Off switch, use Cat ET shorted. Refer to Troubleshooting, "Electrical
in order to check the Configuration. Check the Connectors -Inspect".
following parameters:
3. When the PTO is set with a dedicated PTO On/Off
• "Low Cruise Control Set Speed Limit" switch, use Cat ET to check the Configuration.
Check the following parameters:
• "High Cruise Control Set Speed Limit"
• "PTO Configuration"
• "Idle Vehicle Speed Limit"
• "PTO Vehicle Speed Limit"
• "Idle rpm 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
90
• PTO On/Off Switch f. Check the vehicle speed while the vehicle is
being driven in order to determine that the
• Set/Resume Switch vehicle speed that is indicated by Cat ET
does not vary significantly from the vehicle
• Circuit for Service Brake Switch speed that is indicated by the speedometer.
Possible root causes for problems with the
• Transmission Neutral Switch vehicle speed circuit could be an incorrect
Vehicle Speed Calibration or an intermittent
• Clutch Switch speed signal. If the problem is not apparent,
refer to Troubleshooting, "Vehicle Speed
• Vehicle Speed Circuit - Test".
a, Turn on the On/Off switch for Cruise Control 5. Check the Adaptive Cruise Control for proper
and Idle Control while the status screen on operation.
Cat ET is being viewed. The status screen
should indicate that the switch is changing a, Toggle the cruise control switch to the OFF
ON and OFF. If the problem is related to the position and to the ON position twice within
On/Off switch for Cruise Control and Idle 10 seconds. This will disable the Adaptive
Control, refer to Troubleshooting, "Cruise Cruise Control,
Control Switch Circuit - Test".
b. Attempt to set the cruise control. Operate
b. Toggle the Set/Resume switch from SET to the vehicle under the same conditions that
RESUME while the status screen on Cat ET caused the problem.
is being viewed. The status screen should
indicate that the switch is changing ON C. If the problem still exists, then the problem is
and OFF. If the problem is related to the not the Adaptive Cruise Control.
Set/Resume switch, refer to Troubleshooting,
"Cruise Control Switch Circuit - Test". d. If the problem is fixed, refer to Eaton for the
proper troubleshooting procedure.
¢. 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".
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".
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".
91
i01642805
Driver Questionnaire
S M C S C o d e : 0336
Table 139
Ask the driver to answer the following questions before attempting to repair an intermittent problem, or a problem with
symptoms but no diagnostic codes. Use this and the response guideline to these questions on the next page.
Questions Yes Comments
1. Ask the driver if the Check Engine Lamp turned on during the problem
or if the Check Engine Lamp turned on after the problem.
The Check Engine Lamp stays on for the following time period:
2. Ask the driver for the number of occurrences for this problem.
Ask the driver to duplicate the problem if the problem can be duplicated
in less than one hour.
3. Ask the driver if other shops have worked on the same problem.
If the answer is yes, ask the names of the shops. Also ask for the time
period for the work that was performed.
4. Ask the driver if the engine completely shut down. Ask the driver if the
restart required the use of the ignition key switch.
Ask the driver for the waiting period before the driver could restart the
engine after the shutdown.
5. Ask the driver if the engine had a hesitation, a speed burp or a misfire
without a complete shutdown.
6. Ask the driver if the radio, dash gauges or lights momentarily turn off
during an occurrence of the problem.
Ask the driver if there are any other observations about the truck's
components.
7. Ask the driver if the problem occurs only at specific engine loads.
Ask the driver for additional details.
8. Ask the driver if the problem occurs at a specific engine operating
temperature.
If the problem occurs at a specific engine operating temperature, record
the engine temperature.
9. Ask the driver if the problem occurs only at specific outside
temperatures or temperature ranges.
If the problem occurs only at specific outside temperatures or
temperature ranges, record the outside temperature or temperature
range.
10. Ask the driver if the problem occurs during any other specific
conditions.
11. Ask the driver if the problem occurs at a specific vehicle speed.
If the problem occurs at a specific vehicle speed, record the vehicle
speed.
12. Ask the driver if the vehicle kicked out of cruise control mode, idle
mode or PTO mode.
13. Ask the driver if the problem occurs during the use of the accelerator.
During this time, the engine is not in cruise control mode or PTO mode.
14. Ask the driver if the problem occurs at a specific engine rpm.
If the problem occurs at a specific engine rpm record the engine rpm.
92
i01891626
Driver Questionnaire
Response
SMCS C o d e : 0336
Table 140
1. If the check engine lamp turned on there wilt be a logged diagnostic code. Refer to Troubleshooting, 'q-roubleshooting with
a Diagnostic Code" in order to determine if the driver's indicated symptoms agree with the symptoms that are associated
with the diagnostic code. If the driver's symptoms do not match the symptoms of the diagnostic code, troubleshooting the
diagnostic code will not correct the problem. Review the snapshots that are associated with each diagnostic code in order to
determine the operating conditions of the engine during the occurrence of the problem. Try to duplicate these conditions.
If there are not any logged diagnostic codes, check the ECM battery connections. 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 the electronic service tool 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 the electronic service tool 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 Cimuit 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.
(continued)
93
Table 140, contd)

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 'q-op 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.
i01891623 C. Verify that the information was obtained from

the ECM that is being programmed. DO
ECM Will Not Accept Factory NOT accept the information from the old
Passwords ECM in order to program factory passwords
on a replacement ECM. DO NOT copy the
SMCS Code: 1901-035 information from the old ECM in order to
program factory passwords on a replacement
ECM.
Probable Causes
d. Verify that all characters in the ECM and/or
The probable root causes are listed in order below: the electronic service tool serial number have
been supplied.
• Incorrect password
3. Verify that the correct passwords were entered in
• Incorrect Serial Number the upper case only. Also check the characters
in the password for accuracy.
• Incorrect reason code
4, Turn the key switch to the OFF position and retry.
• Error on Entered Information
Note: Ensure that the recorded information that is
Recommended Actions used to request the password is an exact match to
the information that is displayed on the electronic
Perform the following diagnostic procedures in service tool.
order:
5. If rechecking the passwords does not correct the
1. Verify that the electronic service tool is on the problem, change a customer parameter from the
factory password screen. Also, verify that the current value to another value and then change
electronic service tool expects factory passwords the customer parameter back to the original
rather than customer passwords. value. Then revert to the screen and proceed to
obtain factory passwords again.
2. Verify the following information:
Note: Changing a parameter with the above method
a, Verify that the Engine Serial Number that is changes the Total Tattletale. The new Tattletale will
used to calculate the password is from the require obtaining a new password.
electronic service tool screen rather than the
engine information plate. 6. Verify that the correct reason code from the
factory password screen was entered. Do not
For example, the Engine Serial Number that assume the reason code. This must be obtained
is programmed in a new ECM is XXXO0000. from the electronic service tool. Reason codes
If the Electronic Service Tool indicates that are assigned for specific purposes and reason
the Engine Serial Number is XXXO0000, codes are not interchangeable.
this Engine Serial Number must be used to
obtain factory passwords. DO NOT use the 7, Turn the key switch to the OFF position and retry.
information on the engine information plate.
Note: Ensure that the information that is entered is
b. Verify that all of the information on the an exact match to the information that is displayed
electronic service tool is the information that on the electronic service tool.
was supplied to Caterpillar in order to obtain
the password.
94
i01748834 Electrical Connectors

Electronic Service Tool Will Check for correct installation of the J1/P1 and J2/P2
Not Communicate with ECM ECM connectors and the service tool connector.
Refer to Troubleshooting, "Electrical Connectors
SMCS Code: 0785-035; 1901-035 - Inspect".
Probable Causes Communication Adapter and/or Cables

. If you are using a Communication Adapter II,
• Configuration for the communications adapter
ensure that the firmware and driver files for the
communication adapter are the most current files
• Electrical connectors
that are available. If the firmware and driver files
do not match, the communication adapter will
• Communication adapter and/or cables
not communicate with Cat ET.
• Electrical power supply to the service tool
connector
. Disconnect the communication adapter and
the cables from the service tool connector.
Reconnect the communication adapter to the
• Cat ET and related hardware
service tool connector.
• Electrical power supply to the ECM
. Verify that the correct cable is being used
between the communication adapter and the
• Override switches
service tool connector. Refer to Troubleshooting,
"Electronic Service Tools".
• Personality module (flash file)
• ATA Data Link Electrical Power Supply to the Service

Tool Connector
Recommended Actions Verify that battery voltage is present between
Start the engine. If the engine starts, but the ECM terminals A and B of the service toot connector. If
will not communicate with the Caterpillar Electronic the communication adapter is not receiving power,
Technician (Cat ET), continue with this procedure. the display on the communication adapter will be
If the engine will not start, refer to Troubleshooting, blank.
"Engine Cranks but Will Not Start". If the engine will
not crank, refer to Troubleshooting, "Engine Will Cat ET and Related Hardware
Not Crank".
In order to eliminate Cat ET and the related
Configuration for the Communications hardware as the problem, connect Cat ET to a
different engine. If the same problem occurs on
Adapter a different engine, check Cat ET and the related
hardware in order to determine the cause of the
1. Access "Preferences" under the "Utilities" menu problem.
on Cat ET.
2. Verify that the correct "Communications Interface Electrical Power Supply to the ECM
Device" is selected.
Check power to the ECM. Refer to Troubleshooting,
3. Verify that the correct "Port" is selected for use "Ignition Key Switch Circuit and Battery Supply
by the communication adapter. Circuit - Test".
Note: The most commonly used port is "COM 1" Note: If the ECM is not receiving battery voltage, the
ECM will not communicate.
4. Check for any hardware that is utilizing the same
port as the communications adapter. If any Override Switches
devices are configured to use the same port, exit
or close the software programs for that device. 1. Ensure that the ignition key switch is in the
ON position. Ensure that there are no override
switches that are creating the problem.
95
2. Ensure that there are no aftermarket devices that • Fuel supply

are preventing battery voltage from reaching the
ECM. • Combustion problem
3, Start the engine and then connect Cat ET. Some

type of override switch is interrupting the power
Recommended Actions
to the ECM under the following condition: If
communication occurs with the engine running
order:
but no communication occurs with the key switch
in the ON position.
1. Check the key switch.
Personality Module (Flash File) a. Connect Cat ET to the data link connector.
Ensure that the correct personality module is b. Access the status for "Ignition Key Switch".
properly installed in the ECM.
C, Slowly cycle the key switch ON and OFF
Note: The personality module that is provided in a while the status for "Ignition Key Switch" is
new ECM is blank. The engine will not start and being monitored. The status should indicate
the engine will not communicate with Cat ET until the state of the switch.
the personality module has been flashed. Refer to
Troubleshooting, "Flash Programming". If the ECM will not communicate and the key
switch is in the ON position, refer to Step 3.
ATA Data Link
Note: If the Engine Shutdown Output feature is
Troubleshoot the ATA Data Link for possible used, the status for "Ignition Key Switch" may
problems. Refer to Troubleshooting, "ATA (SAE indicate that the switch is ON even though the key
J1587 / J1708) Data Link Circuit - Test". switch is turned to the OFF position.
2. Check the communications between the ECM

i01908311 and Cat ET.
Engine Cranks but Will Not a. Connect Cat ET to the data link connector.
Start
b. Ensure that the key switch is in the ON
SMCS Code: 1000-035 position. Attempt to access one of the status
screens on Cat ET.
Probable Causes If Cat ET indicates that the ECM will not
The probable root causes are listed in order below: communicate go to Step 3. If the ECM
communicates go to Step 6.
• Key switch
Note: A new ECM has a personality module
• Communications between the ECM and the that is not programmed. A new ECM that is not
Caterpillar Electronic Technician (Cat ET) programmed will cause this symptom. Accessing
the ECM status in "WinFlash" without programming
• Aftermarket engine protection devices the personality module will cause the engine not
to start or accessing the ECM status in "WinFlash"
• Power to ECM without programming the personality module will
cause the engine not to communicate. Cycling the
• Personality Module key switch from the OFF to the ON position will
correct this problem.
• ECM
3. Check aftermarket engine protection devices.
These devices usually interrupt power to the ECM
• Electrical connections to the electronic unit
injector and the ECM will not communicate with Cat ET.
• Engine speed/timing signal a. Check for the correct installation of the

aftermarket engine protection device.
• Engine software
b. Check for the correct operation of the
• Theft deterrent aftermarket engine protection device.
96
¢. Verify that the ECM is receiving battery If Cat ET displays 0 rpm and the engine is
voltage. being cranked, there is a problem in the
circuit for the secondary engine speed/timing
4. Check the electrical power supply to the ECM. sensor or the circuit for the primary engine
speed/timing sensor. Refer to Troubleshooting,
a. Check the power connection of the ECM and "Engine Speed/Timing Circuit - Test".
the ground connection of the ECM.
If an engine rpm is present, check the sensor
b. Verify that the ECM is receiving battery installation. If the sensor is not properly
voltage when the key switch is turned ON. installed, the sensor may read RPM but the
Refer to Troubleshooting, "Ignition Key Switch sensor may not be able to sense the tooth
Circuit and Battery Supply Circuit - Test". pattern. The ability to sense the tooth pattern
is necessary to determine the crankshaft
5. Check the personality module. position. Engine rpm is present when the
engine rpm is 50 rpm or more. Go to Step 9
A new ECM has a Personality Module that is not
programmed. The engine will not start until the
personality module has been flashed. Also, the
engine will not communicate until the personality
module has been flashed.
6. Check the ECM.
Before replacing the ECM, try to flash program

the existing ECM. Refer to Troubleshooting,
"Flash Programming".
If the ECM is suspected of being the problem,

temporarily connect a test ECM. This will show
whether the problem has been resolved or the
problem has not been resolved.
7. Check the electrical connections to the electronic

unit injectors.
a, Ensure that the J300/P300 Electronic Unit

Injector connector is fully connected and
ensure that the J300/P300 Electronic Unit
Injector Connector is free of corrosion.
b. Check for logged diagnostic codes that

are related to the injectors. Refer to
Troubleshooting, "Injector Solenoid Circuit -
Test" if diagnostic codes that are related to
the injectors are present.
8. Check the engine speed/timing signal.
a. Observe the engine rpm on Cat ET while the

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 (12 VDC). Refer to
Illustration 31.
97
SERVICE TOOL BYPASS HARNESS

ECM
2OA ',
IGNITION KEY SWITCH
IN-LINE FUSE
RD--I<t52e UNSWITCHED +BATTERY
UNSWITCHED ÷BATTERY
' B K ' ~ ] 65 ~" -BATTERY
BK'-"~]67 ~" -BATTERY
GY.~I.< ~ ! ~. J1922 DATA LINK NEGATIVE
X G Y ' ~ ] 14 ~" J1922 DATA LINK POSITIVE
UNSWITCHED +BATTERY J1587 DATA LINK POSITIVE
-BATTERY GY-I<t 9 * J1587 DATA LINK NEGATIVE
J1922 DATA LINK NEGATIVE Gy---I< ] 34 <- J1939 DATA LINK POSITIVE
:J1922 DATA LINK POSITIVE GY--I<pO<- J1939 DATA LINK NEGATIVE
:J1587 DATA LINK POSITIVE J1939 DATA LINK SHIELD
:J1587 DATA LINK NEGATIVE
:J1939 DATA LINK POSITIVE J1
J1939 DATA LINK SHIELD
9-PIN
DATA LINK
CONNECTOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass harness
9. Check for the correct engine software. Connect b. Check the fuel quality. Refer to Testing and
Cat ET to the service tool connector. Ensure that Adjusting, "Fuel Quality - Test". Also refer to
252-11 Incorrect Engine Software is not active. Truck Performance and Driveability Diagnostic
Guide, LEBT3477.
If the diagnostic code is present, refer to
Troubleshooting, "ECM Memory - Test". ¢. Check the fuel pressure. Refer to Testing and
Connect Cat ET to the service tool connector.
Check for the following diagnostic codes: d, Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, "Fuel System
• 224-11 Theft Deterrent Active - Prime".
• 224-14 Theft Deterrent Active with Engine e. Check for fuel supply lines that are restricted.
Cranking
10. Ensure that the theft deterrent (if equipped) is
not active. Turn the key switch to the ON position. g. If the temperature is below 0 °C (32 °F), check
Observe the display screen on the CAT ID. for solidified fuel (wax).
If the display screen on the CAT ID indicates that 12. Check for combustion problems.
the theft deterrent is enabled, the theft deterrent
passwords must be entered before the engine Examples of combustion problems are shown in
will start. the following list:
11. Check the fuel supply. • Outside temperatures are too cold.
a. Monitor the exhaust for smoke while the • Mechanical problem


a problem with the fuel supply.
98
i01908312 2. Check the fuel supply.
Engine Misfires, Runs Rough a. Monitor the exhaust for smoke while the
or Is U n s t a b l e engine is being cranked.
S M C S Code: 1000-035 If white smoke is present, there may be a

problem with the fuel quality.
Probable Causes b. Check the fuel quality. Refer to Testing and
Adjusting, "Fuel Quality - Test". Also refer
The probable root causes are listed in order below: to the Truck Performance and Driveability
Diagnostic Guide, LEBT3477.
Note: If the problem is intermittent and the problem
can not be duplicated, refer to Troubleshooting, ¢. Check the fuel pressure. Refer to Testing and
"Intermittent Low Power or Power Cutout". Adjusting, "Fuel System Pressure - Test".
• Individual malfunctioning cylinder d. Ensure that the fuel system has been primed.
• Fuel supply - Prime".
• Accelerator pedal position sensor e. Check for fuel supply lines that are restricted.
• Power train data link f. Check the fuel filters.
• Speed/timing sensors g. If the temperature is below 0 °C (32 °F), check
for solidified fuel (wax).
Recommended Actions
Perform the following diagnostic procedures in Testing and Adjusting, "Air in Fuel - Test".
order:
3. If the problem does not occur during cruise
Note: If the problem only occurs under certain control, check the accelerator pedal position
conditions, test the engine under those conditions. sensor.
Examples of certain conditions are high rpm,
full load and engine operating temperature. a. Use the Cruise/Idle On/Off Switch to put the
Troubleshooting the symptoms under other engine in idle mode.
conditions can give misleading results.
b. Vary the engine rpm with the Set/Resume
1. Check for an individual malfunctioning cylinder. switches.
a. Ensure that the J300/P300 Electronic Unit If both of the following conditions are met,
Injector Connector is fully connected and connect Cat ET and monitor the status of the
ensure that the J300/P300 Electronic Unit accelerator pedal position sensor.
Injector Connector is free of corrosion.
• The engine is stable by using idle mode to
b. Ensure that the J2/P2 ECM connector is fully control the engine rpm.
connected and ensure that the J2/P2 ECM
connector is free of corrosion. • The engine is unstable by using the
C. Connect the Caterpillar Electronic Technician
(Cat ET). Access the "Cylinder Cutout Test" If the status of the accelerator pedal position
by selecting "Diagnostic Tests" under the sensor is unstable, refer to Troubleshooting,
"Diagnostics" menu. Run the "Cylinder Cutout "Accelerator Pedal (Throttle) Position Sensor
Test" in order to disable each cylinder. Circuit - Test".
Disabling each cylinder allows the technician
to isolate the misfiring cylinders. 4. Check the "Power train Data Link". Ensure that
the SAE J1922 or the SAE J1939 Power train
If the misfiring cylinder can be isolated to Data Link is not limiting the power.
a specific cylinder, refer to Troubleshooting,
"Injector Solenoid Circuit - Test". a. Connect Cat ET to the data link connector.
99
b. Monitor the "Power train Data Link" status • PTO On/Off Switch
screen while the vehicle is experiencing
problems.
Recommended Actions
If the "Power train Data Link" status screen Perform the following diagnostic procedures in
indicates that the "Power train Data Link" is
order:
limiting the power or the rpm, verify that this
1. Check the Engine Retarder Mode.
operation, refer to the vehicle OEM for repairs.
If the Engine Retarder Mode is programmed
5. Check the primary engine speed/timing sensor. to Latch or Coast, the engine retarder will not
activate unless the service brake pedal is
If the signal from the primary engine speed/timing
depressed.
sensor is lost intermittently, the engine may
misfire. The misfiring may occur when the
If the Engine Retarder Mode is programmed to
signal source becomes the secondary engine Manual, service brakes are not required.
speed/timing sensor. Ensure that the primary
engine speed/timing sensor is properly installed.
2. Check the Engine Retarder On/Off Switch and
Also, ensure that the wiring is not damaged the Retarder Off/Low/Medium/High Switch.
or pulled too tightly. This may cause an
intermittent connection. Also, ensure that the Note: The Engine Retarder On/Off Switch must be
crankshaft gear and the timing plate are not in the ON position in order to permit engine retarder
damaged. Refer to the following publication for operation.
additional information: Troubleshooting, "Engine
Speed/Timing Sensor Circuit - Test" a, Connect an Electronic Service Tool to the Cab
Data Link Connector.
6. Check the secondary engine speed/timing
sensor.
b. Turn the ignition key to the ON position while
the engine is OFE
If the signal for the secondary engine
speed/timing sensor is lost during engine ¢. Access the status screen for the Engine
start-up, additional time may be required to start Retarder Switch.
the engine. The engine may also misfire during
this time until the ECM determines the proper
d. Move the engine retarder switches to each
firing order. Refer to Troubleshooting, "Engine of the available levels while the status of the
Speed/Timing Circuit - Test". switch is being watched on the Electronic
Service Tool. The available levels of the
i01192767 engine retarder switches have the following
designations:
Engine Retarder (Compression
• Off
Brake) Will Not Turn ON
SMCS Code: 1129-035 • Low
• Medium
Probable Causes
• High
Note: Some vehicles may have a set of switches on
• Customer Specified Parameter (Engine Retarder) the dash and the shift lever.
• Cruise Control On/Off Switch If the status for the Engine Retarder Switches
does not correspond to the position of
• Engine Retarder On/Off Switch the Engine Retarder Switches, refer to
Troubleshooting, "Retarder (Compression
• Retarder Off/Low/Medium/High Switch Brake) Solenoid circuit - Test".
• Accelerator Pedal Position Sensor 3. Check the Accelerator Pedal Position Sensor
and the Clutch Switch.
• Clutch Switch
a. Connect an Electronic Service Tool to the Cab
• Additional Customer Specified Parameters Data Link Connector.
100
b. Turn the ignition key to the ON position while "Engine Retarder Minimum Vehicle Speed" -
the engine is OFE The engine retarder will not turn ON below
the programmed value when the programmed
C. Access the status screen for the Accelerator value is greater than 0 km/h (0 mph).
Pedal Position.
"Engine Retarder Minimum Vehicle Speed
d. Depress the accelerator pedal and release Type" - W h e n vehicle speed drops below the
the accelerator pedal several times while the Engine Retarder Minimum Vehicle Speed and
status screen for the accelerator pedal is this parameter is programmed to Hard Limit
being watched. the engine retarder turns OFE When vehicle
speed drops below the Engine Retarder
The Accelerator Pedal Position should be in a Minimum Vehicle Speed and this parameter is
range of 3 to 100 percent. If the Accelerator programmed to Soft Limit the engine retarder
Pedal Position is not in a range of 3 to 100 remains ON.
percent, refer to Troubleshooting, "Accelerator
Pedal (Throttle) Position Sensor Circuit - Test". "Engine Retarder Delay" - This parameter
provides a programmable delay after the
e. Access the status screen for the Clutch conditions that turn ON the Engine Retarder
Switch. are met.
f. Depress the clutch pedal and release the If the problem is due to the programming
clutch pedal several times while the status of any of the listed parameters, refer to
screen for the Clutch Switch is being watched. Troubleshooting, "Customer Specified
Parameters".
The status screen for the Clutch Switch
should indicate that the clutch pedal is being 5. Check the PTO On/Off Switch.
depressed and released. When the clutch
pedal is being depressed the status screen Note: If the "PTO Configuration" (Customer
should indicate ON. When the clutch pedal Specified Parameter) is programmed to Cab
is being released the status screen should Switches, Remote Switches or Remote Throttle, the
indicate OFE If the status of the Clutch Engine Retarder is disabled when the PTO On/Off
Switch does not correspond to the position circuit is in the ON position.
of the clutch pedal, refer to Troubleshooting,
"Accelerator Pedal (Throttle) Position Sensor a, Connect an Electronic Service Tool to the Cab
Circuit - Test". Data Link Connector.
4. Check additional Customer Specified b. Turn the ignition key to the ON position while
Parameters. the engine is OFE
a. Connect an Electronic Service Tool to the Cab C. Access the status screen for the PTO On/Off
Data Link Connector. Switch.
b. Turn the ignition key to the ON position while If the status of the PTO On/Off Switch does
the engine is OFE not correspond to the position of the PTO
On/Off Switch, refer to Troubleshooting, "PTO
¢. Access the Customer Specified Parameters Switch Circuit - Test".
screen.
i01192776
d. Review the programming of the following
parameters: Engine Vibration
• "Engine Retarder Minimum Vehicle Speed" SMCS Code: 1000-035
• "Engine Retarder Minimum Vehicle Speed
Type" Probable Causes
• "Engine Retarder Delay" The probable root causes are listed in order below:
• Mounting Brackets
• Unbalance of the Clutch Disc

101
• Alignment of the Clutch Disc If the frequency of the vibration is half of the
engine rpm (half order), the vibration is caused
• Misfiring Cylinder by a misfiring cylinder.
• Resonance of the Vehicle If the frequency of the vibration is 3 times the

engine rpm (third order), no corrective action
Recommended Actions can be taken on the engine because this is the
firing frequency of the engine. The problem is in
Perform the following diagnostic procedures in the resonance of the cab or the problem is in the
order: resonance of the chassis.
4. Check for a problem regarding the resonance

1. Check for loose mounting brackets.
of the vehicle.
a. Start the engine.
a. Measure the vibration of the engine through
the entire speed range.
b. Run the engine through the entire Idle Speed
range. Check all vibrating components for the
b. Record the speed of the vibrations when the
following problems:
filter is out.
• Loose mounts
c. Record the amplitudes of the vibrations when
the filter is out.
• Broken mounts
If all of the amplitudes are less than 4.0
• Loose brackets
mils, the engine performance is within the
• Broken brackets specification.
d. If the amplitudes are greater than 4.0 mils,

• Loose fasteners
run the engine at high idle when the filter is
• Broken fasteners installed.
e. Check all vibrations over 4.0 mils for each of

2. Check for unbalance of the Clutch Disc and/or
the following orders of frequency:
misalignment of the Clutch Disc.
• Vibrations of the first order
a. Start the engine.
b. Run the engine through the entire Idle Speed • Vibrations of the second order
range while the clutch is disengaged.
• Vibrations of the third order
If the vibrations are reduced, there is a
balance problem with the clutch disc or the • Vibrations of any other order
clutch disc is out of alignment.
Perform the following tests in order to check the
¢. Repair the clutch disc or replace the clutch vibrations:
disc.
1. Check the vibrations of the first order.
3. Check for a misfiring cylinder.
a. Remove the vibration damper.
Further analysis requires the use of a vibration
b. Recheck the vibration.
instrument. Any instrument that can accurately
measure the displacement of the vibration
If the amplitude of the vibration is less than
and the frequency of the vibration will be
4.0 mils, check the damper pilot.
sufficient. The 40-3030 Vibration Analyzer
can be used to provide a quick identification
If the runout of the damper pilot is less than
and complete identification of all vibration
frequencies that are present in a constant 0.10 mm (0.004 inch), install a new damper.
speed measurement. Refer to Special Instruction
, SEHS7914, "Troubleshooting Vibration In If the runout of the damper pilot is greater
Vehicular Equipment" for additional information. than 0.10 mm (0.004 inch), correct the runout.
102
C, If the amplitude of the vibration was greater i01187011

than 4.0 mils after the removal of the damper,
remove the transmission's pressure plate and Engine Will Not Crank
clutch disc.
S M C S Code: 1000-035
d, Recheck the vibration.
Probable Causes
e, If the amplitude of the vibration was greater
than 4.0 mils after the removal of the Note: This is NOT an electronic system problem.
transmission's pressure plate and clutch Refer to Testing and Adjusting for additional
disc, an engine component is out-of-balance. information.
The following components could be
out-of-balance: The probable root causes are listed in order below:
• BrakeSaver • Batteries
• Connecting rod • Starting circuit
• Crankshaft • Starting motor solenoid
f. If the amplitude of the vibration was less than • Starting motor

4.0 mils after the removal of the transmission's
pressure plate and clutch disc, check the • Flywheel Ring Gear
flywheel runout and the flywheel housing
runout. • Transmission
If the flywheel runout and the flywheel housing • PTO
runout are within the specification, there is
a problem with the clutch and/or a problem • Engine accessory
with the transmission.
• Hydraulic cylinder lock
2. Check the vibrations of the second order.
• Internal engine problem
There is a heavy piston and connecting rod or
there is a light piston or connecting rod.
Recommended Actions
3. Check the vibrations of the third order.
The vibration is being caused by the frequency order:
of the firing order. A problem with resonance
exists within the vehicle. 1. Inspect the batteries.
4. Check any other significant orders of vibration. a. Charge the batteries. Refer to Special
Instruction, SEHS7633, "Battery Test
a. Check all driven accessories. Procedure".
b. Check all fan blades. b. Load test the batteries. Refer to Special
Instruction, SEHS9249, "Use of 40-4911
¢. Check for excessive gear backlash. Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries".
2, Check the vehicle wiring to the starting motor

solenoid. Refer to the OEM vehicle manual.
3. Check the engine start switch and the relay for

switch power.
4. Inspect the starting motor cables for damage

or loose connections.
103
5. If the starting motor cables are corroded, remove • Electronic System problem
the starting motor cables and clean the starting
motor cables. • Personality Module
6, Test starting motor operation. Recommended Actions

7, Inspect flywheel ring gear for damage. Perform the following diagnostic procedures in
order:
8, Ensure free movement of the driveline.
, Check the Air Inlet System for restrictions
9. Remove engine accessories that may lock up or leakage. Check the Exhaust System for
the engine and inspect engine accessories that restrictions or leakage. Refer to Testing and
may lock up the engine. Adjusting, "Air Inlet and Exhaust System -
Inspect".
The following list illustrates examples of engine
accessories that may lock up the engine: , Check the valve lash. Refer to Testing and
Adjusting, "Engine Valve Lash - Inspect/Adjust".
• Air compressor
3. Check the Electronic Unit Injector.
• Power steering pump
a, Ensure that the Electronic Unit Injector
• Engine oil pump
Connector (J300/P300) is fully connected
and ensure that the Electronic Unit Injector
10, Check for fluid in the cylinders (hydraulic
Connector (J300/P300) is free of corrosion.
cylinder lock) by removing the individual
electronic unit injectors. Ensure that the ECM Engine Harness
b.
Connector (J2/P2) is fully connected and
Note: Drain the fuel from the cylinder head. Fuel will
ensure that the Engine Harness Connector
flow from the cylinder head into the cylinders when
(J2/P2) is free of corrosion.
the electronic unit injector is removed.
C. Connect an Electronic Service Tool. Use the
11, Disassemble the engine. Inspect the internal Cylinder Cutout Test. Access the Cylinder
components for the following conditions:
Cutout Test by selecting the "Diagnostic
Menu" and the "Diagnostics Test Menu".
• Seizure
Run the Cylinder Cutout Test in order to
disable each cylinder. Disabling each cylinder
• Broken components allows the technician to isolate the misfiring
cylinders.
• Bent components
If the misfiring cylinder can be isolated to
Refer to Disassembly and Assembly. a specific cylinder, refer to Troubleshooting,
"Injector Solenoid Circuit - Test".
i01191206
4. Check the Boost Pressure Sensor and the
Excessive Black Smoke Atmospheric Pressure Sensor.
SMCS Code: 1088-035 a. Connect an Electronic Service Tool.
Probable Causes b. While the problem is occurring, check for

Diagnostic Codes that are related to the
The probable root causes are listed in order below: Boost Pressure Sensor and the Atmospheric
Pressure Sensor. If a Diagnostic Code is
• Air Inlet System or Exhaust System found, refer to Troubleshooting, "Engine
Pressure Sensor Open or Short Circuit - Test".
• Valve Lash
5. Check for an Electronic System problem.
• Electronic Unit Injector
a. Connect an Electronic Service Tool.
• Boost Pressure Sensor
b. Monitor the Fuel Position, the Rated Fuel Limit
• Atmospheric Pressure Sensor and the FRC Fuel Limit.
104
While the vehicle is operating under full load, If a problem with the Accelerator Pedal
the parameters should meet the following Position Sensor is suspected, refer to
conditions: Troubleshooting, "Accelerator Pedal (Throttle)
Position Sensor Circuit - Test".
• The Fuel Position is equal to the Rated Fuel
Limit. Note: If the engine exceeds the Top Engine Limit,
the "Top Engine Limit with Droop" is programmed
• The Fuel Position is less than the FRC Fuel to YES.
Limit.
, Monitor the vehicle speed signal. Ensure
If the Fuel Position is equal to the Rated Fuel the accuracy of the vehicle speed signal by
Limit and the Fuel Position is less than the comparing the vehicle speed signal to the actual
FRC Fuel Limit, the Electronics are operating vehicle speed.
correctly. Go to Step 7.
If the vehicle speed is greater than the VSL, the
6. If the Fuel Position is not equal to the Rated Fuel Power is limited. If a problem is discovered, refer
Limit and/or the Fuel Position is not less than to Troubleshooting, "Vehicle Speed Circuit - Test".
the FRC Fuel Limit, perform the following tests
in order: . Check the "Power train Data Link". Ensure that
a° Connect an Electronic Service Tool. Data Link is not limiting the power.
b. When the engine is OFF, turn the Ignition Key a, Connect an Electronic Service Tool.
Switch to the ON position. Check the boost
pressure on an Electronic Service Tool Status b. Monitor the "Power train Data Link" Status
Screen. screen while the vehicle is experiencing
problems.
When the engine is OFF, the boost pressure
should be 0 kPa (0 psi). If the "Power train Data Link" Status screen
C, Monitor the status of the Accelerator Pedal limiting the power or the rpm, verify that this
Position Sensor. Operate the engine at high is not normal operation. If this is not normal
idle with the vehicle in Neutral. operation, refer to the vehicle OEM for repairs.
If the engine can not reach the programmed 9. Check the ECM or the Personality Module.
"Top Engine Limit", check the Accelerator
Pedal Position Duty Cycle in order to ensure a. Connect an Electronic Service Tool.
that the Accelerator Pedal Position Duty Cycle
is within calibration (75 to 90 Percent at high b. Verify that the correct Personality Module has
idle). been installed.
If the accelerator pedal position is unstable, Refer to Troubleshooting, "ECM Memory -

check the Accelerator Pedal Position Duty Test".
Cycle. Check the Accelerator Pedal Position
Duty Cycle by slowly operating the accelerator
i01192329
pedal in order to verify that the Accelerator
Pedal Position Sensor is within calibration. Excessive Fuel Consumption
The Accelerator Pedal Position Sensor is
within calibration when both of the following SMCS Code: 1250-035
conditions are met:
• 10 to 22 percent at low idle Probable Causes

• 75 to 90 percent at high idle The probable root causes are listed in order below:
Also, ensure that the duty cycle changes as • Vehicle Operation

• Vehicle Specifications
• Fuel Supply
105
• Air Inlet System or Exhaust System e. Check for fuel supply lines that are restricted.

Recommended Actions
order:
1. Inspect the ECM Totals.
Testing and Adjusting, "Air in Fuel - Test".
a. Inspect the ECM Totals for idle time.
4. Check the Air Inlet System for restrictions
or leakage. Check the Exhaust System for
b. Inspect the Fleet Trip Histograms for excessive
restrictions or leakage. Refer to Testing and
idling or poor driving habits.
Adjusting, "Air Inlet and Exhaust System -
e. Check the following items: Inspect".
• Load factor i01191384
• Average vehicle speed Excessive White S m o k e

• Vehicle Speed Limit S M C S C o d e : 1088-035
Look for excessively high values for these Probable Causes

items.
d. Consider the following environmental
conditions: • Normal Operation
• Wind • Fuel Supply
• Snow • Atmospheric Pressure circuit
2. Check the vehicle specifications. • Coolant Temperature circuit
Check the specifications on the following items: • Electronic Unit Injector
• Gearing or Power train • Combustion problem
• Vehicle Aerodynamics
Recommended Actions
• Heavy Loads
3. Check the fuel supply. order:
a. Monitor the exhaust for smoke while the 1. Be aware of normal operating conditions.
Cold outside temperatures can affect the
If no smoke is present, there may be a production of white smoke.
a problem with the fuel supply. 2, Check the fuel supply.
b. Check the fuel quality. Refer to Testing and a, Monitor the exhaust for smoke while the
Adjusting, "Fuel Quality - Test". Also refer engine is being cranked.
Diagnostic Guide, LEBT3477. If no smoke is present, there may be a
C, Check the fuel pressure. Refer to Testing and a problem with the fuel supply.
b. Check the fuel quality. Refer to Testing and
d. Ensure that the fuel system has been primed. Adjusting, "Fuel Quality - Test". Also refer
Refer to Testing and Adjusting, "Fuel System to the Truck Performance and Driveability
- Prime". Diagnostic Guide, LEBT3477.
106
C. Check the fuel pressure. Refer to Testing and 5. Check the Electronic Unit Injector.
a. Ensure that the Electronic Unit Injector
d. Ensure that the fuel system has been primed. Connector (J300/P300) is fully connected
Refer to Testing and Adjusting, "Fuel System and ensure that the Electronic Unit Injector
- Prime". Connector (J300/P300) is free of corrosion.
e, Check for fuel supply lines that are restricted. b. Ensure that the ECM Engine Harness
Connector (J2/P2) is fully connected and
f. Check the fuel filters. ensure that the Engine Harness Connector
(J2/P2) is free of corrosion.
for solidified fuel (wax). C. Connect an Electronic Service Tool. Use the
Cylinder Cutout Test. Access the Cylinder
h. Check for air in the fuel system. Refer to Cutout Test by selecting the "Diagnostic
Testing and Adjusting, "Air in Fuel - Test". Menu" and the "Diagnostics Test Menu".
3. Check the Atmospheric Pressure circuit. disable each cylinder. Disabling each cylinder
allows the technician to isolate the misfiring
a. Connect an Electronic Service Tool. cylinders.
b. Check for Diagnostic Codes that are related If the misfiring cylinder can be isolated to
to the Atmospheric Pressure circuit. a specific cylinder, refer to Troubleshooting,
C. Monitor the status of the Atmospheric
Pressure Sensor on the Electronic Service 6. Check for combustion problems.
Tool status screen. Compare the value for the
atmospheric pressure on the status screen to Examples of combustion problems are shown in
the actual atmospheric pressure. the following list:
d, If the atmospheric pressure on the status • Outside temperatures are too cold.
screen is at least 7 kPa (1 psi) greater than
the actual atmospheric pressure, inspect the • Mechanical problem
crankcase breather for restrictions.
i01764264
e. Remove a valve cover.
f. Recheck the atmospheric pressure on the

Intermittent Cruise Control,
status screen. Idle, or PTO Kickout
g. If removing the crankcase breather solves the SMCS Code: 1915-035
problem, replace the crankcase breather.
h. If the crankcase breather is not restricted or

Probable Causes
removing the valve cover does not eliminate The probable root causes are listed below:
the problem, proceed to Step 4.
• A clutch pedal position switch that is incorrectly
4. Check the Coolant Temperature circuit. adjusted
a. Connect an Electronic Service Tool. • Malfunctioning On/Off switch for cruise control
and idle control
b. Check for Diagnostic Codes that are related
to the Coolant Temperature circuit. • Malfunctioning switch for Service Brake Pedal
Position
C. Monitor the status of the Coolant Temperature
Sensor on the Electronic Service Tool • Malfunctioning Transmission Neutral Switch
status screen. If an Active Open or Short
Circuit Diagnostic Code is detected, refer to • Vehicle Speed circuit problem
Troubleshooting, "Engine Temperature Sensor
Open or Short Circuit - Test". • Battery power or ground to the ECM
107
• Adaptive cruise control a. Ensure that the operator has not actually
depressed the service brake pedal or the
clutch pedal. Also ensure that the operator
Recommended Actions has not actually shifted the transmission to
Perform the following diagnostic procedures in neutral.
order:
b. Check the status screen on Cat ET while the
service brake or the clutch is being used.
1. Connect Cat ET to the data link connector.
If the problem is not apparent check the
Check the Status Screen for the last item that
switches. Check the service brake switch for
caused the Kickout for the Cruise Control, the
the air system. Ensure that the treadle valve
Idle Control or the PTO Control.
is operating freely. A treadle valve that is not
operating freely can cause pressure spikes.
Note: Cat ET will only provide access to the last
Check the clutch switch adjustment and the
cause of the Kickout. If the ECM is powered down
return spring.
and the ECM is powered up, the display on Cat ET
will be blank. The ECM is powered down when the
C, If the problem is related to the Cruise Control
ignition key switch is turned to the OFF position.
or Idle Control refer to Troubleshooting,
It may be necessary to take the vehicle for a test
"Cruise Control Circuit, Service Brake Pedal
drive in order to repeat the problem. Check Cat ET
Position (Switch 1) Circuit, and Clutch Pedal
before the ECM is turned oft by the keyswitch.
Position Switch Circuit - Test".
If Cat ET indicates "Switch Turned Off", go to
Step 2. d. If the problem is related to the PTO refer to
Troubleshooting, "PTO Switch Circuit - Test".
If Cat ET indicates "Brake", "Clutch" or "Neutral"
. If Cat ET indicates "Bad Vehicle Speed", the
go to Step 3.
vehicle speed signal is erratic or intermittent.
This relates to Cruise Control only.
If the Cat ET indicates "Bad Vehicle Speed",
"Vehicle Speed < Limit" or "Vehicle Speed >=
Limit" go to Step 4. If Cat ET indicates "Vehicle Speed < Limit", the
vehicle speed signal was lost at least briefly. This
pertains to Cruise Control only.
2. If Cat ET indicates "Switch Turned Off", the ECM
has detected an open circuit in the On/Off switch
If Cat ET indicates "Vehicle Speed >= Limit", the
circuit. This pertains to the cruise control, the
idle control or the PTO. Perform the following vehicle speed signal exceeded the programmed
Idle/PTO Vehicle Speed Limit or the vehicle
tests in order:
speed limit is erratic or intermittent. This pertains
Ifl. Ensure that the operator has not actually to Idle Control and PTO Control only.
turned off the Cruise Control On/Off Switch or
the PTO On/Off Switch. Perform the following diagnostic procedure in
order:
b. Check the Status Screen on Cat ET while the a, Inspect the Vehicle speed sensor for debris on
switch is being used. If the problem is not
apparent check the switch and the wiring. the sensor. Inspect the vehicle speed circuit.
b, Check the vehicle speed that is displayed on

C, If the problem is related to the Cruise Control
or Idle Control refer to Troubleshooting, the status screen on Cat ET while the vehicle
is parked. Adjust the engine rpm up and
"Cruise Control Circuit, Service Brake Pedal
down. Also check the vehicle speed while the
Position (Switch 1) Circuit, and Clutch Pedal
vehicle is being driven in order to determine
Position Switch Circuit - Test".
that the vehicle speed that is indicated
by Cat ET does not vary significantly from
d. If the problem is related to the PTO refer to
the vehicle speed that is indicated by the
Troubleshooting, "PTO Switch Circuit - Test".
speedometer. If the problem is not apparent,
refer to Troubleshooting, "Vehicle Speed
3. If Cat ET indicates "Brake", "Clutch" or "Neutral",
Circuit - Test".
the ECM has detected an open circuit in the
switch circuit for the Service Brake, the switch
C, Inspect both ECM connectors for moisture.
circuit for the Clutch or the Transmission Neutral
Refer to Troubleshooting, "Inspecting
switch circuit. Perform the following tests in order:
Electrical Connectors".
108
5. A problem with the battery power, the ground to b. Check for active diagnostic codes on Cat ET.
the ECM or the vehicle wiring can cause erratic
engine rpm or other more severe problems. If this Note: Certain diagnostic codes will cause the
is a suspected cause, refer to Troubleshooting, engine to shutdown. Troubleshoot all diagnostic
"Ignition Key Switch Circuit and Battery Supply codes before continuing with this procedure.
Circuit Test".
2. Check the Battery power or ground to the ECM.
6. Check for proper operation of the Adaptive
Cruise Control. a. Ensure that the following connectors have
been installed correctly:
a. Toggle the cruise control switch to the OFF
position and to the ON position twice within • J1/P1 and J2/P2 ECM connectors
10 seconds. This will disable the Adaptive
Cruise Control. • J300/P300 Injector connector
b. Attempt to set the cruise control. Operate • J401/P401 Primary engine speed/timing
the vehicle under the same conditions that sensor connector
caused the problem.
• J402/P402 Secondary engine speed/timing
c. If the problem still exists, then the problem is sensor connector
not the Adaptive Cruise Control.
b. If the problem occurs only after engine
d. If the problem is fixed, refer to Eaton for the warm-up and the problem disappears after
proper troubleshooting procedure. the engine cooldown, the circuit breakers
may be tripping because of the heat. Check
the circuit breakers on the vehicle in order
i01908313
to determine if the circuit breakers reset
Intermittent Engine Shutdown automatically.
SMCS Code: 1000-035 3. Check aftermarket engine protection devices.

These devices usually interrupt power to the ECM
and the ECM will not communicate with Cat ET.
Probable Causes
a. Check for the correct installation of the
The probable root causes are listed in order below: aftermarket engine protection device.
• Diagnostic codes b. Check for the correct operation of the

aftermarket engine protection device.
• Battery power or ground to the ECM
¢. Verify that the ECM is receiving battery
• Aftermarket engine protection devices voltage.
• Fuel supply 4. Check the fuel supply.
• Engine speed/timing sensors a. Monitor the exhaust for smoke while the
• ECM or personality module
Note: Induce the engine to shut down before problem with the fuel quality or there may be
attempting to troubleshoot the problem. a problem with the fuel supply.
Recommended Actions b. Check the fuel quality. Refer to Testing and

Adjusting, "Fuel Quality - Test". Also refer to
Perform the following diagnostic procedures in Truck Performance and Driveability Diagnostic
order: Guide, LEBT3477.
1. Check for diagnostic codes. ¢. Check the fuel pressure. Refer to Testing and
a. Connect the Caterpillar Electronic Technician
(Cat ET).
109
d. Ensure that the fuel system has been primed. b. Check for Diagnostic Codes that are capable
Refer to Testing and Adjusting, "Fuel System of Derating the engine when "Engine
- Prime". Monitoring" is programmed to "Derate" or
"Shutdown".
• 110-00 High Coolant Temperature Warning
f. Check the fuel filters. (61)
g. If the temperature is below 0 °C (32 °F), check • 110-11 Very High Coolant Temperature (61)
• 111-11 Very Low Coolant Level (62)
5. Check the Engine Speed/Timing Sensors.
• 100-11 Very Low Oil Pressure (46)
Refer to Troubleshooting, "Engine Speed/Timing
Sensor Circuit - Test". 3. Check the Battery power or ground to the ECM.
6. Check the ECM or the personality module, a. Ensure that the following connectors have
been installed correctly:
Refer to Troubleshooting, "ECM Memory - Test".
• ECM connectors (J1/P1 and J2/P2) with
seventy pins
i01190888
Intermittent Low Power or • Injectorconnector(J300/P300)

Power Cutout • Crankshaft Position Sensor connector
(J401/P401)
SMCS Code: 1000-035
• Camshaft Position Sensor connector
Probable Causes (J402/P402)
The probable root causes are listed in order below: b. Use an Electronic Service Tool to check for a
168-02 Intermittent Battery (51) Diagnostic
• Poor electrical connections Code. Check the power connections for the
ECM and the ground connections for the ECM.
• "Engine Monitoring" If a problem is suspected, wire a bypass.
Refer to Troubleshooting, "Ignition Key Switch
• Battery power or ground to the ECM Circuit and Battery Supply Circuit - Test".
• Air Inlet System (Boost) 4. Check for an Electronic System problem.
• Accelerator Pedal Position Sensor a. Connect an Electronic Service Tool.
• Fuel Supply b. Monitor the Fuel Position, the Rated Fuel Limit
and the FRC Fuel Limit.
• Vehicle Speed Circuit
While the vehicle is operating under full load,
• Powertrain Control the parameters should meet the following
conditions:
• Torque Limit Switch
• The Fuel Position is equal to the Rated Fuel
Limit.
R e c o m m e n d e d Actions
• The Fuel Position is less than the FRC Fuel
Perform the following diagnostic procedures in Limit.
order:
If the Fuel Position is equal to the Rated Fuel
1. Check the vehicle harness and the connectors. Limit and the Fuel Position is less than the
Refer to Troubleshooting, "Inspecting Electrical FRC Fuel Limit, the Electronics are operating
Connectors". correctly. Go to Step 6.
2. Check the parameters for "Engine Monitoring".

110
5. If the Fuel Position is not equal to the Rated Fuel 7. Check the "Power train Data Link". Ensure that
Limit and/or the Fuel Position is not less than the SAE J1922 or the SAE J1939 Power train
the FRC Fuel Limit, perform the following tests Data Link is not limiting the power.
in order:
a, Connect an Electronic Service Tool.
b. Monitor the "Power train Data Link" Status
b. When the engine is OFF, turn the Ignition Key screen while the vehicle is experiencing
Switch to the ON position. Check the boost problems.
pressure on an Electronic Service Tool Status
Screen. If the "Power train Data Link" Status screen
When the engine is OFF, the boost pressure limiting the power or the rpm, verify that this
should be 0 kPa (0 psi). is not normal operation. If this is not normal
¢. Monitor the status of the Accelerator Pedal
Position Sensor. Operate the engine at high 8. Check the fuel supply.
idle with the vehicle in Neutral.
If the engine can not reach the programmed engine is being cranked.
"Top Engine Limit", check the Accelerator
Pedal Position Duty Cycle in order to ensure If no smoke is present, there may be a
that the Accelerator Pedal Position Duty Cycle problem with the fuel quality or there may be
is within calibration (75 to 90 Percent at high a problem with the fuel supply.
idle).
b. Check the fuel quality. Refer to Testing and
If the accelerator pedal position is unstable, Adjusting, "Fuel Quality - Test". Also refer
check the Accelerator Pedal Position Duty to the Truck Performance and Driveability
Cycle. Check the Accelerator Pedal Position Diagnostic Guide, LEBT3477.
Duty Cycle by slowly operating the accelerator
pedal in order to verify that the Accelerator C, Check the fuel pressure. Refer to Testing and
Pedal Position Sensor is within calibration. Adjusting, "Fuel System Pressure - Test".
The Accelerator Pedal Position Sensor is
within calibration when both of the following d. Ensure that the fuel system has been primed.
conditions are met: Refer to Testing and Adjusting, ',Fuel System
- Prime".
• 10 to 22 percent at low idle
e= Check for fuel supply lines that are restricted.
• 75 to 90 percent at high idle
Also, ensure that the duty cycle changes as
the pedal position changes. g. If the temperature is below 0 °C (32 °F), check
If a problem with the Accelerator Pedal
Position Sensor is suspected, refer to h. Check for air in the fuel system. Refer to
Troubleshooting, "Accelerator Pedal (Throttle) Testing and Adjusting, "Air in Fuel - Test".
Position Sensor Circuit - Test".
9. Check the Torque Limit Switch.
Note: If the engine exceeds the Top Engine Limit,
the "Top Engine Limit with Droop" is programmed a. Connect an Electronic Service Tool.
to YES.
b. Check the setting for the Customer Parameter
6. Monitor the vehicle speed signal. Ensure for the "Torque Limit".
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 Circuit - Test".
111
If the "Torque Limit" is programmed below • "Lower Gears Engine RPM Limit"
3400 N.m (2500 Ib ft), check the status
screen for the Torque Limit Switch. Ensure • "Intermediate Gears Engine RPM Limit"
that the status screen indicates that the
Torque Limit Switch is OFE If the status of • "Gear Down Protction Engine RPM Limit"
the Torque Limit Switch is QN and a Torque
Limit is programmed, the system is operating Note: If the "Rating Number" is programmed to 0,
correctly. If the switch that is connected to the engine is limited to 119 kW (160 hp).
this signal input is not switching ON and
switching OFF, refer to Troubleshooting, "PTO d. Set each parameter to the parameter's
Switch Circuit - Test". maximum value one at a time and determine
i01816258
2. Check cold mode operation.
Low Power/Poor or No Note: This is normal operation if the problem occurs
Response to Throttle only after start-up in cold weather.
SMCS Code: 1000-035 a. Connect the electronic service tool.
Probable Causes b. Monitor the electronic service tool in order to

verify that the engine has progressed from
The probable root causes are listed in order below: cold mode.
• Customer specified parameters (normal An active cold mode is indicated in the upper
operation) corner of any status screen.
• Cold mode operation 3. Check the PTO on/off switch.
• PTO on/off switch a. Verify that the PTO on/off switch is in the OFF
position.
• Electronic system problem
b. Connect the electronic service tool.
• Fuel supply
¢. Verify that the status for the "PTO On/Off
• Leakage in air-to-air aflercooler core Switch" on the electronic service tool
corresponds to the position of the switch.
• Air inlet system or exhaust system
d. Cycle the PTO on/off switch while you observe
• Individual malfunctioning cylinder the status screen.
• Torque limit switch 4. Check for an electronic system problem.
a. Connect the electronic service tool.

Recommended Actions
b. Monitor the "Fuel Position", the "Rated Fuel
Perform the following tests in order: Limit" and the "FRC Fuel Limit" on the status
screen.
1. Check customer specified parameters.
While the vehicle is operating under full load,
a. Verify that the complaint is not normal the parameters should meet the following
operation (programmed parameter). conditions:
b. Connect the electronic service tool. • The "Fuel Position" is equal to the "Rated
Fuel Limit".
• The "Fuel Position" is less than the "FRC
• "Rating Number" Fuel Limit".
• "Top Engine Limit" If the "Fuel Position" is equal to the "Rated

Fuel Limit" and the "Fuel Position" is less
• "Vehicle Speed Limit" than the "FRC Fuel Limit", the Electronics are
operating correctly. Go to Step 6.
112
5. If the "Fuel Position" is not equal to the "Rated 7. Check the "Powertrain Data Link". Ensure that
Fuel Limit" and/or the "Fuel Position" is not less the SAE J1922 or the SAE J1939 Powertrain Data
than the "FRC Fuel Limit", perform the following Link is not limiting the power.
tests in order:
b. Monitor the "Powertrain Data Link" status
b. When the engine is OFF, turn the ignition key screen while the vehicle is experiencing
switch to the ON position. Check the status problems.
for "Boost Pressure" on the electronic service
tool. If the "Powertrain Data Link" status screen
indicates that the "Powertrain Data Link " is
When the engine is OFF, the boost pressure limiting the power or the rpm, verify that this
should be 0 kPa (0 psi). is not normal operation. If this is not normal
C, Monitor the status of the accelerator pedal
position sensor. Operate the engine at high 8. Check the fuel supply.
idle with the vehicle in Neutral.
If the engine can not reach the programmed engine is being cranked.
"Top Engine Limit", check the duty cycle of
the accelerator pedal position in order to If no smoke is present, there may be a
ensure that the duty cycle is within calibration problem with the fuel quality or there may be
(75 to 90 Percent at high idle). a problem with the fuel supply.
If the accelerator pedal position is unstable, b. Check the fuel quality. Refer to Testing and
check the duty cycle of the accelerator Adjusting, "Fuel Quality - Test". Also refer
pedal position. Check the duty cycle of the to the Truck Performance and Driveability
accelerator pedal position by slowly operating Diagnostic Guide, LEBT3477.
the accelerator pedal in order to verify that
the accelerator pedal position sensor is within ¢. Check the fuel pressure. Refer to Testing and
calibration. The accelerator pedal position Adjusting, "Fuel System Pressure - Test".
sensor is within calibration when both of the
following conditions are met: d. Ensure that the fuel system has been primed.
• 10 to 22 percent at low idle - Prime".
• 75 to 90 percent at high idle e. Check for fuel supply lines that are restricted.
Also, ensure that the duty cycle changes as f. Check the fuel filters.
If a problem with the accelerator pedal for solidified fuel (wax).
position sensor is suspected, refer to
Troubleshooting, "Accelerator Pedal (Throttle) h, Check for air in the fuel system. Refer to
Position Sensor Circuit - Test". Testing and Adjusting, "Air in Fuel - Test".
Note: If the engine exceeds the "Top Engine Limit", 9. Check for leakage in the Air-to-Air Aftercooler
the "Top Engine Limit with Droop" is programmed Core. Refer to Testing and Adjusting, "Aftercooler
to YES. - Test".
6. Monitor the vehicle speed signal. Ensure 10. Check the air inlet system for restrictions
the accuracy of the vehicle speed signal by or leakage. Check the exhaust system for
comparing the vehicle speed signal to the actual restrictions or leakage. Refer to Testing and
vehicle speed. Adjusting, "Air Inlet and Exhaust System -
Inspect".
If the vehicle speed is greater than the "VSL", the
power is limited. If a problem is discovered, refer 11. Check for an individual malfunctioning cylinder.
to Troubleshooting, "Vehicle Speed Circuit - Test".
113
a, Ensure that the J300/P300 Injector Solenoid • Torque Limit Switch

Harness connector is fully connected and
free of corrosion. Recommended Actions
b. Ensure that the J2/P2 ECM connector is fully Perform the following diagnostic procedures in
connected and free of corrosion. order:
C. Connect the electronic service tool. Use the
1. Check Customer Specified Parameters.
"Cylinder Cutout Test". Access the "Cylinder
Cutout Test" by selecting the "Diagnostic a. Verify that the complaint is not normal
Menu" and the "Diagnostics Test Menu". operation (programmed parameter).
Run the "Cylinder Cutout Test" in order to
disable each cylinder. Disabling each cylinder b. Connect an Electronic Service Tool.
cylinders.
If the misfiring cylinder can be isolated to • "Lower Gears Engine RPM Limit"
"Injector Solenoid Circuit - Test". • "Intermediate Gears Engine RPM Limit"
d. Perform a PAR Test (Performance Analysis • "Gear Down Protection Engine RPM Limit"
Report).
d. Set each parameter to the parameter's
12. Check the torque limit switch. maximum value one at a time and determine
2. Check Cold Mode Operation.
b. Check the setting for the customer parameter
for the "Torque Limit". Note: This is normal operation if the problem occurs
only after start-up in cold weather.
If the "Torque Limit" is programmed below
3400 N-m (2500 Ib ft), check the status
screen for the torque limit switch. Ensure
b. Monitor the Electronic Service Tool in order to
torque limit switch is OFF. If the status verify that the engine has progressed from
of the torque limit switch is ON and a Cold Mode.
"Torque Limit" is programmed, the system is
operating correctly. If the torque limit switch An Active Cold Mode is indicated in the upper
that is connected to this signal input is not corner of any Status Screen.
switching ON and switching OFF, refer to
Troubleshooting, "PTO Switch Circuit - Test". 3. Check for an individual malfunctioning cylinder.
i01191691 a. Ensure that the Electronic Unit Injector

Connector (J300/P300) is fully connected
Poor Acceleration or Response and ensure that the Electronic Unit Injector
Connector (J300/P300) is free of corrosion.
SMCS Code: 1000-035
b. Ensure that the ECM Engine Harness
Probable Causes Connector (J2/P2) is fully connected and
ensure that the Engine Harness Connector
The probable root causes are listed in order below: (J2/P2) is free of corrosion.
• Customer Specified Parameters (normal C, Connect an Electronic Service Tool. Use the
operation) Cylinder Cutout Test. Access the Cylinder
Cutout Test by selecting the "Diagnostic
• Cold Mode Operation Menu" and the "Diagnostics Test Menu".
• Individual malfunctioning cylinder disable each cylinder. Disabling each cylinder
• "Power train Data Link" cylinders.
• Personality Module
114
If the misfiring cylinder can be isolated to

4, Check the "Power train Data Link". Ensure that

Data Link is not limiting the power.
b, Monitor the "Power train Data Link" Status

screen while the vehicle is experiencing
problems.
If the "Power train Data Link" Status screen

limiting the power or the rpm, verify that this
5, Check the ECM or the Personality Module.
b, Verify that the correct Personality Module has

been installed.
Refer to Troubleshooting, "ECM Memory -

Test".
6. Check the Torque Limit Switch.
b, Check the setting for the Customer Parameter

for the "Torque Limit".
If the "Torque Limit" is programmed below

3400 N.m (2500 Ib ft), check the status
screen for the Torque Limit Switch. Ensure
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".
CATERPILLAR
TROUBLESHOOTING WITH A DIAGNOSTIC CODE
TABLE OF CONTENTS
DESCRIPTION PAGE
DIAGNOSTIC CODES ........................................................................................................................................................ 115
NO DIAGNOSTIC CODE DETECTED (55) .......................................................................................................................... 116
0001-11 CYLINDER #1 INJECTOR CURRENT FAULT (72) ................................................................................................. 116
0022-11 PRIMARY TO SECONDARY ENGINE SPEED SIGNAL CALIBRATION (42) ........................................................... 118
0022-13 ENGINE SPEED SIGNAL CALIBRATION NOT PERFORMED (42)......................................................................... 120
0030-08 PTO THROTTLE SIGNAL INVALID (29) ................................................................................................................ 120
0030-13 PTO THROTTLE OUT OF CALIBRATION (29)....................................................................................................... 120
0041-03 8 VOLT SUPPLY VOLTAGE HIGH (21) ................................................................................................................. 121
0041-04 8 VOLT SUPPLY VOLTAGE LOW (21).................................................................................................................. 121
0043-02 KEY SWITCH FAULT (71) ..................................................................................................................................... 121
0052-11 AIR INLET SHUTOFF SHUTDOWN (00) ................................................................................................................ 122
0054-05 AUXILIARY OUTPUT #06 CURRENT LOW (66)..................................................................................................... 122
0054-06 AUXILIARY OUTPUT #06 CURRENT HIGH (66) .................................................................................................... 123
0055-05 AUXILIARY OUTPUT #07 CURRENT LOW (67)..................................................................................................... 123
0055-06 AUXILIARY OUTPUT #07 CURRENT HIGH (67) .................................................................................................... 123
0064-12 SECONDARY ENGINE SPEED LOSS OF SIGNAL (34) ......................................................................................... 124
0071-00 IDLE SHUTDOWN OVERRIDE (01) ....................................................................................................................... 124
0071-01 IDLE SHUTDOWN (47) ......................................................................................................................................... 125
0071-14 PTO SHUTDOWN (47) .......................................................................................................................................... 125
0084-00 VEHICLE OVER-SPEED WARNING (41) ............................................................................................................... 125
0084-01 VEHICLE SPEED LOSS OF SIGNAL (31) .............................................................................................................. 126
0084-02 VEHICLE SPEED SIGNAL INVALID (36) ............................................................................................................... 126
0084-08 VEHICLE SPEED SIGNAL OUT OF RANGE (36)................................................................................................... 127
0084-10 VEHICLE SPEED SIGNAL RATE OF CHANGE (36) .............................................................................................. 127
0084-14 QUICK STOP OCCURRENCE............................................................................................................................... 127
0091-08 THROTTLE POSITION INVALID (32)..................................................................................................................... 128
0091-13 THROTTLE POSITION OUT OF CALIBRATION (32).............................................................................................. 128
0100-01 LOW OIL PRESSURE WARNING (46) ................................................................................................................... 129
0100-03 OIL PRESSURE VOLTAGE HIGH (24) .................................................................................................................. 132
0100-04 OIL PRESSURE VOLTAGE LOW (24) ................................................................................................................... 132
0100-11 VERY LOW OIL PRESSURE (46) .......................................................................................................................... 133
0102-00 EXCESSIVE BOOST PRESSURE ......................................................................................................................... 136
0102-03 BOOST PRESSURE VOLTAGE HIGH (25) ............................................................................................................ 137
0102-04 BOOST PRESSURE VOLTAGE LOW (25)............................................................................................................. 137
0105-00 HIGH INTAKE MANIFOLD AIR TEMPERATURE WARNING (64) ........................................................................... 137
0105-03 INTAKE MANIFOLD AIR TEMPERATURE VOLTAGE HIGH (38) ........................................................................... 138
0105-04 INTAKE MANIFOLD AIR TEMPERATURE VOLTAGE LOW (38)............................................................................ 138
0105-11 VERY HIGH INTAKE MANIFOLD AIR TEMPERATURE (64) .................................................................................. 139
0108-03 BAROMETRIC PRESSURE VOLTAGE HIGH (26) ................................................................................................. 139
0108-04 BAROMETRIC PRESSURE VOLTAGE LOW (26).................................................................................................. 139
0110-00 HIGH COOLANT TEMPERATURE WARNING (61) ................................................................................................ 140
0110-03 COOLANT TEMPERATURE VOLTAGE HIGH (27) ................................................................................................ 140
0110-04 COOLANT TEMPERATURE VOLTAGE LOW (27) ................................................................................................. 141
0110-11 VERY HIGH COOLANT TEMPERATURE (61)........................................................................................................ 141
0111-01 LOW COOLANT LEVEL WARNING (62)................................................................................................................ 141
0111-02 COOLANT LEVEL SIGNAL INVALID (12).............................................................................................................. 142
0111-03 COOLANT LEVEL VOLTAGE HIGH (12) ............................................................................................................... 143
0111-04 COOLANT LEVEL VOLTAGE LOW (12)................................................................................................................ 143
0111-11 VERY LOW COOLANT LEVEL (62)....................................................................................................................... 143
0121-05 LOW/HIGH RETARDER CURRENT LOW (14) ....................................................................................................... 144
0121-06 LOW/HIGH RETARDER CURRENT HIGH (14)....................................................................................................... 145
0122-05 MED/HIGH RETARDER CURRENT LOW (14)........................................................................................................ 145
0122-06 MED/HIGH RETARDER CURRENT HIGH (14)....................................................................................................... 145
0168-02 ECM BATTERY POWER INTERMITTENT (51)....................................................................................................... 146
0171-03 AMBIENT AIR TEMPERATURE VOLTAGE HIGH.................................................................................................. 146
0171-04 AMBIENT AIR TEMPERATURE VOLTAGE LOW................................................................................................... 146
0171-11 AMBIENT AIR TEMPERATURE DATA LOST ........................................................................................................ 147
0174-00 HIGH FUEL TEMPERATURE WARNING (65) ........................................................................................................ 147
0174-03 FUEL TEMPERATURE VOLTAGE HIGH (13) ........................................................................................................ 147
0174-04 FUEL TEMPERATURE VOLTAGE LOW (13) ......................................................................................................... 148
0190-00 ENGINE OVER-SPEED WARNING (35) ................................................................................................................. 148
0190-12 PRIMARY ENGINE SPEED LOSS OF SIGNAL (34) ............................................................................................... 148
0191-07 TRANSMISSION NOT RESPONDING (68)............................................................................................................. 149
0224-11 THEFT DETERRENT ACTIVE (00) ........................................................................................................................ 149
0224-14 THEFT DETERRENT ACTIVE WITH ENGINE CRANKING (00) .............................................................................. 149
0231-02 J1939 DATA INCORRECT (58) ............................................................................................................................. 150
0231-11 J1939 DATA LINK FAULT (58).............................................................................................................................. 150
0231-12 J1939 DEVICE NOT RESPONDING....................................................................................................................... 151
0232-03 5 VOLT SUPPLY VOLTAGE HIGH (21) ................................................................................................................. 151
0232-04 5 VOLT SUPPLY VOLTAGE LOW (21).................................................................................................................. 151
0246-11 BRAKE PEDAL SWITCH #1 FAULT ...................................................................................................................... 152
0247-11 BRAKE PEDAL SWITCH #2 FAULT ...................................................................................................................... 152
0249-11 J1922 DATA LINK FAULT (58).............................................................................................................................. 152
0252-11 ENGINE SOFTWARE INCORRECT (59) ................................................................................................................ 153
0253-02 CHECK CUSTOMER OR SYSTEM PARAMETERS (56)......................................................................................... 153
0253-11 CHECK TRANSMISSION CUSTOMER PARAMETERS (56)................................................................................... 154
115
Troubleshooting with a (Table 141, contd)

Flash
Diagnostic Code Code Code Description of Code
110-03 Coolant Temperature voltage high

27
i01907469 110-04 Coolant Temperature voltage low
Diagnostic Codes 28 91-13 Throttle Sensor Calibration
SMCS Code: 1900 30-08 PTO Throttle signal invalid

29
30-13 PTO Throttle out of calibration
Table 141
31 84-01 Vehicle Speed loss of signal
Flash
Code Description of Code
Code 32 91-08 Throttle Position Invalid
52-11 Air Inlet Shutoff Shutdown Secondary Engine Speed loss of
64-12
34 signal
84-14 Quick Stop Occurrence
190-12 Primary Engine Speed loss of signal
171-03 Ambient Air Temperature voltage high
35 190-00 Engine Overspeed Warning
171-04 Ambient Air Temperature voltage low
84-02 Vehicle Speed signal invalid
171-11 Ambient Air Temperature Data Lost
00
36 84-08 Vehicle Speed signal out of range
224-11 Theft Deterrent Active
84-10 Vehicle Speed signal rate of change
Theft Deterrent Active with Engine
224-14
Cranking Intake Manifold Air Temperature
105-03
voltage high
246-11 Brake Pedal Switch #1 Fault 38
Intake Manifold Air Temperature
247-11 Brake Pedal Switch #2 Fault 105-04
voltage low
01 71-00 Idle Shutdown Override 41 84-00 Vehicle Overspeed Warning
111-02 Coolant Level signal invalid Primary to Secondary Engine Speed
22-11
12 111-03 Coolant Level voltage high Signal Calibration
42
111-04 Coolant Level voltage low Engine Speed Signal Calibration Not
22-13
Performed
174-03 Fuel Temperature voltage high
13 100-01 Low Oil Pressure Warning
174-04 Fuel Temperature voltage low 46
100-11 Very Low Oil Pressure
121-05 Low/High Retarder current low
71-01 Idle Shutdown
121-06 Low/High Retarder current high 47
14 71-14 PTO Shutdown
122-05 Meal/High Retarder current low
51 168-02 ECM Battery Power Intermittent
122-06 Meal/High Retarder current high
55 N/A No Diagnostic Code Detected
41-03 8 Volt Supply voltage high
Check Customer or System
41-04 8 Volt Supply voltage low 253-02
Parameters
21 56
232-03 5 Volt Supply voltage high Check Transmission Customer
253-11
Parameters
232-04 5 Volt Supply voltage low
231-11 J1939 Data Link Fault
100-03 Oil Pressure voltage high 58
24 249-11 J1922 Data Link Fault
100-04 Oil Pressure voltage low
59 252-11 Engine Software Incorrect
102-00 Excessive Boost Pressure
110-00 High Coolant Temperature Warning
25 102-03 Boost Pressure voltage high 61
110-11 Very High Coolant Temperature
102-04 Boost Pressure voltage low
111-01 Low Coolant Level Warning
108-03 Barometric Pressure voltage high 62
26 111-11 Very Low Coolant Level
108-04 Barometric Pressure voltage low
(continued)
(continued
116
(Table 141, contd) i01901799
Flash
Code Code Description of Code 0001-11 Cylinder #1 Injector
105-00 High Intake Manifold Air Temperature
current fault (72)
Warning
64 SMCS Code: 1290-038
105-11 Very High Intake Manifold Air
Temperature Conditions Which Generate This Code:
65 174-00 High Fuel Temperature Warning
The ECM detects one of the following items after
54-05 Auxiliary Output #06 current low attempting to operate the injector:
66
54-06 Auxiliary Output #06 current high
• A low current condition (open circuit) exists in the
55-05 AuxiliaryOutput #07 current low wiring for the No. 1 cylinder injector solenoid.
67
55-06 Auxiliary Output #07 current high • A high current condition (short circuit) in the
injector solenoid for the No. 1 cylinder exists.
68 191-07 Transmission Not Responding
System Response:
71 43-02 Key Switch Fault
1-11 Cylinder #1 Injector current fault The ECM will log the diagnostic code and the ECM
72 will trigger a snapshot. The check engine lamp will
2-11 Cylinder #2 Injector current fault
illuminate while this diagnostic code is active. The
3-11 Cylinder #3 Injector current fault automatic "Cylinder Cutout Test" will not work when
73 there is an active diagnostic code.
4-11 Cylinder #4 Injector current fault
5-11 Cylinder #5 Injector current fault Possible Performance Effect:
74
6-11 Cylinder #6 injector current fault The injector may not operate while the diagnostic
codes are active. The following conditions may
exist:
i01501859
No Diagnostic Code Detected • Engine misfires
(55) • Low power
SMCS Code: 1900 Troubleshooting:
Conditions Which Generate This Code: Perform the following diagnostic procedure:
"Injector Solenoid Circuit - Test"
A Flash Code 55 indicates that the system has not
detected any system faults since the last powerup. Results:
System Response: • OK - STOR
This code will not appear on a service tool. The

check engine lamp is used to display the flash iO1901879
code. For more information on flash codes, refer

to Troubleshooting, "Check Engine Lamp Circuit -
0002-11 Cylinder #2 Injector
Test". current fault (72)
Troubleshooting: SMCS Code: 1290-038
There are no problems that require troubleshooting. Conditions Which Generate This Code:
Results: The ECM detects one of the following items after

attempting to operate the injector:
• OK - STOR
wiring for the No. 2 cylinder injector solenoid.
117
• A high current condition (short circuit) in the • Engine misfires

• Low power
System Response:
Troubleshooting:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will Perform the following diagnostic procedure:
illuminate while this diagnostic code is active. The "Injector Solenoid Circuit - Test"
automatic "Cylinder Cutout Test" will not work when
there is an active diagnostic code. Results:
Possible Performance Effect: • OK - STOR
The injector may not operate while the diagnostic

i01901988
exist: 0004-11 Cylinder #4 Injector
• Engine misfires current fault (73)
• Low power SMCS Code: 1290-038
Troubleshooting: Conditions Which Generate This Code:
Perform the following diagnostic procedure: The ECM detects one of the following items after
"Injector Solenoid Circuit - Test" attempting to operate the injector:
Results: • A low current condition (open circuit) exists in the

• OK - STOR
• A high current (short circuit) in the injector
solenoid for the No. 4 cylinder exists.
i01901960
0003-11 Cylinder #3 Injector System Response:
current fault (73) The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
SMCS Code: 1290-038 illuminate while this diagnostic code is active. The
Conditions Which Generate This Code: there is an active diagnostic code.
The ECM detects one of the following items after Possible Performance Effect:
• A low current condition (open circuit) exists in the codes are active. The following conditions may
wiring for the No. 3 cylinder injector solenoid. exist:
• A high current condition (short circuit) in the • Engine misfires

• Low power
System Response:
Troubleshooting:
will trigger a snapshot. The check engine lamp will Perform the following diagnostic procedure:
illuminate while this diagnostic code is active. The "Injector Solenoid Circuit - Test"
there is an active diagnostic code. Results:
Possible Performance Effect: • OK - STOR

exist:
118
i01g01999 • A high current condition (short circuit) exists in

the injector solenoid for the No. 6 cylinder.
0005-11 Cylinder #5 Injector
current fault (74) System Response:
SMCS Code: 1290-038 The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
Conditions Which Generate This Code: illuminate while this diagnostic code is active. The
The ECM detects one of the following items after there is an active diagnostic code.
Possible Performance Effect:
wiring for the No. 5 cylinder injector solenoid. The injector may not operate while the diagnostic
• A high current condition (short circuit) exists in exist:
the injector solenoid for the No. 5 cylinder.
• Engine misfires
System Response:
• Low power
will trigger a snapshot. The check engine lamp will Troubleshooting:
illuminate while this diagnostic code is active. The
automatic "Cylinder Cutout Test" will not work when Perform the following diagnostic procedure:
there is an active diagnostic code. "Injector Solenoid Circuit - Test"
Possible Performance Effect: Results:
The injector may not operate while the diagnostic • OK - STOR

exist: i01816316
• Engine misfires 0022-11 Primary to Secondary

• Low power Engine Speed Signal
Calibration (42)
Troubleshooting:
SMCS Code: 1912-038
Perform the following diagnostic procedure:
"Injector Solenoid Circuit - Test" Conditions Which Generate This Code:
Results: The ECM detects the following conditions:
• OK - STOR • A timing calibration has been successfully

completed.
i01902006
• The primary speed/timing sensor and the
0006-11 Cylinder #6 Injector secondary speed/timing sensor are off by more
than 3 degrees.
current fault (74)
System Response:
SMCS Code: 1290-038
The ECM will use the default timing.
Conditions Which Generate This Code:
The ECM detects one of the following items after
attempting to operate the injector: The engine may run rough when this code is active.
119
Troubleshooting: Test Step 3. Cylinder Head

Test Step 1, Engine Overspeed A. Determine whether the cylinder head was
removed.
A. Check the ECM for indications of an engine
overspeed. B. If the cylinder head was removed, the backlash
for the camshaft may be out of the specification.
B. If there are indications of an engine overspeed,
check the cluster gear for proper alignment. C. Check the backlash for the camshaft. Refer to
Also check the cluster gear for damage. Refer Testing and Adjusting, "Gear Group (Front) -
to Testing and Adjusting, "Gear Group (Front) Time".
- Time".
Expected Result:
Expected Result:
The backlash for the camshaft should be within
The cluster gear is properly aligned and there is no specifications.
damage to the cluster gear.
Results:
Results:
• OK - Proceed to Test Step 4.
• Not OK - The backlash for the camshaft is not
• Not OK - The cluster gear is not aligned correctly within specifications.
or there is damage to the cluster gear.
Repair: Adjust the backlash for the camshaft.
Repair: Align the cluster gear or repair the cluster
gear. Refer to Testing and Adjusting, "Gear Group
(Front) - Time".
Run the engine until the engine reaches operating
temperature. Run the engine until the engine reaches operating
temperature.
Verify that the repair eliminates the problem.
STOR
STOR
Test Step 2. Accident
Test Step 4. Engine Speed/Timing
A. Determine whether the vehicle has been involved Sensors
in an accident.
A. Check the engine speed/timing sensors for
If the vehicle was involved in an accident, then proper installation. The engine speed/timing
the cluster gear may have been damaged. sensors can not be interchanged.
B. Check the cluster gear for damage. B. Verify that the sensor wires are connected
properly. Refer to the electrical schematic for
Expected Result: proper wiring. Make sure that the positive
terminal on the ECM is connected to the positive
The cluster gear is not damaged. terminal on the engine speed/timing sensors.
Also, make sure that the negative terminal on the
Results: ECM is connected to the negative terminal on
the engine speed/timing sensors.
Expected Result:
• Not OK - There is damage to the cluster gear.
The engine speed/timing sensors are properly
Repair: Repair the cluster gear. installed. Also, the engine speed/timing sensors are
wired correctly.
Run the engine until the engine reaches operating
temperature. Results:
Verify that the repair eliminates the problem. • OK
STOR
120
Repair: Refer to Troubleshooting, "Engine i01852956

Speed/Timing Sensor Circuit - Test".
0030-08 PTO Throttle signal
STOR invalid (29)
• Not OK - There is a problem with the installation SMCS Code: 1913-038
or the wiring of the engine speed/timing sensors.
Repair: Install the sensors properly or repair the
wiring. The ECM detects the following conditions:
Run the engine until the engine reaches operating • The "PTO Configuration" is programmed to
temperature. "Remote Throttle".
Verify that the repair eliminates the problem. • The ECM is not receiving a valid signal from the
PTO throttle.
STOR
• The ECM has been powered for at least three
i01816317
seconds.
0022-13 Engine Speed Signal Note: If the "PTO Configuration" is programmed to

"Remote Throttle", the ECM must receive a proper
Calibration Not Performed (42) signal from the remote throttle at all times. The
remote throttle signal must be present even when
SMCS Code: 1912-038 the PTO ON/OFF switch is in the OFF position.
Conditions Which Generate This Code: System Response:
The ECM detects the following conditions: The ECM returns the engine to low idle when the
problem is detected. "DIAG" will be displayed next
• A timing calibration has never been performed to the status for "Throttle Position" on the electronic
on a new ECM or the timing is off by more than service tool.
3 degrees.
System Response:
The engine will remain at low idle while the
The ECM uses default timing. diagnostic code is active.
Possible Performance Effect: Troubleshooting:
The engine may run rough or the engine may emit Perform the following diagnostic procedure:
white smoke in the exhaust. "Remote PTO Accelerator Position Sensor Circuit -
Test"
Troubleshooting:
Results:
Perform the following diagnostic procedure: "Engine
Speed/Timing Sensor - Calibrate" • OK - STOR
Results:
i01852958
• OK - STOR
0030-13 PTO Throttle out of
calibration (29)
SMCS Code: 1913-038
The ECM detects the following conditions:

121
• The duty cycle of the signal for the PTO throttle is Note: The 8 volt supply provides power to the
less than 5 percent or more than 95 percent for accelerator pedal position sensor.
more than two seconds.
Troubleshooting:
• The PTO Configuration is programmed to "Remote
Throttle". Perform the following diagnostic procedure:
"Accelerator Pedal (Throttle) Position Sensor Circuit
• The ECM has been powered for atleastthree - Test"
seconds.
Results:
Sys~m Response:
• OK - STOR
The ECM returns the engine to low idle when the
problem is detected. "DIAG" will be displayed next
i01901712
to the status for "Throttle Position" on the electronic
service tool. 0041-04 8 Volt Supply voltage
Possible Performance Effect: low (21)
The engine will remain at low idle while the SMCS Code: 5574-038
diagnostic code is active.
Troubleshooting:
Note: The Remote Accelerator Pedal Position
Sensor can not be calibrated. • The 8 volt supply is less than 7.5 VDC for more
than one second.
"Remote PTO Accelerator Position Sensor Circuit - • The ECM has been powered for more than three
Test" seconds.
Results: System Response:
• OK - STOR An active diagnostic code may not cause any

noticeable effect on engine response unless the
voltage drops below 6.5 VDC.
i01901711

0041-03 8 Volt Supply voltage
high (21) The engine may be limited to Low Idle.
SMCS Code: 5574-038 Note: The 8 volt supply provides power to the
Troubleshooting:
• The 8 volt supply is more than 8.5 VDC for more "Accelerator Pedal (Throttle) Position Sensor Circuit
than one second. - Test"
• The ECM has been powered for more than three Results:
seconds.
• OK - STOR
System Response:
i01901710
An active diagnostic code may not cause any
noticeable effect on engine response unless the
voltage is above 12 or 13 VDC.
0043-02 Key Switch Fault (71)
SMCS Code: 1408-038; 1553-038
The engine may be limited to low idle.
The ECM detects the following condition:
122
• The key switch was rapidly cycled at least three • Engine speed is greater than 2500 rpm.
times within the last second.
• "Air Inlet Shutoff Relay Control" is programmed
This indicates that the battery circuit to the key to J2/P2:13.
switch has an intermittent condition or a low battery
condition while the engine is running. • There is no detected vehicle speed.
Note: This code can be generated by rapidly • There are no active vehicle speed faults.
cycling the key switch. Some control modules on the
vehicle require this action in order to prompt flash • All required interlocks are set.
codes. If this occurs, clear the logged diagnostic
codes in order to prevent future confusion or an System Response:
incorrect diagnosis.
The ECM will disable the unit injectors and the ECM
Note: This code can also be generated when an will activate the air inlet shutoff relay. "J2/P2:13 Air
attempt is made in order to restart the engine Inlet Shutoff Relay Control ON" will be displayed
immediately after a shutdown. The engine may not next to the status for "Air Inlet Shutoff Relay Control"
start if the engine speed did not reach 0 rpm prior on the electronic service tool.
to the restart.
System Response:
The engine will shut down.
This response depends on the amount of time that
occurs in the fault mode. Troubleshooting:
The electronic service tool will display the state of Talk to t h e O p e r a t o r

the key switch on the status screen. The Check
Engine Lamp and the Warning Lamps may come on Determine the reason for the engine overspeed.
as if the key switch was turned on and the engine
started. Results:
Possible Performance Effect: • OK - The reason for the engine overspeed was
determined. STOP.
The engine may experience burps in engine rpm,
and engine shutdowns that are intermittent or • Not OK - The reason for the engine overspeed
incomplete. The ECM may stop the fuel injection was not determined.
process.
Repair: If there is a problem with the Air Inlet
Troubleshooting: Shutoff circuit, refer to Troubleshooting, "Air Inlet
Shutoff Circuit - Test".
Perform the following diagnostic procedure: "Ignition
Key Switch Circuit and Battery Supply Circuit - Test" STOR
Results:
i01855346
• OK - STOR 0054-05 Auxiliary Output #06

i01854999
current low (66)
SMCS Code: 1901-038
0052-11 Air Inlet Shutoff
Shutdown (00) Conditions Which Generate This Code:
SMCS Code: 1078-038 The ECM detects the following conditions:
Conditions Which Generate This Code: • There is a low current condition (open circuit) in
the circuit for the lockout solenoid for more than
This code indicates that the engine was shutdown two seconds.
due to an engine overspeed condition.
• The "Transmission Style" is programmed to "Eaton
The ECM detects the following conditions: Top 2".
123
System Response: i01855453
The solenoid that is currently enabled will remain 0055-05 Auxiliary Output #07
in the ON position until neutral is detected.
Then manual operation occurs until the system
current low (67)
powers down. Manual operation is defined as both SMCS Code: 1901-038
solenoids OFE
The ECM disables the Eaton Top 2 mode.
• There is a low current condition (open circuit) in
Troubleshooting: the circuit for the shift solenoid.
Perform the following diagnostic procedure: "Eaton • The "Transmission Style" is programmed to "Eaton
Top 2 Transmission Circuit - Test" Top 2".
Results: System Response:
• OK - STOR The solenoid that is currently enabled will remain
i01855368
powers down. Manual operation is defined as both
0054-06 Auxiliary Output #06 solenoids OFE
current high (66) Possible Performance Effect:
SMCS Code: 1901-038 The ECM disables the Eaton Top 2 mode.
Conditions Which Generate This Code: Troubleshooting:
The ECM detects the following conditions: Perform the following diagnostic procedure: "Eaton
Top 2 Transmission Circuit - Test"
• There is a high current condition (short circuit) in
the circuit for the lockout solenoid for more than Results:
two seconds.
• OK - STOR
Top 2".
i01855454
System Response:
0055-06 Auxiliary Output #07
The solenoid that is currently enabled will remain
current high (67)
Then manual operation occurs until the system SMCS Code: 1901-038
solenoids OFE Conditions Which Generate This Code:
Possible Performance Effect: The ECM detects the following conditions:
The ECM disables the Eaton Top 2 mode. • There is a high current condition (short circuit) in
the circuit for the shift solenoid.
Troubleshooting:
Perform the following diagnostic procedure: "Eaton Top 2".
Top 2 Transmission Circuit - Test"
System Response:
Results:
The solenoid that is currently enabled will remain
• OK - STOR in the ON position until neutral is detected.
solenoids OFE
124
Possible Performance Effect: i01857555
The ECM disables the Eaton Top 2 mode. 0071-00 Idle Shutdown
Troubleshooting:
Override (01)
SMCS Code: 1901-038
Perform the following diagnostic procedure: "Eaton
Top 2 Transmission Circuit - Test" Conditions Which Generate This Code:
Results: The ECM detects one of the following conditions:
• OK - STOR The "Allow Idle Shutdown Override" parameter is
programmed to "Yes" and the status of the brake
i01905821
switch or the clutch switch changes.
0064-12 Secondary Engine The "Allow Idle Shutdown Override" parameter

is programmed to "J1587 Outside Temp Based"
Speed loss of signal (34) or "Outside Temperature Based". The outside
temperature is above the maximum programmed
SMCS Code: 1912-038 temperature or the outside temperature is below
the minimum programmed temperature.
The ECM also detects the following conditions:
• The idle shutdown timer is within the final 90
• The signal for the secondary engine speed/timing seconds.
sensor is intermittent or lost.
• The "Idle Shutdown Time" parameter is
System Response: programmed to at least three minutes.
The engine may misfire or the engine may run rough System Response:
during starting. The check engine lamp will not be
illuminated for this code unless the code has been The idle shutdown timer stops counting.
active for ten hours. "OVERRIDE" will be displayed next to the status
for "Idle Shutdown Status" on the electronic service
Possible Performance Effect: tool.
There should not be a noticeable change in Note: The idle shutdown timer will not begin
engine response unless the signal for the primary counting again for shutdown until the vehicle is
engine speed/timing sensor is lost. The engine moved and the accelerator pedal is depressed.
will shut down if both the signal for the primary
engine speed/timing sensor and the signal for the Customer passwords are required to clear this
secondary engine speed/timing sensor are lost. diagnostic code.
Troubleshooting: Possible Performance Effect:
Perform the following diagnostic procedure: "Engine None
Speed/Timing Sensor Circuit - Test"
Troubleshooting:
Results:
Perform the following diagnostic procedure: "Idle
• OK - STOR Shutdown Timer - Test"
Results:
• OK - STOR
125
i01857558 • The "PTO Shutdown Time" parameter is

programmed to at least three minutes.
0071-01 Idle Shutdown (47)
System Response:
SMCS Code: 1901-038
The ECM remains powered after the engine
Conditions Which Generate This Code: shutdown. "NOT ACTIVE" will be displayed next to
the status for "PTO Shutdown" on the electronic
The ECM detects the following conditions: service tool.
• The idle shutdown timer has expired and the Customer Passwords are required to clear this
engine has shut down. diagnostic code.
• The "Idle Shutdown Time" parameter is Possible Performance Effect:
programmed to at least three minutes.
The engine is shut down.
• Vehicle speed is 0 mph.
Troubleshooting:
• Coolant temperature is greater than 38 °C
(100.4 °F). Perform the following diagnostic procedure: "PTO
Shutdown Timer - Test"
System Response:
Results:
The ECM remains powered after the engine
shutdown. "COUNTING" will be displayed next • OK - STOR
to the status for "Idle Shutdown Status" on the
electronic service tool.
i01863221
Customer Passwords are required to clear this
diagnostic code. 0084-00 Vehicle Overspeed
Warning (41)
SMCS Code: 7463-038
The engine is shut down.
Troubleshooting:
The ECM detects one of the following conditions:
Perform the following diagnostic procedure: "Idle
Shutdown Timer - Test" • The "Soft Vehicle Speed Limit" parameter is
programmed to "No" and the vehicle speed
Results: exceeds the programmed "Vehicle Speed Limit"
by more than 10 MPH for more than 20 seconds.
• OK - STOR
The "Soft Vehicle Speed Limit" parameter is
programmed to "Yes" and the vehicle speed
i01857561
exceeds the programmed "Vehicle Speed Limit"
0071-14 PTO Shutdown (47) by more than 15 MPH for more than 20 seconds.
SMCS Code: 1901-038 System Response:
Conditions Which Generate This Code: The ECM will not energize the injector solenoids
while the diagnostic code is active. "VEHICLE
The ECM detects the following conditions: SPEED LIMIT" will be displayed on the status
screen when the vehicle speed limit is exceeded.
• The timer for the PTO has expired and the engine
has shut down. Customer passwords are required to clear this code.
• The PTO On/Off switch is in the ON position. Possible Performance Effect:
• The "PTO Configuration" parameter is Injection is disabled until the vehicle speed falls
programmed to "Cab Switches", "Remote below the programmed "Vehicle Speed Limit".
Switches", or "Remote Throttle".
126
Troubleshooting: Possible Performance Effect:
This diagnostic code does not necessarily indicate The ECM will limit engine rpm to the programmed
that there is an electronic problem. If the vehicle "VSL Protection".
speed calibration is wrong, perform the following
procedure: Note: A fuel system restriction has been known to
cause this diagnostic code although this occurrence
Perform the following diagnostic procedure: "Vehicle is not common. This situation exists because the
Speed Circuit - Calibrate" injectors are unable to provide sufficient fuel in
order to achieve the desired rpm under normal load
Results: conditions. Because the ECM cannot reach the
desired rpm under the normal load conditions, the
• OK - STOR ECM suspects that the vehicle is under load. This
should only occur when the vehicle is in motion.
i01863422
Troubleshooting:
0084-01 Vehicle Speed loss of Check the fuel pressure in order to ensure that
signal (31) a fuel system restriction is not the cause of the
problem when the vehicle is not moving.
SMCS Code: 7463-038
Perform the following diagnostic procedure: "Vehicle
Conditions Which Generate This Code: Speed and Speedometer Circuit - Test"
The ECM detects the following conditions: Results:
• The vehicle speed signal indicates that the • OK - STOP.

vehicle speed is 0 MPH.
• Engine speed is greater than the programmed i01863534

"VSL Protection" minus 100 RPM for at least 0.06
seconds.
0084-02 Vehicle Speed signal
invalid (36)
• Desired engine speed is greater than the
programmed "VSL Protection". SMCS Code: 7463-038
• The change in engine speed is less than 133 Conditions Which Generate This Code:
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 vehicle speed signal indicates a constant
MPH.
The following condition must also be met if
the "Vehicle Speed Input" is programmed to • Engine speed is greaterthan 950 rpm for atleast
"J 1939-ABS" or "J 1939-Trans". 0.06 seconds.
• The message for vehicle speed is not received • The "VSL Protection" parameter is programmed
over the J1939 data link for more than 0.5 to a value that is less than 2120 rpm.
seconds.
System Response:
Sys~m Response:
"DIAG" will be displayed next to the status for
The ECM will limit engine rpm to the programmed "Vehicle Speed" on the electronic service tool.
"VSL Protection". If the ECM is providing the
speedometer signal, the speedometer will show 0 Possible Performance Effect:
rpm. "DIAG" will be displayed next to the status for
"Vehicle Speed" on the electronic service tool. Engine rpm is limited to the programmed "VSL
Protection" for one hour.
127
Troubleshooting: i01863539
This code may indicate tampering with the vehicle 0084-10 Vehicle Speed signal
speed circuit. rate of change (36)
Perform the following diagnostic procedure: "Vehicle SMCS Code: 7463-038
Speed and Speedometer Circuit - Test"
Results:
• OK - STOR
• The vehicle speed signal changes more than
i01863538
5 MPH on eight consecutive readings in three
seconds.
0084-08 Vehicle Speed signal
• The engine speed is greater than the programmed
out of range (36) "VSL Protection" minus 100 rpm.
SMCS Code: 7463-038 • The "VSL Protection" parameter is programmed
to a value that is less than 2120 rpm.
Note: If the ABS is the source of the vehicle speed,
The ECM detects the following conditions: the ABS must not be active.
• The vehicle speed signal indicates that vehicle System Response:
speed is greater than 127.5 MPH for more than
two seconds. "DIAG" will be displayed next to the status for
"Vehicle Speed" on the electronic service tool. The
• The "VSL Protection" parameter is programmed check engine lamp will illuminate.
to a value that is less than 2120 rpm.
System Response:
Engine rpm is limited to the programmed "VSL
Vehicle speed is set to 0 km/h (0 mph). If the Protection" for eight seconds.
ECM is providing the speedometer signal, the
speedometer will not display vehicle speed. "DIAG" Troubleshooting:
will be displayed next to the status for "Vehicle
Speed" on the electronic service toot. Perform the following diagnostic procedure: "Vehicle
Speed and Speedometer Circuit - Test"
Results:
The ECM will limit the engine speed to the
programmed "VSL Protection". • OK - STOR
Troubleshooting:
i01863535
Perform the following diagnostic procedure: "Vehicle
Speed and Speedometer Circuit - Test" 0084-14 Quick Stop
Results:
Occurrence
SMCS Code: 7463-038
• OK - STOR
• The vehicle speed slows at a rate that exceeds

the "Quick Stop Rate" that is programmed.
• The service brake is applied.

128
System Response: Possible Performance Effect:
The ECM records the engine speed, vehicle speed, The engine will remain at low idle while the
the throttle position, cruise control status, clutch diagnostic code is active.
switch status and brake switch status.
Troubleshooting:
Customer passwords are required to clear this
diagnostic code. Perform the following diagnostic procedure:
"Accelerator Pedal (Throttle) Position Sensor Circuit
Possible Performance Effect: - Test"
None Results:
Troubleshooting: • OK - STOP.
This diagnostic code does not represent an

i01864488
electronic system fault.
An excessive number of occurrences may be

0091-13 Throttle Position out
caused by the following circumstance: of calibration (32)
• The parameter for the "Quick Stop Rate" may be SMCS Code: 1913-038
set too low.
Note: This setting can be affected by the load on
the vehicle. If the vehicle is operated without a The ECM detects the following conditions:
trailer or with no load, the vehicle will stop faster
than the same vehicle with a heavy load. • The duty cycle for the accelerator pedal position
sensor is less than 5 percent or the duty cycle
Expected Result: is greater than 95 percent for more than two
seconds.
Results:
• OK - STOR seconds.
System Response:
i01864487
The ECM sets "Throttle Position" to 0%. "DIAG" will
0091-08 Throttle Position be displayed next to the status for "Throttle Position"
Invalid (32) on the electronic service tool.
SMCS Code: 1913-038 Possible Performance Effect:
Conditions Which Generate This Code: The engine will remain at low idle while the
Troubleshooting:
• The signal frequency from the accelerator pedal
position sensor is less than 150 Hz or the signal Perform the following diagnostic procedure:
frequency is greater than 1050 Hz for more than "Accelerator Pedal (Throttle) Position Sensor Circuit
two seconds. - Test"
• The ECM has been powered for at least three Results:

seconds.
• OK - STOP.
System Response:
The ECM sets the "Throttle Position" to 0%. "DIAG"

will be displayed next to the status for "Throttle
Position" on the electronic service tool.
129
i01907616 System Response:

0100-01 Low Oil Pressure The Caterpillar Electronic Technician (Cat ET) will
Warning (46) display "LOW OIL PRESSURE" and "DIAG" next
to the status for "Engine Oil Pressure". The check
SMCS Code: 1924-038 engine lamp and the warning lamp will illuminate.
Conditions Which Generate This Code: Customer passwords are required to clear this
diagnostic code.
• The engine oil pressure is below the trip line in
Illustration 32 or Illustration 33 for more than eight None
seconds.
Troubleshooting:
Test Step 1. Check the Engine Oil Level
A. Check the engine oil level.
Expected Result:
v
L
The engine oil level is OK.
Results:
~5 • OK - T h e engine oil level is OK. Proceed to Test
1(
Step 2.
I..iJ
• Not OK - The engine oil level is low.
Repair: Add engine oil to the proper level. Refer

to the Operation and Maintenance Manual for
500 800 1000 1200 1400 1700 2100 more information.
Engine Speed (rpm)
STOP.
C-10 and C -12 low oil pressure Test Step 2. Verify Proper Sensor
Installation
305- ~ ........ A. Check the installation of the engine oil pressure

291- sensor.
264 -
B. Check the wiring of the engine oil pressure
sensor. Refer to the Electrical Schematic for the
v 210- proper wiring. Ensure that all of the wires and
connectors are properly connected.
158-
13._ Expected Result:
The sensor is properly installed and the wiring is
-~, correct.
LJ
Results:
• OK - T h e sensor is properly installed. Proceed
to Test Step 3.
500 700 1000 1200 1600 2000 2200
Engine Speed (rpm)
• Not OK - The sensor is not installed properly.
g00997505
Illustration 33
3406E, C-15, C-16, and C-18 low oil pressure
Repair: Install the engine oil pressure sensor
properly. Repair the wiring and/or the connectors
to the sensor.
130
Verify that the repair eliminates the problem. • Not OK - Both - The boost pressure and the
engine oil pressure are greater than 10 kPa
STOP. (2 psi). Proceed to Test Step 5.
Test Step 3. Check for Active Diagnostic Test Step 5. Check the Supply Voltage to
Codes the Pressure Sensors
A. Connect Cat ET to the data link connector. A. Disconnect the barometric pressure sensor
(atmospheric pressure), the boost pressure
B. Check for active diagnostic codes that are sensor, and the engine oil pressure sensor.
related to the barometric pressure sensor
(atmospheric pressure) or the boost pressure B. Turn the key switch to the ON position.
sensor.
C. Measure the voltage between terminal A (Engine
Expected Result: Pressure Sensor +5V) and terminal B (Engine
Pressure Sensor Common) of each pressure
There are no diagnostic codes that are related sensor connector on the engine harness.
to the barometric pressure sensor (atmospheric
pressure) or the boost pressure sensor. Expected Result:
Results: The voltage is 5.0 + 0.16 VDC.
• OK -There are no diagnostic codes. Proceed Results:

to Test Step 4.
• OK - T h e voltage is within the range.
• Not OK - There is a diagnostic code that
is related to the barometric pressure sensor Repair: Reconnect the engine oil pressure sensor
(atmospheric pressure) and/or the boost pressure and the boost pressure sensor.
sensor.
Temporarily connect a new barometric pressure
Repair: Troubleshoot the diagnostic code before sensor (atmospheric pressure).
continuing with this procedure.
If the new sensor fixes the problem, reconnect
STOP. the suspect sensor.
Test Step 4. Check the Status Screen If the problem returns, permanently replace the
sensor.
A. Turn the key switch to the ON position. The
engine should be off. Verify that the repair eliminates the problem.
B. Monitor the status for "Boost Pressure" and STOP.

"Engine Oil Pressure" on Cat ET.
• Not OK - There is a problem with the 5 volt
Expected Result: supply.
"Boost Pressure" and "Engine Oil Pressure" should Repair: Check the J2/P2 ECM connector and the
be less than 10 kPa (2 psi). sensor connectors for corrosion and moisture.
Results: Check the 5 volt supply wire. Verify that the wire
is not cut and that the wire is completely inserted
• OK - T h e boost pressure and the engine oil into the connectors for the pressure sensors on
pressure are less than 10 kPa (2 psi). Proceed the engine harness.
to Test Step 6.
• Not OK - Boost Pressure - T h e boost pressure
is greater than 10 kPa (2 psi). Proceed to Test STOR
Step 8.
Test Step 6. Install a Pressure Gauge
• Not OK - Engine Oil Pressure - The engine oil
pressure is greater than 10 kPa (2 psi). Proceed A. Remove the engine oil pressure sensor.
to Test Step 9.
131
B. Install a 1U-5470 Engine Pressure Group into • Not OK - The engine oil pressure is lower than
the oil gallery with a Tee fitting in the port for the the trip line on the oil pressure map. There is a
engine oil pressure sensor. mechanical problem.
C. Connect the engine oil pressure sensor to the Repair: Refer to Testing and Adjusting, "Engine
Tee fitting. Oil Pressure - Test".
D. Turn the key switch to the ON position. STOR
E. Monitor the status for "Engine Oil Pressure" on Test Step 8. Check the Supply Voltage to
Cat ET. the Boost Pressure Sensor
F. Start the engine and run the engine at low idle. A. Disconnect the boost pressure sensor.
G. Compare the pressure reading on the gauge to B. Turn the key switch to the ON position.
the pressure reading on Cat ET.
H. Monitor the status screen and the gauge while Pressure Sensor +5V) and terminal B (Engine
you increase the engine speed. Pressure Sensor Common) of the connector for
the boost pressure sensor on the engine harness.
Expected Result:
Expected Result:
The gauge and the status screen are within 35 kPa
(5.0 psi) of each other. The voltage is 5.0 + 0.16 VDC.
Results: Results:
• OK - T h e sensor is functioning properly. Proceed • OK - T h e voltage is within the range.
to Test Step 7.
Repair: Temporarily connect a new boost pressure
• Not OK - T h e sensor is not functioning properly. sensor.
Repair: Temporarily install a new engine oil If the new sensor fixes the problem, reconnect
pressure sensor. the suspect sensor.
If the new sensor repairs the problem, reinstall If the problem returns, permanently replace the
the suspect sensor. sensor.
If the problem returns, replace the sensor. Verify that the repair eliminates the problem.
Verify that the repair eliminates the problem. STOR
STOR • 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 32 or Check the 5 volt supply wire. Verify that the wire
Illustration 33. is not cut and that the wire is completely inserted
into the connector for the boost pressure sensor
Expected Result: on the engine harness.
The engine oil pressure is above the trip points in Verify that the repair eliminates the problem.
Illustration 32 or Illustration 33.
STOR
Results:
Test Step 9. Check the Supply Voltage to
• OK - The engine oil pressure appears to be OK the Engine Oil Pressure Sensor
at this time. STOR
A. Disconnect the engine oil pressure sensor.
B. Turn the key switch to the ON position.

132
C. Measure the voltage between terminal A (Engine • The engine is not running or the engine coolant
Pressure Sensor +5V) and terminal B (Engine temperature is greater than 38 °C (100.4 °F).
Pressure Sensor Common) of the connector for
the engine oil pressure sensor on the engine System Response:
harness.
The ECM will default to 600 kPa (87.0 psi) for engine
Expected Result: oil pressure. "DIAG" will be displayed next to the
status for "Engine Oil Pressure" on the electronic
The voltage is 5.0 + 0.16 VDC. service tool.
Results: Possible Performance Effect:
• OK - T h e voltage is within the range. The engine may experience low power when this
Repair: Temporarily connect a new engine oil
pressure sensor. Troubleshooting:
If the new sensor fixes the problem, reconnect Perform the following diagnostic procedure: "Engine
the suspect sensor. Pressure Sensor Open or Short Circuit - Test"
If the problem returns, permanently replace the Results:

sensor.
• OK - STOR
i01814729
STOR
• Not OK - There is a problem with the 5 volt

0100-04 Oil Pressure voltage
supply. low (24)
Repair: Check the sensor connector for corrosion SMCS Code: 1924-038
and moisture.
Check the 5 volt supply wire. Verify that the wire
is not cut and that the wire is completely inserted The ECM detects the following conditions:
into the connector for the engine oil pressure
sensor on the engine harness. • The signal voltage from the engine oil pressure
sensor is less than 0.2 VDC for more than eight
Verify that the repair eliminates the problem. seconds.
STOR • The ECM has been powered for at least two

seconds.
i01814727 • The engine is not running or atmospheric pressure
is greater than 80 kPa (11.6 psi).
0100-03 Oil Pressure voltage
high (24) System Response:
SMCS Code: 1924-038 The ECM will default to 600 kPa (87.0 psi) for engine
oil pressure. "DIAG" will be displayed next to the
Conditions Which Generate This Code: status for "Engine Oil Pressure" on the electronic
service tool.
• The signal voltage from the engine oil pressure
sensor is greater than 4.8 VDC for more than The engine may experience low power when this
eight seconds. code is active.
• The ECM has been powered for at least two

seconds.
133
Troubleshooting:

Pressure Sensor Open or Short Circuit - Test"
Results:
13..
• OK - STOR
i01907618
0100-11 Very Low Oil Pressure o

(46)
SMCS Code: 1924-038

500 700 10001200 1600 2200
Engine Speed (rpm)
• The engine oil pressure is below the trip line in Illustration 35 g00998096
Illustration 34 or Illustration 35 for more than eight
3406E, C-15, C-16, and C-18 map for very low oil pressure
seconds.
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
Q_
engine lamp and the warning lamp will illuminate.

diagnostic code.
L
EL
~5
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
500 800 1000 1200 1400 1700 2200 shutdown after this code has been active for 30
Engine Speed (rpm) seconds.
Note: If "Engine Monitoring" is programmed to
C-10 and C-12 map for very low oil pressure "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:
The engine oil level is OK.
Results:
• OK - T h e engine oil level is OK. Proceed to Test

Step 2.
134
• Not OK - The engine oil level is low. Not OK - There is a diagnostic code that
is related to the barometric pressure sensor
Repair: Add engine oil to the proper level. Refer (atmospheric pressure) and/or the boost pressure
to the Operation and Maintenance Manual for sensor.
more information.
Repair: Troubleshoot the diagnostic code before
STOR continuing with this procedure.
Test Step 2. Verify Proper Sensor STOR

Installation
Test Step 4. Check the Status Screen
A. Check the installation of the engine oil pressure
sensor. A. Turn the key switch to the ON position. The
engine should be off.
B. Check the wiring of the engine oil pressure
sensor. Refer to the Electrical Schematic for the B. Monitor the status for "Boost Pressure" and
proper wiring. Ensure that all of the wires and "Engine Oil Pressure" on Cat ET.
connectors are properly connected.
Expected Result:
Expected Result:
"Boost Pressure" and "Engine Oil Pressure" should
The sensor is properly installed and the wiring is be less than 10 kPa (2 psi).
correct.
Results:
Results:
OK - T h e boost pressure and the engine oil
• OK - T h e sensor is properly installed. Proceed pressure are less than 10 kPa (2 psi). Proceed
to Test Step 3. to Test Step 6.
• Not OK - T h e sensor is not installed properly, Not OK - Boost Pressure - The boost pressure
is greater than 10 kPa (2 psi). Proceed to Test
Repair: Install the engine oil pressure sensor Step 8.
properly. Repair the wiring and/or the connectors
to the sensor. Not OK - Engine Oil Pressure - The engine oil
pressure is greater than 10 kPa (2 psi). Proceed
Verify that the repair eliminates the problem. to Test Step 9.
STOR Not OK - Both - The boost pressure and the

engine oil pressure are greater than 10 kPa
Test Step 3. Check for Active Diagnostic (2 psi). Proceed to Test Step 5.
Codes
A. Connect Cat ET to the data link connector. the Pressure Sensors
B. Check for active diagnostic codes that are A. Disconnect the barometric pressure sensor
related to the barometric pressure sensor (atmospheric pressure), the boost pressure
(atmospheric pressure) or the boost pressure sensor, and the engine oil pressure sensor.
sensor.
Expected Result:
There are no diagnostic codes that are related Pressure Sensor +5V) and terminal B (Engine
to the barometric pressure sensor (atmospheric Pressure Sensor Common) of each pressure
pressure) or the boost pressure sensor. sensor connector on the engine harness.
Results: Expected Result:
• OK -There are no diagnostic codes. Proceed The voltage is 5.0 + 0.16 VDC.
to Test Step 4.
135
Results: Results:
• OK - The voltage is within the range. • OK - T h e sensor is functioning properly. Proceed
to Test Step 7.
Repair: Reconnect the engine oil pressure sensor
and the boost pressure sensor. • Not OK - The sensor is not functioning properly.
Temporarily connect a new barometric pressure Repair: Temporarily install a new engine oil
sensor (atmospheric pressure). pressure sensor.
If the new sensor fixes the problem, reconnect If the new sensor repairs the problem, reinstall
the suspect sensor. the suspect sensor.
If the problem returns, permanently replace the If the problem returns, replace the sensor.
sensor.
STOR
STOR
Test Step 7. Compare the Readings to the
• Not OK - There is a problem with the 5 volt Oil Pressure Map
supply.
A. Compare the readings from the pressure gauge
Repair: Check the J2/P2 ECM connector and the to the oil pressure maps in Illustration 34 or
sensor connectors for corrosion and moisture. Illustration 35.
Check the 5 volt supply wire. Verify that the wire Expected Result:
into the connectors for the pressure sensors on The engine oil pressure is above the trip points in
the engine harness. Illustration 34 or Illustration 35.
Verify that the repair eliminates the problem. Results:

STOR • OK - T h e engine oil pressure appears to be OK
at this time. STOR
Test Step 6. Install a Pressure Gauge
• Not OK - The engine oil pressure is lower than
A, Remove the engine oil pressure sensor. the trip line on the oil pressure map. There is a
mechanical problem.
B. Install a lU-5470 Engine Pressure Group into
the oil gallery with a Tee fitting in the port for the Repair: Refer to Testing and Adjusting, "Engine
engine oil pressure sensor. Oil Pressure - Test".
C. Connect the engine oil pressure sensor to the STOR

Tee fitting.
D, Turn the key switch to the ON position. the Boost Pressure Sensor
E, Monitor the status for "Engine Oil Pressure" on A. Disconnect the boost pressure sensor.
Cat ET.
F, Start the engine and run the engine at low idle.
C, Measure the voltage between terminal A (Engine
G. Compare the pressure reading on the gauge to Pressure Sensor +5V) and terminal B (Engine
the pressure reading on Cat ET. Pressure Sensor Common) of the connector for
the boost pressure sensor on the engine harness.
H. Monitor the status screen and the gauge while
you increase the engine speed. Expected Result:
Expected Result: The voltage is 5.0 + 0.16 VDC.
The gauge and the status screen are within 35 kPa

(5.0 psi) of each other.
136
Results: Verify that the repair eliminates the problem.
• OK - T h e voltage is within the range. STOR
Repair: Temporarily connect a new boost pressure Not OK - There is a problem with the 5 volt
sensor. supply.
If the new sensor fixes the problem, reconnect Repair: Check the sensor connector for corrosion
the suspect sensor. and moisture.
If the problem returns, permanently replace the Check the 5 volt supply wire. Verify that the wire
sensor. is not cut and that the wire is completely inserted
into the connector for the engine oil pressure
Verify that the repair eliminates the problem. sensor on the engine harness,
STOE Verify that the repair eliminates the problem.
• Not OK - There is a problem with the 5 volt STOR

supply.
i01909510
Repair: Check the sensor connector for corrosion
and moisture. 0102-00 Excessive Boost
Check the 5 volt supply wire. Verify that the wire Pressure
into the connector for the boost pressure sensor SMCS Code: 1917-038
on the engine harness.
STOP.
• The actual boost pressure is higher than the
Test Stej0 9. Check the Supply Voltage to desired boost pressure.
the Engine Oil Pressure Sensor
System Response:
A. Disconnect the engine oil pressure sensor.
Boost pressure is set to 0 kPa (0 psi). "DIAG" will
B. Turn the key switch to the ON position. be displayed next to the status for "Boost Pressure"
on the Caterpillar Electronic Technician (Cat ET).
Pressure Sensor +SV) and terminal B (Engine Possible Performance Effect:
Pressure Sensor Common) of the connector for
the engine oil pressure sensor on the engine The engine may experience low power when the
harness. diagnostic code is active.
Expected Result: Troubleshooting:
The voltage is 5.0 + 0.16 VDC. Determine the cause of the excessive boost
pressure such as a wastegate for the turbocharger
Results: that has failed or a line for the wastegate that has
been pinched.
Results:
Repair: Temporarily connect a new engine oil
pressure sensor. • OK - STOR

the suspect sensor.
If the problem returns, permanently replace the

sensor.
137

0102-03 Boost Pressure The ECM will default to 0 kPa (0 psi) for boost
voltage high (25) pressure. The ECM will use the default torque map.
SMCS Code: 1917-038 "Boost Pressure" on the electronic service tool.
Conditions Which Generate This Code: Possible Performance Effect:
The ECM detects the following conditions: The engine will experience low power when this
• The signal voltage from the boost pressure
sensor is greater than 4.8 VDC for more than two Troubleshooting:
seconds.
• The ECM has been powered for a t l e a s t t w o Pressure Sensor Open or Short Circuit - Test"
seconds.
Results:
• The engine is not running or the rack position is
less than 50% with the engine retarder off. • OK - STOR
S y s ~ m Response: i01909721
The ECM will default to 0 kPa (0.0 psi) for boost 0105-00 High Intake Manifold
pressure. The ECM will use the default torque map.
"DIAG" will be displayed next to the status for Air Temperature Warning (64)
"Boost Pressure" on the electronic service tool.
SMCS Code: 1921-038
The engine will experience low power when this
diagnostic code is active. The ECM detects the following conditions:
Troubleshooting: • The intake manifold air temperature is greater

than 90 °C (194.0 °F) for more than four seconds.
Pressure Sensor Open or Short Circuit - Test" • The engine has been running for atleast 30
seconds.
Results:
• The engine coolant temperature is above 99 °C
• OK - STOR (210.0 °F).
System Response:
i01814738
0102-04 Boost Pressure "Intake Manifold Air Temperature" on the electronic
voltage low (25) service tool. The warning lamp will turn on if
the "Engine Monitoring Lamps" parameter is
SMCS Code: 1917-038 programmed to "Warning Lamp". The check engine
lamp will turn on if the "Engine Monitoring Lamps"
Conditions Which Generate This Code: parameter is programmed to "Option 1"
The ECM detects the following conditions: Customer passwords are required to clear this
diagnostic code.
• The signal voltage from the boost pressure sensor
is less than 0.2 VDC for more than one second. Possible Performance Effect:
• The ECM has been powered for at least two None

seconds.
Troubleshooting:
This diagnostic code indicates an excessive

temperature in the intake manifold.
138
Check the Aftercooler Possible Performance Effect:
A. Check the air-to-air aftercooler for debris and/or None

restriction to the air flow.
Troubleshooting:
Expected Result:
There are no restrictions to the air flow through the Temperature Sensor Open or Short Circuit - Test"
air-to-air aftercooler.
Results:
Results:
• OK - STOR
• OK - There are no restrictions in the air flow.
i01814165
Repair: Determine the cause of the high
temperatures. Heavy loads and high ambient air
temperatures could cause the temperature to be
0105-04 Intake Manifold Air
above the trip point. Temperature voltage low (38)
STOR SMCS Code: 1921-038
• Not OK - There are restrictions in the air flow. Conditions Which Generate This Code:
Repair: Remove the restrictions in the air flow, The ECM detects the following conditions:
Verify that the repair eliminates the problem. • The signal voltage from the intake manifold air
temperature sensor is less than 0.2 VDC for more
STOR than eight seconds.

i01814169 seconds.
0105-03 Intake Manifold Air System Response:
Temperature voltage high (38)
The ECM will default to 85 °C (185.0 °F) for the
SMCS Code: 1921-038 intake manifold air temperature. "DIAG" will be
displayed next to the status for "Intake Manifold Air
Conditions Which Generate This Code: Temperature" on the electronic service tool. The
ECM will turn on the cooling fan.
• The signal voltage from the intake manifold air
temperature sensor is greater than 4.9 VDC for None
more than eight seconds.
Troubleshooting:
• Engine coolant temperature is above -10 °C
(15.0 °F). Perform the following diagnostic procedure: "Engine
Temperature Sensor Open or Short Circuit - Test"
seconds. Results:
System Response: • OK - STOR
The ECM will default to 85 °C (185.0 °F) for the

intake manifold air temperature. "DIAG" will be
displayed next to the status for "Intake Manifold Air
Temperature" on the electronic service tool. The
ECM will turn on the cooling fan.
139
i01905825 Verify that the repair eliminates the problem.

0105-11 Very High Intake STOP.
Manifold Air Temperature (64)
i01901959
SMCS Code: 1921-038
0108-03 Barometric Pressure
voltage high (26)
SMCS Code: 1923-038
• The intake manifold air temperature is greater
than 109 °C (228 °F) for more than two seconds. Conditions Which Generate This Code:
• The engine has been running for at least 30 The ECM detects the following conditions:
seconds.
• The signal voltage from the atmospheric pressure
• The engine coolant temperature is above 99 °C sensor is greater than 4.9 VDC for more than 30
(210 °F). seconds.
System Response: • The ECM has been powered for at least two
seconds.
"Intake Manifold Air Temperature" on the electronic System Response:
service tool. The warning lamp will turn on if
the "Engine Monitoring Lamps" parameter is The ECM will default to 100 kPa (15 psi) for
programmed to "Warning Lamp". The check engine atmospheric pressure. "DIAG" will be displayed
lamp will turn on if the "Engine Monitoring Lamps" next to the status for "Atmospheric Pressure" on
is programmed to "Option 1" the electronic service tool.
Customer Passwords are required to clear this Possible Performance Effect:

diagnostic code,
The engine may experience low power while this
Possible Performance Effect: code is active.
None Troubleshooting:
Troubleshooting: Perform the following diagnostic procedure: "Engine

Check the Aftercooler
Results:
A. Check the air-to-air aftercooler for debris and/or
restriction to the air flow. • OK - STOR
Expected Result: i01901977
There are no restrictions to the air flow through the 0108-04 Barometric Pressure
air-to-air aftercooler.
voltage low (26)
Results:
SMCS Code: 1923-038
• 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
• The signal voltage from the atmospheric pressure
above the trip point.
sensor is less than 0.2 VDC for more than 30
seconds.
STOR
• Not OK - There are restrictions in the air flow.
seconds.
Repair: Remove the restrictions in the air flow.
140
• The engine is not running or the engine has been Possible Performance Effect:
running for more than ten seconds.
None
System Response:
Troubleshooting:
The ECM will default to 100 kPa (15 psi) for
atmospheric pressure. "DIAG" will be displayed Check the Cooling System
next to the status for "Atmospheric Pressure" on
the electronic service tool. Refer to Testing and Adjusting, "Cooling System -
Check".
Results:
The engine may experience low power while this
code is active. • OK - STOR
Troubleshooting:
i01814161

0110-03 Coolant Temperature
voltage high (27)
Results:
SMCS Code: 1906-038
• OK - STOR
i01907621 The ECM detects the following conditions:
0110-00 High Coolant • The signal voltage from the engine coolant
Temperature Warning (61) temperature sensor is greater than 4.9 VDC for
SMCS Code: 1906-038
• The ECM has been powered for a t l e a s t t w o
Conditions Which Generate This Code: seconds.
The ECM detects the following conditions: • The engine has been running for more than seven
minutes.
• The engine coolant temperature is greater than
103 °C (217 °F) for the C-10 or C-12. System Response:
• The engine coolant temperature is greater than The ECM will default to 90 °C (194.0 °F) for engine
108 °C (226 °F) for the 3406E, C-15, C-16 and coolant temperature. "DIAG" will be displayed next
C-18. to the status for "Engine Coolant Temperature" on
the electronic service tool. The ECM will activate
• The engine has been running at least 30 seconds. the cooling fan after this code has been active for
System Response:
"Engine Coolant Temperature" on the Caterpillar None
Electronic Technician (Cat ET). The check engine
lamp and the warning lamp will illuminate. Troubleshooting:
Note: If a high coolant temperature lamp is installed, Perform the following diagnostic procedure: "Engine
the high coolant temperature lamp will turn on Temperature Sensor Open or Short Circuit - Test"
instead of the warning lamp.
Results:
diagnostic code. • OK - STOR
141

0110-04 Coolant Temperature "DIAG" will be displayed next to the status for
voltage low (27) "Engine Coolant Temperature" on the Caterpillar
Electronic Technician (Cat ET). The check engine
SMCS Code: 1906-038 lamp and the warning lamp will illuminate.
Conditions Which Generate This Code: If a high coolant temperature lamp is installed, the
high coolant temperature lamp will turn on instead
The ECM detects the following conditions: of the warning lamp.
• The signal voltage from the engine coolant Customer passwords are required to clear this
temperature sensor is less than 0.2 VDC for more diagnostic code.
than eight seconds.
• The ECM has been powered for a t l e a s t t w o
seconds. The engine will be derated to the default torque
map and vehicle speed will be limited to 72 km/h
Sys~m Response: (45 mph).
The ECM will default to 90 °C (194.0 °F) for engine Note: If the "Engine Monitoring" parameter is
coolant temperature. "DIAG" will be displayed next programmed to "Shutdown", the engine will be
to the status for "Engine Coolant Temperature" on shutdown once this code has been active for 20
the electronic service tool. The ECM will activate seconds.
the cooling fan after this code has been active for
more than eight seconds. Note: If the "Engine Monitoring" parameter is
programmed to "Warning", the engine power is not
Troubleshooting: affected.
None Troubleshooting:
Perform the following diagnostic procedure: "Engine Check the Cooling System
Refer to Testing and Adjusting, "Cooling System -
Results: Check".
• OK - STOR Results:
• OK - STOR
i01907623
0110-11 Very High Coolant i01856577
Temperature (61) 0111-01 Low Coolant Level

SMCS Code: 1906-038 Warning (62)
Conditions Which Generate This Code: SMCS Code: 5574-038-CLT
The ECM detects the following conditions: Conditions Which Generate This Code:
• The engine coolant temperature is greater than The ECM detects the following conditions:
106 °C (223 °F) for the C-10 or C-12.
• The coolant level is low for more than ten seconds.
• The engine coolant temperature is greater than
111 °C (232 °F) for the 3406E, C-15, C-16 and • The "Coolant Level Sensor" parameter is
C-18. programmed to "4-pin" or "2-wire Float Sensor".
• The engine has been running for at least 30 • The engine has been running for at least 30
seconds. seconds.
142
System Response: Results:

The ECM will display "Low" and "DIAG" next to the • OK - T h e engine is not losing any engine coolant.
status for "Engine Coolant Level" on the electronic
service tool. The check engine lamp and the Repair: Ensure that the engine coolant level is
warning lamp will turn on while this code is active. normal.
Note: If a lamp for low coolant level is installed, the Run the engine until the engine reaches normal
lamp for low coolant level will turn on instead of the operating temperatures.
warning lamp.
Stop the engine and allow the engine to cool.
Factory passwords are required to clear this
diagnostic code. Recheck the engine coolant level. If the coolant
level is low, add more engine coolant.
STOR
None
• Not OK - The engine is leaking engine coolant or
Troubleshooting: there is coolant in the engine oil.
Test Step 1. Check the Coolant Level Repair: Repair the leaks.
A. Check the engine coolant level. Refer to the Verify that the repair eliminates the problem.
Operation and Maintenance Manual for more
information. STOR
Expected Result:
i01856833
The engine coolant level is normal. 0111-02 Coolant Level signal

Results: invalid (12)
• OK - T h e engine coolant level is normal. SMCS Code: 5574-038-CLT
Repair: Ensure that the coolant level sensor is Conditions Which Generate This Code:
properly installed.
STOR
• The coolant level sensor is sending an invalid
• Not OK - The engine coolant level is low. signal for more than ten seconds.
Repair: Add coolant to the engine. Refer to the • The "Coolant Level Sensor" parameter is
Operation and Maintenance Manual for more programmed to "4-pin" or "2-wire Float Sensor".
information.
Proceed to Test Step 2. seconds.
Test Step 2. Check for Leaks in the System Response:

Cooling System
The ECM will default to OK for engine coolant level.
A, Check for leaking engine coolant. "DIAG" will be displayed next to the status for
"Engine Coolant Level" on the electronic service
B, Check for coolant in the engine oil. tool.
Expected Result: Possible Performance Effect:
There are no leaks. There is no coolant in the None

engine oil.
143
Troubleshooting: • The "Coolant Level Sensor" parameter is

programmed to "2-wire float sensor".
"Coolant Level Sensor Circuit - Test" • The ECM has been powered for at least two
seconds.
Results:
System Response:
• OK - STOR
The ECM will default to "OK" for coolant level.
i01855647
"Engine Coolant Level" on the electronic service
0111-03 Coolant Level voltage tool.
high (12) Possible Performance Effect:
SMCS Code: 5574-038-CLT None
Conditions Which Generate This Code: Troubleshooting:
The ECM detects the following conditions: Perform the following diagnostic procedure:
"Coolant Level Sensor Circuit - Test"
• The signal voltage from the coolant level sensor is
greater than 4.5 VDC for more than ten seconds. Results:
• The "Coolant Level Sensor" parameter is • OK - STOR

programmed to "2-wire Float Sensor".
• The ECM has been powered for at least two i01856872

seconds.
0111-11 Very Low Coolant
System Response: Level (62)
The ECM will default to OK for coolant level. "DIAG" SMCS Code: 5574-038-CLT
will be displayed next to the status for "Engine
Coolant Level" on the electronic service tool. Conditions Which Generate This Code:
None • The coolant level is very low for more than 20

seconds.
Troubleshooting:
• The "Coolant Level Sensor" parameter is
Perform the following diagnostic procedure: programmed to "4-pin" or "2-wire Float Sensor".
"Coolant Level Sensor Circuit - Test"
• The engine has been running for at least 30
Results: seconds.
• OK - STOR System Response:
The ECM will display "Low" and "DIAG" next to the

i01855649
status for "Engine Coolant Level" on the electronic
0111-04 Coolant Level voltage service tool. The check engine lamp and the
warning lamp will turn on while this code is active.
low (12)
Note: If a lamp for low coolant level is installed, the
SMCS Code: 5574-038-CLT lamp for low coolant level will turn on instead of the
warning lamp.
The ECM detects the following conditions: diagnostic code.
• The signal voltage from the coolant level sensor

is less than 0.5 VDC for more than ten seconds.
144
Possible Performance Effect: Stop the engine and allow the engine to cool.
The engine power is derated by 35% at a rate of Recheck the engine coolant level, If the coolant
1% per second. The vehicle speed is limited to a level is low, add more engine coolant.
maximum of 72 km/h (45 mph).
STOP.
Note: If "Engine Monitoring" is programmed to
Shutdown, the engine will be shutdown once this Not OK - T h e engine is leaking engine coolant or
diagnostic code has been active for 30 seconds. there is coolant in the engine oil.
Troubleshooting: Repair: Repair the leaks.
Test Step 1. Check the Coolant Level Verify that the repair eliminates the problem.
A. Check the engine coolant level. Refer to the STOP.

Operation and Maintenance Manual for more
information,
i01822141
Expected Result: 0121-05 Low/High Retarder

The engine coolant level is normal. current low (14)
Results: SMCS Code: 1129-038
• OK - T h e engine coolant level is normal. Conditions Which Generate This Code:
Repair: Ensure that the coolant level sensor is The ECM detects the following conditions:
properly installed.
• The ECM detects a low current condition
STOP. (open circuit) for one second while the ECM is
attempting to energize the solenoid for cylinder
• Not OK - The engine coolant level is low. 3 and cylinder 4.
Repair: Add coolant to the engine. Refer to the • The engine retarder switch is in the Low or High
Operation and Maintenance Manual for more position.
information.
System Response:
Proceed to Test Step 2.
The ECM will turn on the check engine lamp.
Test Step 2. Check for Leaks in the
Cooling System Possible Performance Effect:
A. Check for leaking engine coolant. The engine retarder may not activate.
B. Check for coolant in the engine oil. Troubleshooting:
Expected Result: Perform the following diagnostic procedure:

"Retarder (Compression Brake) Solenoid Circuit -
There are no leaks. There is no coolant in the Test"
engine oil.
Results:
Results:
• OK - STOP.
• OK - T h e 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.
145
i01822140 Possible Performance Effect:

0121-06 Low/High Retarder The engine retarder may not activate.
current high (14) Troubleshooting:
SMCS Code: 1129-038
Conditions Which Generate This Code: "Retarder (Compression Brake) Solenoid Circuit -
Test"
Results:
• The ECM detects a high current condition
(short circuit) for one second while the ECM is • OK - STOR
attempting to energize the solenoid for cylinder
3 and cylinder 4. i01822446
• The engine retarder switch is in the Low or High 0122-06 Med/High Retarder
position.
current high (14)
System Response:
SMCS Code: 1129-038
The engine retarder may not activate.
• The ECM detects a high current condition
Troubleshooting: (short circuit) for one second while the ECM is
attempting to energize the solenoids for cylinder
Perform the following diagnostic procedure: 1, cylinder 2, cylinder 5, and cylinder 6.
"Retarder (Compression Brake) Solenoid Circuit -
Test" • The engine retarder switch is in the Medium or
High position.
Results:
System Response:
• OK - STOR
i01822450 Possible Performance Effect:

0122-05 MedlHigh Retarder The engine retarder may not activate.
current low (14) Troubleshooting:
SMCS Code: 1129-038
Conditions Which Generate This Code: "Retarder (Compression Brake) Solenoid Circuit -
Test"
Results:
• The ECM detects a low current condition
(open circuit) for one second while the ECM is • OK - STOR
attempting to energize the solenoids for cylinder
1, cylinder 2, cylinder 5, and cylinder 6.
• The engine retarder switch is in the Medium or

High position.
System Response:

146
i01901783 i01855588
0168-02 ECM Battery Power 0171-03 Ambient Air

Intermittent (51) Temperature voltage high
SMCS Code: 1401-038 SMCS Code: 1928-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
This condition indicates that the battery circuit to The ECM detects the following conditions:
the ECM has a battery condition that is intermittent
while the engine is running. If battery voltage The signal voltage from the ambient air
disappears without returning, the ECM will not log temperature sensor is greater than 4.92 VDC for
this diagnostic code and the engine will shut down. more than eight seconds.
The ECM detects the following conditions: The "Allow Idle Shutdown Override" parameter is
programmed to "Outside Temperature Based" or
• The key switch is in the ON position. "J1587 Outside Temperature Based".
• The engine is running. • The ECM has been powered for at least two
seconds.
• The engine is not cranking.
System Response:
seconds. The ECM will default to 65 °C (149 °F) for outside
air temperature. "DIAG" will be displayed next to
The ECM will detect one of the following conditions: the status for "Outside Temperature Sensor" on the
• The battery voltage drops below 6 VDC for at
least 0.50 seconds. Possible Performance Effect:
• Three voltage readings in the past seven seconds "Allow Idle Shutdown Override" is disabled while
were below 6 VDC. this code is Active.
System Response: Troubleshooting:
The ECM may stop injecting fuel. This may be Perform the following diagnostic procedure: "Engine
dependent on the length of time of the occurrence Temperature Sensor Open or Short Circuit - Test"
of the fault.
Results:
The Check Engine Lamp and the Warning Lamp
may come on as if the ignition key switch was just • OK - STOR
turned on and the engine started,
i01855591
The engine may experience changes in the engine

0171-04 Ambient Air
rpm, and intermittent engine shutdowns or complete Temperature voltage low
engine shutdowns while the conditions that cause
this diagnostic code are present. SMCS Code: 1928-038
Troubleshooting: Conditions Which Generate This Code:
Perform the following diagnostic procedure: "Ignition The ECM detects the following conditions:
Key Switch Circuit and Battery Supply Circuit - Test"
• The signal voltage from the ambient air
Results: temperature sensor is less than 0.2 VDC for more
than eight seconds.
• OK - STOR
147
• The "Allow Idle Shutdown Override" parameter is Results:

programmed to "Outside Temperature Based" or
"J1587 Outside Temperature Based". • OK - STOR

i01864495
seconds.
System Response:
0174-00 High Fuel Temperature
Warning (65)
The ECM will default to 65 °C (149 °F) for outside
air temperature. "DIAG" will be displayed next to SMCS Code: 1922-038
the status for "Outside Temperature Sensor" on the
electronic service tool. Conditions Which Generate This Code:
"Allow Idle Shutdown Override" is disabled while • The fuel temperature is above 90 °C (194 °F) for
this code is active. more than 30 seconds.
Troubleshooting: • The engine has been running for at least three

minutes.
Temperature Sensor Open or Short Circuit - Test" System Response:
Results: "DIAG" is displayed next to the status for "Fuel

Temperature" on the electronic service tool.
• OK - STOR
diagnostic code.
i01901704
0171-11 Ambient Air Possible Performance Effect:
Temperature Data Lost None
SMCS Code: 1928-038 Troubleshooting:
Conditions Which Generate This Code: No troubleshooting is required.
The ECM detects the following conditions: Results:
• The ECM is not receiving information about the • OK - STOR

ambient air temperature from the SAE J1587 data
link.
i01814156
The "Allow Idle Shutdown Override" is programmed

to the J1587 Outside Temp Based option.
0174-03 Fuel Temperature
voltage high (13)
System Response:
SMCS Code: 1922-038
The temperature based idle shutdown override is
disabled. Outside air temperature is set to 65 °C Conditions Which Generate This Code:
(149 °F).
The signal voltage from the fuel temperature
None sensor is greater than 4.9 VDC for more than
eight seconds.
Troubleshooting:
Engine coolant temperature is above -10 °C
Perform the following diagnostic procedure: "ATA (15.0 °F).
(SAE J1587 / J1708) Data Link Circuit - Test"
The ECM has been powered for at least two
seconds.
148
The ECM will default to the lower of engine coolant 0190-00 Engine Overspeed
temperature or 50 °C (122.0 °F) for fuel temperature.
"DIAG" will be displayed next to the status for "Fuel
Warning (35)
Temperature" on the electronic service tool. SMCS Code: 1912-038
Possible Performance Effect: Conditions Which Generate This Code:
None The ECM detects the following conditions:
Troubleshooting: • The engine speed exceeded 2600 rpm for more
than 0.6 seconds.
Temperature Sensor Open or Short Circuit - Test" • A valid engine speed/timing signal is detected.
Results: • The ECM has been powered for at least three
seconds.
• OK - STOP.
System Response:
i01814157
The ECM will not energize the injectors above
0174-04 Fuel Temperature the programmed "Top Engine Limit". "Top Engine
Limit" will be displayed on the status screen on the
voltage low (13) electronic service tool.
SMCS Code: 1922-038 Factory passwords are required to clear this
diagnostic code.
The engine will lose power above 2600 rpm.
• The signal voltage from the fuel temperature
sensor is less than 0.2 VDC for more than eight Troubleshooting:
seconds.
There are no problems that require troubleshooting.
seconds. This diagnostic code indicates an excessive engine
speed. This diagnostic code does not indicate a
System Response: problem with the ECM or the Engine Speed/Timing
Sensor.
The ECM will default to the lower of engine coolant
temperature or 50 °C (122.0 °F) for fuel temperature. Results:
"DIAG" will be displayed next to the status for "Fuel
Temperature" on the electronic service tool. • OK - STOP.
i01905839
None
0190-12 Primary Engine Speed
Troubleshooting: loss of signal (34)
Perform the following diagnostic procedure: "Engine SMCS Code: 1912-038
Results:
• OK - STOP.
• The signal from the primary engine speed/timing
sensor is intermittent or lost.
149
The ECM will use the secondary engine 0224-11 Theft Deterrent Active
speed/timing sensor to determine engine speed.
The check engine lamp will not be illuminated for
(00)
this code unless the code has been active for 10 SMCS Code: 1901-038
hours.
The theft deterrent feature has been enabled. The
There may be a slight change in engine response correct password must be entered in order to
when the ECM is switched to the secondary engine disable the theft deterrent. Then, the engine can
speed/timing sensor. be started.
Troubleshooting: Note: This diagnostic code represents an event. This
diagnostic code does not represent an electronic
Perform the following diagnostic procedure: "Engine system fault.
Speed/Timing Sensor Circuit - Test"
The ECM will operate in the "Secure Idle" mode if
Results: the theft deterrent password is entered. The engine
must be running in order to operate in the "Secure
• OK - STOR Idle" mode. The ECM will be in the "Secure Idle"
mode until the theft deterrent password is entered
i01855314
again.
0191-07 Transmission Not System Response:

Responding (68) Electronic System Response The diagnostic code
is active only. The diagnostic code will be active
SMCS Code: 3174-038 when the theft deterrent feature is enabled.
Conditions Which Generate This Code: Service Tool Display and Lamps Caterpillar
Electronic Technician (ET) will not display a status.
The ECM detects the following conditions: The Check Engine Lamp will be illuminated.
• Three attempts to complete an Eaton Top 2 shift Engine Response The engine will not start until
were unsuccessful. the correct password is entered. The engine will
be limited to the Low Idle rpm if the "Secure Idle"
• The "Transmission Style" is programmed to "Eaton mode is active.
Top 2".
Troubleshooting:
System Response:
This diagnostic code indicates that the theft
The solenoid that is currently enabled will remain deterrent feature has been enabled. There is no
in the ON position until neutral is detected. electronic system fault.
Then Manual operation occurs until the system
powers down. Manual operation is defined as both No Troubleshooting is required.
solenoids OFE
Results:
• OK - STOP.
The ECM disables the Eaton Top 2 mode.
Troubleshooting: i01901708
Perform the following diagnostic procedure: "Eaton 0224-14 Theft Deterrent Active
Top 2 Transmission Circuit - Test" with Engine Cranking (00)
Results: SMCS Code: 1901-038
• OK - STOP. Conditions Which Generate This Code:

150
• The engine is cranking. System Response:
• The theft deterrent is active. J1939 communications to the engine and from the
engine are terminated for the specific message
System Response: while this code is active. The functionality of some
features may be affected while this code is active.
The diagnostic code is active only. The diagnostic Traction control or transmission controls may be
code will be active when the theft deterrent is disabled. "Diag" or "J1939 No Support" will be
enabled and the engine is cranking for more than displayed next to the status on the electronic
5 seconds. service tool.
Possible Performance Effect: Possible Performance Effect:
The engine will not start until the correct password Features that utilize the J1939 data link may not
is entered. work properly or the features may be disabled.
Troubleshooting: Perform the following diagnostic procedure:

"Powertrain Data Link Circuit - Test"
Enter the correct passwords.
Results:
There are no problems that require troubleshooting.
• OK - STOR
Results:
i01225728
• OK - STOR
0231-11 J1939 Data Link Fault
iO1852913
(58)
0231-02 J1939 Data Incorrect SMCS Code: 1901-038
(58)
SMCS Code: 1901-038
This condition indicates that the SAE J1939 Data
Conditions Which Generate This Code: Link is not communicating correctly.
The ECM detects the following condition: System Response:
• The parameter "Powertrain Data Link" must be Electronic System Response The Communications
programmed to J1939. with other control modules that use the SAE J1939
Data Link may be interrupted while the Diagnostic
The ECM also detects one of the following Code is Active.
conditions:
Note: If the vehicle is not using the J1939 Data Link,
• The ECM is unsuccessful in receiving a specific program the "Power Train Data Link" (Customer
message from a device. Parameter) to "None" or J1922. After the "Power
Train Data Link" is programmed correctly the
or following Active Diagnostic Code should be
repaired:
• The device is broadcasting a fault code.
• 231-11 J1939 Data Link Fault (58)
or
Troubleshooting:
• The device is broadcasting a code that is not
supported. Contact the OEM dealer in order to determine if the
vehicle was built in order to use the J1922 or J1939
Data Link. If the vehicle is not using the J1922 or
J1939 Data Link, program the "Power Train Data
Link" (Customer Parameter) to "None". This will
repair the problem.
151
If the vehicle is using the J1922 or J1939 Data Link • The 5 volt supply is greater than 5.16 VDC for
for Power Train Control, proceed with the following more than one second.
procedure:
Perform the following diagnostic procedure: seconds.
"Powertrain Data Link Circuit - Test"
System Response:
Results:
The ECM sets all of the pressure sensors to the
• OK - STOR default values below:
• Atmospheric Pressure 100 kPa (15.0 psi)

i01617802
0231-12 J1939 Device Not • Boost pressure 0 kPa (0.0 psi)
Responding • Engine Oil Pressure 600 kPa (87.0 psi)
SMCS Code: 1901-038 The ECM will use a default torque map. "DIAG"
will be displayed next to the status for all of the
Conditions Which Generate This Code: pressure sensors on the electronic service tool.
This condition indicates that the J1939 data link has Possible Performance Effect:
a short circuit or an open circuit. All of the following
conditions must be met: The engine will experience low power when this
• The parameter "Powertrain Data Link" must be
programmed J 1939. Troubleshooting:
• The ECM is unsuccessful in receiving a response Perform the following diagnostic procedure: "5 Volt
to a message that has been transmitted for 10 Engine Pressure Sensor Supply Circuit - Test"
seconds.
Results:
Electronic System Response J1939
communications to the engine and from the • OK - STOR
engine are terminated while this code is active. The
functionality of some features may be affected while
this code is active. Traction control or transmission i01814917
controls may be disabled.
0232-04 5 Volt Supply voltage
Service Tool Display or Lamps The Caterpillar low (21)
Electronic Technician (ET) will display "NO COMM"
on the status screen next to the inputs that are not SMCS Code: 5574-038
receiving communications.
"Powertrain Data Link Circuit - Test" The ECM detects the following conditions:
Results: • The 5 volt supply is less than 4.84 VDC for more
than one second.
• OK - STOR
seconds.
i01814912
0232-03 5 Volt Supply voltage System Response:
high (21) The ECM sets all of the pressure sensors to the
default values below:
SMCS Code: 5574-038
• Atmospheric Pressure 100 kPa (15 psi)
• Boost pressure 0 kPa (0 psi)
• Engine Oil Pressure 600 kPa (87 psi)
152
The ECM will use a default torque map. "DIAG" Results:

will be displayed next to the status for all of the
pressure sensors on the electronic service tool. • OK - STOR

i01855537
The engine will experience low power when this 0247-11 Brake Pedal Switch #2
Fault
Troubleshooting:
SMCS Code: 1435-038-BRK
Perform the following diagnostic procedure: "5 Volt
Engine Pressure Sensor Supply Circuit - Test" Conditions Which Generate This Code:
Results: The ECM detects the following conditions:
• OK - STOR • 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.
i01855532
• The engine is running.
0246-11 Brake Pedal Switch #1
Fault • The ECM has been powered for at least three
seconds.
Note: The "Transmission Style" parameter must be
Conditions Which Generate This Code: programmed to Automatic Option 2 or Automatic
Option 3.
System Response:
• The status of the service brake pedal position
switch 1 and the service brake pedal position This diagnostic code will prevent cruise control,
switch 2 do not match for at least 15 seconds. PTO operation, or idle operation.
• The engine is running. Possible Performance Effect:
• The ECM has been powered for at least three The engine will disengage or the engine will not
seconds. allow setting of the cruise control, the PTO, or the
idle speed.
Note: The "Transmission Style" parameter must be
programmed to Automatic Option 2 or Automatic Troubleshooting:
Option 3.
Perform the following diagnostic procedure: "Service
System Response: Brake Pedal Position (Switch 2) Circuit - Test"
This diagnostic code will prevent cruise control, Results:

PTO operation, or idle operation.
• OK - STOP.
i01643896
The engine will disengage or the engine will not
allow the setting of the Cruise Control, the PTO, or 0249-11 J1922 Data Link Fault
the Idle speed,
(58)
Troubleshooting:
SMCS Code: 1901-038
Perform the following diagnostic procedure: "Service
Brake Pedal Position (Switch 1) Circuit -Test" Conditions Which Generate This Code:
This condition indicates that the SAE J1922 Data

Link is not communicating correctly.
153
System Response: Troubleshooting:
Electronic System Response The Communications Perform the following diagnostic procedure: "ECM
with other control modules that use the SAE J1922 Memory - Test"
Data Link are disabled while the Diagnostic Code
is Active. Results:
Note: If the vehicle is not using the J1922 Data • OK - STOR

Link for the vehicle's Power Train Control, program
the "Power Train Data Link" (Customer Parameter)
i01643894
to "None". After the "Power Train Data Link"
is programmed correctly the following Active
Diagnostic Code should be repaired:
0253-02 Check Customer or
System Parameters (56)
• 249-11 Powertrain Data Link (58)
SMCS Code: 1901-038
Troubleshooting:
Contact the OEM dealer in order to determine if the
vehicle was built in order to use the J1922 or J1939 This condition indicates a Customer Specified
Data Link for Power Train Control. If the vehicle is Parameter or a System Configuration Parameter that
not using the J1922 or J1939 Data Link for Power requires programming has not been programmed.
Train Control, program the "Power Train Data Link" Once this parameter has been programmed, the
(Customer Parameter) to "None". This will repair the code may still be active. This can happen if there is
problem. yet another parameter that requires programming.
If the vehicle is using the J1922 or J1939 Data Link System Response:
for Power Train Control, proceed with the following
procedure: Electronic System Response The fault is Active
only and the fault is not Logged. If the Personality
Perform the following diagnostic procedure: Module Code of the new Personality Module does
"Powertrain Data Link Circuit - Test" not match the Code of the old Personality Module,
the engine is limited to low idle. If the "Rating
Results: Number" has not been programmed, the ECM limits
the engine to 119 kW (160 hp). When a new ECM is
• OK - STOR initially powered up, the following parameters must
be programmed to avoid this diagnostic code:
i01822603 • "FLS" (Full Load Setting)
0252-11 Engine Software • "FTS" (Full Torque Setting)
Incorrect (59)
• "Vehicle Speed Calibration"
SMCS Code: 1901-038
• "Rating Number"
• "Engine Serial Number"
• "Injector Codes Calibration"
• The engine software and the ECM are not
compatible. Engine Response The ECM will limit the engine
to low idle if the parameter is the FLS or the FTS.
System Response: The ECM may also limit the power if the parameter
is a rating number.
Troubleshooting:
diagnostic code. Perform the following diagnostic procedure: "ECM
Memory - Test"
Results:
The engine will not start.
• OK - STOR
154
i01225847
0253-11 Check Transmission

Customer Parameters (56)
SMCS Code: 1901-038
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:
• "Top Gear Ratio"
• "Top Gear Minus One Ratio"
• "Top Gear Minus Two Ratio"
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:
• OK - STOR
CATERPILLAR
DIAGNOSTIC FUNCTIONAL TESTS
TABLE OF CONTENTS
DESCRIPTION PAGE
5 VOLT ENGINE PRESSURE SENSOR SUPPLY CIRCUIT - TEST...................................................................................... 155
ACCELERATOR PEDAL (THROTTLE) POSITION SENSOR CIRCUIT - TEST ..................................................................... 160
AIR INLET SHUTOFF CIRCUIT - TEST............................................................................................................................... 168
ATA (SAE J1587/J1708) DATA LINK CIRCUIT-TEST ......................................................................................................... 174
AUXILIARY BRAKE CIRCUIT - TEST ................................................................................................................................. 180
CHECK ENGINE LAMP CIRCUIT - TEST............................................................................................................................ 185
CLUTCH PEDAL POSITION SWITCH CIRCUIT - TEST ....................................................................................................... 190
COOLANT LEVEL SENSOR CIRCUIT - TEST..................................................................................................................... 195
COOLING FAN CIRCUIT AND A/C HIGH PRESSURE SWITCH CIRCUIT - TEST ................................................................ 205
CRUISE CONTROL SWITCH CIRCUIT - TEST.................................................................................................................... 219
DIAGNOSTIC ENABLE SWITCH CIRCUIT - TEST .............................................................................................................. 227
EATON TOP 2 TRANSMISSION CIRCUIT - TEST ............................................................................................................... 231
ECM MEMORY - TEST ....................................................................................................................................................... 238
ELECTRICAL CONNECTORS - INSPECT .......................................................................................................................... 240
ENGINE PRESSURE SENS OR OPEN OR SHORT CIRCUIT -TEST..................................................................................... 247
ENGINE RUNNING OUTPUT CIRCUIT - TEST .................................................................................................................... 254
ENGINE SHUTDOWN OUTPUT CIRCUIT - TEST................................................................................................................ 257
ENGINE SPEED/TIMING SENSOR CIRCUIT - TEST ........................................................................................................... 260
ENGINE TEMPERATURE SENSOR OPEN OR SHORT CIRCUIT- TEST.............................................................................. 267
FAN OVERRIDE SWITCH CIRCUIT - TEST ........................................................................................................................ 273
IDLE SHUTDOWN TIMER - TEST....................................................................................................................................... 278
IGNITION KEY SWITCH CIRCUIT AND BATTERY SUPPLY CIRCUIT- TEST ...................................................................... 281
IGNORE BRAKE/CLUTCH SWITCH CIRCUIT - TEST ......................................................................................................... 287
INJECTOR SOLENOID CIRCUIT - TEST ............................................................................................................................ 291
MULTI-TORQUE - TEST..................................................................................................................................................... 303
NEUTRAL SWITCH CIRCUIT - TEST.................................................................................................................................. 304
POWERTRAIN DATA LINK CIRCUIT - TEST ...................................................................................................................... 311
PTO ENGINE RPM SET SPEED (INPUT A AND INPUT B) CIRCUIT - TEST ........................................................................ 319
PTO SHUTDOWN TIMER - TEST ....................................................................................................................................... 324
PTO SWITCH CIRCUIT - TEST ........................................................................................................................................... 326
PTO SWITCH ON LAMP CIRCUIT TEST ............................................................................................................................ 336
REMOTE PTO ACCELERATOR POSITION SENSOR CIRCUIT -TEST ................................................................................ 342
RETARDER (COMPRESSION BRAKE) SOLENOID CIRCUIT-TEST.................................................................................... 349
SERVICE BRAKE PEDAL POSITION (SWITCH 1) CIRCUIT-TEST ...................................................................................... 358
SERVICE BRAKE PEDAL POSITION (SWITCH 2) CIRCUIT-TEST ...................................................................................... 363
STARTING AID OUTPUT CIRCUIT - TEST ......................................................................................................................... 368
STARTING AID SWITCH CIRCUIT - TEST .......................................................................................................................... 371
TACHOMETER CIRCUIT - TEST ........................................................................................................................................ 375
TORQUE LIMIT SWITCH CIRCUIT - TEST.......................................................................................................................... 380
TWO SPEED AXLE SWITCH CIRCUIT - TEST .................................................................................................................... 384
VEHICLE SPEED AND SPEEDOMETER CIRCUIT - TEST .................................................................................................. 388
WARNING LAMP CIRCUIT - TEST ..................................................................................................................................... 397
155
Diagnostic Functional
Tests
i01907586
5 Volt Engine Pressure Sensor

Supply Circuit- Test
SMCS Code: 5574-038
System Operation Description:
Use this procedure under the following situation:
Use this procedure to troubleshoot the system when

one of the following diagnostic codes is active or
easily repeated:
• 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
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.
156
Engine
Oil Atmospheric Control Boost
Pressure Pressure Module Pressure
Sensor Sensor (ECM) Sensor
C-10 AND C-12 LEFT SIDE VIEW C-10 AND C-12 TOP VIEW
Sensor locations for C-10 and C-12 engines
Boost Atmospheric Engine Oil

Pressure Pressure Control Pressure
Sensor Sensor Module Sensor
(ECM)
3406E LEFT SIDE VIEW 3406E RIGHT SIDE VIEW

Sensor locations for 3406E engines
157
Boost Engine
Pressure Control
Sensor Module
(ECM)
J
-1
Atmospheric ¢=t Oil

Pressure Pressure
Sensor Sensor
J
]
Sensor locations for C-15, C-16 and C-18 engines
ENGINEBOOSTP R E S S U R E I - - G ~
ENGINE PRESSURE SENSOR
ENGINE PRESSURE COMMON
SENSOR --I'--YL~I A,~]~
+SVt--OR-I<.l B,~]~- L/A746
--P200 J200
ECM
ENGINE PRESSURE SENSOR COMMON I--YL-I%I B'~J~

ENGINE PRESSURE SENSOR +5VI--OR--KI A@-',
P203 J 2 0 3 MON
ENGINEOIL P R E S S U R E ~ ! ~ -
ENGINE PRESSURE SENSOR COMMON
ENGINE PRESSURE SENSOR +SV
P201 J201
Schematic
158
ENGINEPRESSURESENSOR+5V
130000000000
ENGINEPRESSURESENSORCOMMON
Z3OOOOO " ~ . t ~ O 0 ENGINEATMOSPHERICPRESSURE
31OOOO ( @ ) OOOql24
390 0 0 0 0 0 0 032i ENGINEOILPRESSURE
ENGINEBOOSTPRESSURE
470000 ooo~
5700000 o 0000048
700 0 0 0 0 0 0 0 0 0 0 0 C)SSq~
~,., ~ r"-l/~<
~:,
ECM Side Engine Harness Connector P2
~,~ I! II
1 2x.3_4_5_6 ~ 8_9_10_11_12.13~ ENGINE PRESSURE SENSOR+SV
Q~QOOOQQQQQ I ENGINE PRESSURE SENSOR COMMON
14~ >EEl< kJt.Jk.JLJk.2231
ENGINE ATMOSPHERIC PRESSURE
- vvvo ENG]NEOIL PRESSURE
48(,.)(J(~j~ ~.) S ENGINEBOOSTPRESSURE

U, ooo oooo
k ~58 59 60 6! 62 63 r-z 65 66 6708 09 70,,/
'I
-~ II II J
Harness Side
P2 ECM connector
B. Connect the Caterpillar Electronic Technician
Jack (Cat ET) to the data link connector.
Pin-B ~ Pin-A C, Disconnect the P2 ECM connector from the ECM.

(C°mm°n)~wS(Supply) D. Check the ECM connector for corrosion and
moisture.
E. Turn the key switch to the ON position.

\~. J/ -""- Pin-C
(Signal)
F. Check for active diagnostic codes on Cat ET.
Plug Note: A "voltage high" diagnostic code (open
Socket-A ~ Socket-B circuit) should be active for all of the engine
(Supply)'~ r--I (~(Common) pressure sensors.
Expected Result:
The 5 volt diagnostic codes are not active. A
Socket-C~ "voltage high" diagnostic code (open circuit) should
(Signa0
be active for all of the engine pressure sensors.
Illustration41 g00810608
Sensor connector
Results:
Test Step 1. Disconnect the ECM • OK - T h e 5 volt diagnostic codes are not active.
Connector and Check for Active Repair: Reconnect the P2 ECM connector.
Diagnostic Codes
A. Turn the key switch to the OFF position.
159
• Not OK - The 5 volt diagnostic codes are still B, Measure the voltage between terminal C (Signal)
active. and terminal B (Pressure Sensor Common) of the
connector for the suspect sensor on the engine
Repair: Connect a test ECM. harness.
If the test ECM fixes the problem, reconnect the Expected Result:
suspect ECM.
The voltage should be less than 7.0 VDC.
If the problem returns, permanently install the
new ECM Results:
Verify that the repair eliminates the problem. • OK - T h e voltage is within the range.
STOR Repair: Temporarily connect a new sensor.
Test Step 2. Disconnect the Sensors If the problem is resolved with the new sensor,
reconnect the suspect sensor.
A. Turn the key switch to the ON position.
If the problem returns, replace the suspect sensor.
B, Monitor the active diagnostic code screen on
Cat ET. Verify that the repair eliminates the problem.
C. Disconnect the pressure sensors one at a time. STOR

Wait for 30 seconds after each pressure sensor
is disconnected. • Not OK - The voltage is greater than 7.0 VDC.
Note: The 5 volt diagnostic code will become Repair: Inspect the signal wire for a short circuit
inactive if a pressure sensor is the cause of the 5 to a voltage source.
volt diagnostic code.
Repair the signal wire or replace the signal wire.
D, Ensure that all of the pressure sensors are
disconnected. Verify that the repair eliminates the problem.
Expected Result: STOR
The 5 volt diagnostic code is still active when all of Test Step 4. Determine the Condition that
the pressure sensors are disconnected. is Present
Results: A. Turn the key switch to the ON position.
• OK - T h e 5 volt diagnostic code is still active. B, Access the active diagnostic code screen on
Cat ET.
Repair: Leave all of the pressure sensors
disconnected. Expected Result:
Proceed to Test Step 4. 232-03 or 232-04 is active.
• Not OK - T h e 5 volt diagnostic code disappears Results:

when the pressure sensors are disconnected.
• 232-03 - Proceed to Test Step 5.
Repair: Reconnect all of the pressure sensors
except the suspect sensor. • 232-04 - Proceed to Test Step 7.
Proceed to Test Step 3. Test Step 5. Measure the 5 Volt Supply to

the Sensor
Test Step 3. Check the Signal Wire
A, Turn the key switch to the ON position.
Note: All of the pressure sensors should be
Note: The suspect sensor should be disconnected. disconnected.
160
B. Measure the voltage between terminal A Verify that the repair eliminates the problem.
(Pressure Sensor +5V) and chassis ground for
each pressure sensor. STOR
Expected Result: Test Step 7. Check the Resistance of the

Harness
The voltage should be 5.0 + 0.16 VDC.
Results:
B. Verify that all of the sensors are disconnected.
• OK - T h e 5 volt supply is within the range.
Proceed to Test Step 6. C. Measure the resistance between terminal A
(Pressure Sensor +5V) and terminal B (Pressure
• Not OK - T h e voltage is greater than 5.16 volts. Sensor Common) of each connector for the
pressure sensor on the engine harness.
Repair: Check the 5 volt supply wire for a short to
a higher voltage source. Expected Result:
Repair the 5 volt supply wire or replace the 5 volt The resistance should be greater than 20,000
supply wire. Ohms, or "OL" is displayed on the multimeter.
STOP. • OK - T h e 5 volt supply and the pressure sensor

common are not shorted.
Test Step 6, Check the Common Wire
Repair: Check the 5 volt supply for a short to
A. Turn the key switch to the ON position. ground.
B. Measure the voltage between terminal A Repair the 5 volt supply wire or replace the 5 volt
(Pressure Sensor +5V) and terminal B (Pressure supply wire.
Sensor Common) on all of the pressure sensors.
C. While the voltage is monitored, perform a 45 N
(10 Ib) pull test on the common wires for the 5 STOR
volt supply.
• Not OK - There is a short between the 5 volt
• P2:3 (Pressure Sensor Common) supply and the pressure sensor common.
• P2:42 (Pressure Sensor Common (Actuator)) Repair: Locate the short between the 5 volt
supply and the pressure sensor common.
Expected Result:
Repair the faulty wiring or replace the faulty
The voltage should be 5.0 + 0.16 VDC. wiring.
• OK - The voltage is within the range. STOR
Repair: If the problem is intermittent, refer to

i01878777
Troubleshooting, "Electrical Connectors- Inspect".
STOR
Accelerator Pedal (Throttle)
Position Sensor Circuit- Test
• Not OK - The voltage is not within the range.
SMCS Code: 1913-038
Repair: Inspect the common wire for an open
circuit. System Operation Description:
Repair the common wire or replace the common Accelerator Pedal Position Sensor
wire.
161
The accelerator pedal position sensor is used to

provide a throttle position signal to the 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 pedal mounted accelerator pedal position

sensor is attached directly to the accelerator pedal
assembly and the pedal mounted 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.
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.
If the vehicle is using the ECM dedicated PTO

functions, 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 parameters:
• Remote Switches
• Remote Throttle
Note: In the cab switches configuration, the cab

accelerator pedal can be used in order to control
the engine rpm for the PTO operation. The cab
accelerator pedal can also be ignored in the "Cab
Switches" PTO configuration. Programming of
customer parameters is required in order to ignore
the cab accelerator pedal in the "Cab switches"
configuration.
The ECM is in PTO mode if the "PTO On/Off Switch"

is on. This can be checked with the electronic
service tool. Refer to Troubleshooting, "PTO Switch
Circuit - Test" for testing if the PTO is being used.
ECM
AP SENSOR/SwITCHSENSORCOMMONFBK--~-§-F~
] + 8 A ,>, V c985-BU--K,
H795-PK-~'~-~-~-~AP
I - - 4~+8v R SENSOR/S.
D - ~SENSOR
NOM
MOC
ACCELERATORPEDAL POSITIONbWH--~ C I) I C986-BR~ACCELERATOR PEDAL POSITION
J403 P403 P1 J1
Schematic for cab accelerator pedal position sensor
162
~ o oo oo o3o~e o.~~,~ AP SENSOR/SWITCH SENSOR COMMON

INPUT SENSOR COMMON ~2
]11i,9000011
I~'~00000~o 0~00,4 +8V
LLi ;o oo o ° ooOO o Oo,,iI II

ACCELERATOR PEDAL POSITION
ECM Side Vehicle Horness Connector P1
+8V
AP SENSOR/SWIICH SENSOR COMMON
INPUT SENSOR COMMON |2
® , 8888'1
C)5~rll ACCELERATOR PEDAL POSITION
II I] ~
Horness Side
g00668027
Illustration 43
Terminal locationsfor ECM
Test Step 1. Monitor the Status for the Results:

"Accelerator Pedal Position"
• OK - T h e accelerator pedal position sensor is
A. Connect the electronic service tool to the data operating correctly.
link connector.
B. Turn the key switch to the ON position. Troubleshooting, "Electrical Connectors- Inspect".
C. Access the status for the "Accelerator Pedal Verify that the engine is not in PTO mode. PTO
Position". mode may cause the accelerator pedal position
sensor to be ignored.
D. While the status is monitored, depress the
accelerator pedal and release the accelerator Verify that all required parameters are
pedal. programmed. Certain unprogrammed parameters
may cause the engine to be limited to low idle.
ExpectedResult: Refer to Troubleshooting, "System Configuration
Parameters".
The status for the "Accelerator Pedal Position" is
100% when the accelerator is fully depressed. The STOP.
status for the "Accelerator Pedal Position" is 0%
when the accelerator is fully released. • Not OK - The accelerator pedal position sensor
is not operating correctly. Proceed to Test Step 2.
163
Test Step 2. Monitor the Duty Cycle • P1:66
A, Turn the key switch to the ON position. C. Check the ECM connector (Allen Head Screw)
for the proper torque of 6.0 N.m (55 Ib in).
B. Access the following display screen in order:
D. Check the harness and wiring for abrasion and
• "Service" pinch points from the accelerator pedal position
sensor to the ECM.
• "Calibrations"
Expected Result:
• "Monitor Throttle Position Sensor"
All connectors, pins and sockets should be
C. While the duty cycle is being monitored, depress completely coupled and/or inserted and the harness
the accelerator pedal and release the accelerator and wiring should be free of corrosion, abrasion
pedal. or pinch points.
Expected Result: Results:
The duty cycle is 10% to 22% when the accelerator • OK - Proceed to Test Step 4.
pedal is released. The duty cycle is 75% to 90%
when the accelerator pedal is depressed. • Not OK
Results: Repair: Perform the following repair:
• OK - T h e duty cycle is within the specified range. Repair the connectors or wiring and/or replace
the connectors or wiring. Ensure that all of the
Repair: If the problem is intermittent, refer to seals are properly in place and ensure that the
Troubleshooting, "Electrical Connectors- Inspect". connectors are completely coupled.
Verify that the engine is not in PTO mode. PTO Verify that the repair eliminates the problem.
mode may cause the accelerator pedal position
sensor to be ignored. STOR
Verify that all required parameters are Test Step 4. Check for Active Diagnostic
programmed. Certain unprogrammed parameters Codes
may cause the engine to be limited to low idle.
Refer to Troubleshooting, "System Configuration A. Turn the key switch to the ON position.
Parameters".
B. Check for active diagnostic codes on the
STOR electronic service tool.
• Not OK - The duty cycle is not within the range. Note: When the ECM automatically calibrates new
Proceed to Test Step 3. duty cycle values for the low idle throttle position
and the high idle throttle position the ECM assumes
Test Step 3. Inspect Electrical Connectors 22 percent duty cycle at low idle and 75 percent
and Winng duty cycle at high idle. As a result, you may notice
that the throttle position status reaches 100 percent
A. Thoroughly inspect the J1/P1 ECM connector, well before the accelerator pedal is fully depressed.
the firewall bulkhead connector and the This is normal. After some cycling of the accelerator
accelerator pedal position sensor connector. pedal to the high idle position, the ECM will adjust
Refer to Troubleshooting, "Electrical Connectors the calibration automatically. The ECM will adjust
- Inspect" for details. the calibration automatically provided that the high
idle stop position is within the 75 to 90 percent duty
B. Perform a 45 N (10 Ib) pull test on each of the cycle range, and the low idle is in the 10 to 22
wires in the ECM connector that are associated percent duty cycle range. During normal operation,
with the accelerator pedal position sensor: you may also notice that more movement of the
accelerator pedal is required for the throttle position
• P1:3 status to increase above 3 percent. You may also
observe that the status reaches the 100 percent
• P1:4 value prior to the limit of the high idle position. This
is done in order to ensure that the throttle reaches
• P1:5 these two critical points for engine operation.
164
Expected Result: B. Remove the signal wire for the accelerator pedal
position sensor (terminal "C") from P403. This
Result 1 91-08 or 91-13 is Active. is the harness side of the accelerator pedal
position sensor connector.
Result 2 41-03 is Active.
C. Install a breakout T with 3 terminals between the
Result 3 41-04 is Active. J403 and the P403 Accelerator pedal position
sensor connector.
Results:
D. Connect the multimeter probes to terminal "C"
• Result 1 - Proceed to Test Step 5. (Accelerator Pedal Position) and terminal "B"
(Accelerator/Switch Sensor Common) of the
• Result 2 - Proceed to Test Step 10. breakout T.
• Result 3 - Proceed to Test Step 12. E. While the duty cycle is being monitored on the
multimeter, depress the accelerator pedal and
Test Step 5. Check the Supply Voltage release the accelerator pedal.
at the Sensor for the Accelerator Pedal
Position Sensor Expected Result:
A. Install a breakout T with 3 terminals at the The duty cycle is between 10% and 22% when the
accelerator pedal position sensor connector accelerator pedal is fully released. The duty cycle is
J403/P403. between 75% and 90% when the accelerator pedal
is fully depressed.
B, Turn the key switch to the ON position.
Results:
C, Measure the voltage at terminal "A" (+8 V) with
reference to terminal "B" (Accelerator/Switch • OK - T h e accelerator pedal position sensor is
Sensor Common). working correctly.
Expected Result: Repair: Insert the signal wire into terminal C of

the P403 connector.
The measured voltage is between 7.5 VDC and 8.5
VDC for the pedal mounted throttle position sensor Proceed to Test Step 7.
that is used in the cab.
Not OK - Leave the PWM probe connected to
Results: the breakout T. Insert the wire (terminal C) into
the vehicle harness connector. The accelerator
• OK - Proceed to Test Step 6. pedal position sensor or the accelerator pedal
assembly is faulty. Proceed to Test Step 8.
• Not OK - The sensor is not receiving the correct
voltage. Test Step 7. Check the Duty Cycle of the
Accelerator Pedal Position Sensor at the
Repair: Inspect the electrical connectors and ECM
wiring.
Note: Performing certain steps within this procedure
Repair the faulty wiring. requires the use of a multimeter that is capable of
measuring a PWM duty cycle.
A, Turn the key switch to the OFF position.
STOR
B, Remove the wire for the accelerator pedal
Test Step 6. Check the Duty Cycle at the position sensor P1:66.
Sensor
Note: You may be required to disconnect the P1
Note: Performing certain steps within this procedure ECM connector in order to remove the terminal for
requires the use of a multimeter that is capable of the signal input of the accelerator pedal position
measuring a PWM duty cycle. sensor.

165
C. Connect the multimeter probes between the E. Display the duty cycle output of the accelerator
removed wire and P1:5 (Accelerator/Switch pedal position sensor while the sensor slot is
Sensor Common). released. Use a screwdriver to advance the
sensor slot to the maximum position. Refer to
D. Reconnect the P1 ECM connector to the ECM. Illustration 44.
E, Turn the key switch to the ON position. When the sensor is removed from the accelerator
pedal assembly, the following diagnostic code
F. While the duty cycle output of the accelerator may be generated:
pedal position sensor is being monitored on the
multimeter, depress the accelerator pedal and • 91-13 Throttle Sensor Calibration (28)
release the accelerator pedal.
This is normal. The diagnostic code should
G. Turn the key switch to the OFF position. disappear when the sensor is properly
assembled back into the accelerator pedal
H. Reinsert the signal wire into P1:66 of the P1 ECM assembly.
connector.
Expected Result:
The duty cycle is between 10% and 22% when the
accelerator pedal is fully released. The duty cycle is
between 75% and 90% when the accelerator pedal
is fully depressed.
Results:
• OK - A good signal from the accelerator pedal
position sensor is reaching the ECM. Verify that
the ECM is receiving the proper battery voltage. If
the ECM is receiving the proper battery voltage,
temporarily connect a test ECM and verify that the
problem is resolved. If the problem disappears
with the test ECM, reconnect the suspect ECM.
If the problem returns with the suspect ECM,
replace the ECM. STOR
• Not OK - There is a problem with signal wire

for the accelerator pedal position sensor in the
vehicle wiring harness. Proceed to Test Step 9.
Test Step 8. Remove the Accelerator

Pedal Position Sensor from the
Accelerator Pedal Assembly
B. Remove the accelerator pedal position sensor

from the accelerator pedal assembly. Note
sensor orientation in the accelerator pedal
assembly, and the sensor pigtail routing prior to
sensor removal. Thoroughly inspect the pigtail
for signs of abrasion.
C. Connect the multimeter that is capable of

measuring a PWM duty cycle to terminal "C" of
the breakout T.
D. Turn the key switch to the ON position.

166
A Mote sensor to accelerator I)edol assembly. Key must match Ul)

with the sensor slot. Check the sensor housina for o flush fit to the
I)edol assembly mountinq surface (This ensures slot on sensor
has mated correctly with the pedal assembly key.)
B Ensure the sensor is oriented the some as it was arior to removal

to ensure sensor harness pigtail is routed correctly.
C Line up screw holes and install mounting screws.
NOTE: Procedure is identicalfor the suspended Mounting screw holes

accelerator pedal assembly.
Sensor housing - - ~ ~ ~ , ~
Mounting screw holes Accelerator Block Assembly

--0
~/ Mounting screw holes
/ ,nsorou
Key must match up ( I ~ )l I )
with sensor slot prior ~"-~"~/~ IS
n un ,ng s o r .
installation
\ ;j
Accelerator Block Assembly

g00706977
Illustration 44
Accelerator pedal assembly
Expected Result: Not OK - T h e accelerator pedal position sensor

is faulty. Check the accelerator pedal assembly
When the sensor is removed from the accelerator in order to ensure that the accelerator pedal
pedal assembly and the sensor slot is released, the assembly is not causing damage to the sensor.
duty cycle is 10 percent or less. When the sensor If the accelerator pedal assembly is causing
slot is moved to the maximum position, the duty damage to the sensor, refer to the OEM dealer
cycle increases to 90 percent or more. for correct replacement of the accelerator pedal
assembly. If the accelerator pedal assembly
Results: appears OK, replace the accelerator pedal
position sensor. STOR
• OK - T h e accelerator pedal position sensor is
working correctly. Clear any diagnostic codes that Test Step 9. Route the Supply Bypass
were caused by performing this test procedure. Wires to the Accelerator Pedal Position
Refer to the OEM dealer for correct replacement Sensor
of the accelerator pedal assembly. STOR
167
B. Remove the signal wire for the accelerator pedal Expected Result:
position sensor from P1:66.
The 41-03 changes to 41-04 when the jumper wire
C. Remove terminal "C" (Accelerator Pedal Position) is installed.
from the accelerator pedal position sensor
connector. Results:
D. Route new wiring from the ECM to the accelerator • OK - T h e r e is a problem with the accelerator
pedal position sensor. pedal position sensor.
E. Turn the key switch to the ON position. Repair: Remove the breakout T.
F. Check the duty cycle of the accelerator pedal Temporarily connect a new sensor.
position sensor on the electronic service tool
while the accelerator pedal assembly is being If the new sensor eliminates the problem,
moved over the full range. reconnect the suspect sensor.
Expected Result: If the problem returns, permanently replace the

sensor.
The duty cycle is between 10% and 22% when the
accelerator pedal is fully released. The duty cycle is Verify that the repair eliminates the problem.
between 75% and 90% when the accelerator pedal
is fully depressed. STOP.
Results: • Not OK - Proceed to Test Step 11.
• OK Test Step 11. Short the +8 Volt Supply at

the E C M
Repair: Perform the following repair:
A. Turn the key switch to the Off position.
The wiring from the ECM to the accelerator pedal
position sensor appears faulty. Permanently install B. Connect a 140-2266 Cable (Seventy-Pin
new wiring. Breakout) between the J1 and P1 ECM
connectors.
C. Insert a jumper wire between terminal 4 and
STOP. terminal 5 of the breakout T.
• Not OK - Double check the wiring, the J1/P1 D. Turn the key switch to the On position.
ECM connector and the sensor connector. If a
problem still exists, restart the test procedure. E. Check for active diagnostic codes on the
STOP. electronic service tool.
Test Step 10. Short the +8 Volt Supply at Expected Result:

the Sensor
The 41-03 changes to 41-04 when the jumper wire
A. Turn the key switch to the Off position. is installed.
B. Connect a breakout T between the J403 and Results:

the P403 Accelerator Pedal Position Sensor
connectors. • OK -There is a problem with the wiring between
the ECM and the accelerator pedal position
C. Insert a jumper wire between terminal A and sensor.
terminal B of the breakout T.
Repair: Remove the breakout T.
B. Turn the key switch to the On position.
Inspect the wiring between the ECM and the
E. Check for active diagnostic codes on the sensor.
Repair the faulty wiring.
168
Verify that the repair eliminates the problem. B. Remove the wires from P1:4 and P1:5.
STOP. C. Turn the key switch to the On position.
• Not OK - There may be a problem with the ECM. D. Check for active diagnostic codes on the
Repair: Remove the breakout T.
Expected Result:
Temporarily connect a test ECM.
The 41-04 changes to 41-03 when the wires are
If the test ECM fixes the problem, reconnect the removed.
suspect ECM.
Results:
ECM. • OK -There is a problem with the wiring between
the ECM and the accelerator pedal position
Verify that the repair eliminates the problem. sensor.
STOR Repair: Inspect the wiring between the ECM and

the sensor.
Test Step 12. Disconnect the Sensor
Repair the faulty wiring.
B. Disconnect the J403/P403 Accelerator Pedal
Position Sensor connector. STOR
C, Turn the key switch to the On position. • Not OK - There may be a problem with the ECM.
D. Check for active diagnostic codes on the Repair: Temporarily connect a test ECM.
If the test ECM fixes the problem, reconnect the
Expected Result: suspect ECM.
The 41-04 changes to 41-03 when the jumper wire If the problem returns, permanently replace the
is installed. ECM
• OK -There is a problem with the accelerator STOP.

pedal position sensor.
i01620144
Repair: Temporarily connect a new sensor.
If the new sensor eliminates the problem,

Air Inlet Shutoff Circuit- Test
reconnect the suspect sensor. SMCS Code: 1078-038
If the problem returns, permanently replace the System Operation Description:
sensor.
The Air Inlet Shutoff is available for certain engine
Verify that the repair eliminates the problem. ratings that operate in areas with large amounts of
combustible gases. The air inlet shutoff will protect
STOR the engine from an overspeed when these gases
are present. When an overspeed is detected, a
• Not OK - Proceed to Test Step 13. relay activates the air inlet shutoff and injection is
disabled until the engine speed reaches 0 rpm. This
Test Step 13. Remove the +8 Volt Supply is accomplished by closing a flap in order to cut
Wires from the ECM off the air supply to the engine. Once the Air Inlet
Shutoff is activated the flap must be manually reset
A. Turn the key switch to the Off position. before the engine can be restarted.
169
--]
Air Inlet Shutoff

Solenoid Air Inlet
Shutoff Reloy
J520/P520 ECM
J702-BK P ~ Solenoid Common
586-PK Air Inlet Shutoff Output
Note: Refer to electricol

schemotic for more intormotion
Schematic
C. Turn the keyswitch to the ON position.
D, Start the engine. Increase the engine speed from

low idle to 1400 rpm to 1600 rpm.
12;
oooooooooooo
O O O O o 00000141111 E, Go to the "Air Inlet Shutoff System Control Test"
1oooo oooo2,1111 on ET.
3 9 0 0 0 0 Ill~__)~l 0000321111
,Toooo ~ oooo401111 F. Start the test.
5700000 o ooooo,81111
oooooooooooo )))j Expected Result:
Fuel injection is disabled. The air inlet shutoff is

Air Inlet Shutoff Output
ECM Side (P2) activated and the engine is shutdown.
Results:
• OK - T h e engine is shutdown when the "Air Inlet

Shutoff System Control Test" is activated. The air
tff-OOOO Cx3oo3, inlet shutoff is working correctly.
I~oUL~ ~ t,JtJ, J~J 47
Repair: Reset the air inlet shutoff system. Talk to
the operator in order to determine the reason for
\ ~s8 59 6 0 61 ~2 63 n ~5 66 67 68 69 7 o j the overspeed.
Horness Side (P2) STOR
• Not OK - The engine did not shut down. Proceed

Illustration 46 g00848591 to Test Step 2.
Terminal locationsfor the ECM connector P2
Test Step 2. Check the Interlock for the
Test Step 1. Perform the "Air Inlet Shutoff Air Inlet Shutoff
System Control Test"
A. Verify that J1/P1:62 (Output 12) is connected to
A. Turn the keyswitch to the OFF position. the +Battery.
B. Connect the Caterpillar Electronic Technician Expected Result:

(ET) to the cab data link connector.
J1/P1:62 is connected to the +Battery.
170
Results: B, Connect ET to the cab data link connector.
• OK -J1/P1:62 (Output 12)is connected to the C, Turn the keyswitch to the ON position. Do not
+Battery. Proceed to Test Step 3. start the engine.
• Not OK -J1/P1:62 (Output 12) is not connected D, Go to the "Air Inlet Shutoff Relay Output" test
to the +Battery. on ET.
Repair: Connect J1/P1:62 to the +Battery. E, Start the test and listen for a click from the relay
for the air inlet shutoff.
Repeat Test Step 1.
Expected Result:
Test Step 3. Inspect Electrical Connectors
and Wiring The relay is active.
A. Turn the keyswitch to the OFF/RESET position. Results:

B, Thoroughly inspect the J1/P1 ECM connector • OK - A click is heard. The relay is active.
and all other connectors in the circuit. Refer Proceed to Test Step 5.
to Troubleshooting, "Electrical Connectors -
Inspect" for details. • Not OK - There is a problem with the relay circuit.
C. Perform a 45 N (10 Ib) pull test on the wires that
are associated with the air inlet shutoff system. Test Step 5. Check the Supply Voltage to
the Air Inlet Shutoff Solenoid
D, Check the ECM connector (allen head screw) for
the proper torque of 6.0 N.m (55 Ib in).
E, Check the harness and wiring for abrasion and

for pinch points from the sensors back to the
ECM.
Expected Result:
Terminals4
completely coupled and/or inserted and the harness
and wiring should be free of corrosion, abrasion
or pinch points.
Results: g00850138
47
Illustration
• OK - A l l the wires and connections are OK. AirInletShutoffSolenoid
AI Disconnect the air inlet shutoff solenoid.
• Not OK
B, Turn the keyswitch to the ON position.
C. Proceed to the "Air Inlet Shutoff Relay Output"
Repair the connectors or wiring and/or replace test on ET.
seals are properly in place and ensure that the D, Activate the relay for the air inlet shutoff solenoid.
connectors are completely coupled.
E. Use signal reading probes to measure the
Verify that the repair eliminates the problem. voltage across the two terminals of the air inlet
shutoff solenoid.
STOR
Note: Air inlet shutoff systems that were produced
Test Step 4. Perform the "Air Inlet Shutoff after February 2002 may use a one second pulse
Relay Output" Test to control the relay. The relay will only be activated
for one second. A voltage test tamp may be used
A, Turn the keyswitch to the OFF position. in place of a multimeter.
171
Expected Result: Test Step 7. Check the Resistance of the

Relay
The supply voltage should be greater than 10 VDC
or the test lamp illuminates for at least one second.
Results:
J520 , ~ Ir"
• OK - T h e 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 6.
• Not OK - T h e air inlet shutoff solenoid is not

receiving the correct signal. Proceed to Test Step
1 2
10.
Test Step 6. Check the Resistance of the

Solenoid Illustration 48 g0085oo59
Relay Terminals
A. Disconnect the wires for the air inlet shutoff
solenoid. A. Turn the keyswitch to the OFF/RESET position.
B, Measure the resistance of the air inlet shutoff B. Unplug the relay for the air inlet shutoff solenoid.
solenoid.
C. Measure the resistance between J520:1
C, Reconnect the wires for the air inlet shutoff (Solenoid Common) and J520:2 (Air Inlet Shutoff
solenoid. Output).
Expected Result: Expected Result:

Resistance should be 15 to 20 Ohms. The resistance should be between 5 Ohms and 10
Ohms.
Results:
Results:
• OK - T h e resistance of the air inlet shutoff
solenoid is OK. • OK - The resistance of the relay is OK. Proceed
to Test Step 8.
Repair: Check electrical connections. Refer to
Troubleshooting, "Electrical Connectors - Inspect" • Not OK - The relay is faulty.
for more information.
Repair: Replace the relay.
STOP.
• Not OK - The resistance of the solenoid is out of
specification. STOP.
Repair: Replace the air inlet shutoff solenoid.
STOP.
172
Test Step 8. Check the Signal Voltage to Test Step 9. Check the Power Supply to
the Relay the Relay
P520
F'~
p~ ECM
Solenoid Common
I
Air Tnlet Shutoff Output
Terminals
Note: Refer Lo electrical
l;chemoti¢ for more information
Illustration 49 g00850154 Illustration 50 g00850141

Schematic for the Relay Signal Air Inlet Shutoff Relay
A. Unplug the relay for the air inlet shutoff solenoid. A. Measure the voltage between the +Battery
terminal of the relay and the engine ground.
B. Turn the keyswitch to the ON position.
Expected Result:
C. Proceed to the "Air Inlet Shutoff Relay Output"
test on ET. The voltage should be 12.0 + 4.0 VDC.
D. Activate the system for the air inlet shutoff Results:

solenoid.
• OK - T h e relay is receiving power. Proceed to
E. Measure the voltage between P520:1 (Solenoid Test Step 10.
Common) and P520:2 (Air Inlet Shutoff Output).
• Not OK - There is a problem in the wiring
Expected Result: between the relay and the +Battery terminal.
The voltage should be 12.0 + 4.0 VDC. Repair: Repair the circuit.
• OK - T h e relay is receiving the signal from the STOP.

ECM. Proceed to Test Step 9.
Test Step 10. Check the Output Voltage
• Not OK - The relay is not receiving the signal of the Relay
from the ECM. Proceed to Test Step 11.
Terminals
Air Inlet Shutoff Relay
173
A. Ensure that all connectors are connected to the C, Unplug the relay for the air inlet shutoff.
wiring harness.
D, Measure the resistance between P2:13 (Air Inlet
B. Turn the keyswitch to the ON position. Shutoff Output) and P2:9 (Solenoid Common).
C. Go to the "Air Inlet Shutoff Relay Output" test Expected Result:

on ET.
The resistance should be greater than 20,000 Ohms.
D. Activate the system for the air inlet shutoff
solenoid. Results:
E. Measure the voltage from the output terminal on • OK -There are no shorts in the wiring harness.
the relay to the engine ground. Proceed to Test Step 12.
Expected Result: • Not OK - There is a short in the wiring harness

between the ECM and the relay.
The voltage should be 12.0 + 4.0 VDC.
Repair: Repair the circuit.
Results:
• OK - T h e r e is a problem in the wiring between
the relay and the air inlet shutoff solenoid. STOR
Repair: Repair the circuit. Test Step 12. Check the Relay Signal at
the E C M
Air Inlet Shutoff Output Solenoid Common
STOR
• Not OK - The relay is not sending power to the

air inlet shutoff solenoid. The relay is bad.
000~00000000 1
2S O O O O 0 O 0 0 0 0 0 14
~1OOOO ~ 000024
Repair: Replace the relay for the air inlet shutoff. 3,0000 II @Jll 0 0 0 0 3 2
Verify that the repair eliminates the problem. 1111470000 0oo040
1111 700000 0 0 0 0 0 0 4 8
STOR Ill 17oo O O 00000000058
Test Step 11. Check for Shorts in the

Wiring Harness between the Relay and
the ECM
Solenoid Common Air ]nlet Shutoff Output ECM connector P1 (ECM side)
\
Solenoid Common Air Inlet Shutoff Output
14 2,3
59 60 63~X6263 I"-1 65 66 67 68 69 70
II II
ECM connector P1 (Harness Side)
A. Ensure that the keyswitch is in the OFF/RESET ECM connector P1 (Harness side)
position.
A. Turn the keyswitch to the OFF/RESET position.
B. Disconnect the J2/P2 ECM connector.
174
B. Remove the wire from P2:13 (Air Inlet Shutoff The following background information is related
Output) in the P2 ECM connector. to this procedure:
C, Turn the keyswitch to the ON position. The ATA data link (American Trucking Association)
is the standard data link that is used by the
D. Activate the "Air Inlet Shutoff Relay Output" test ECM to communicate with electronic service
on ET. tools. The SAE specification J1587 defines the
format of the messages and data that is being
E, Measure the voltage between the open terminal communicated. The SAE specification J1708
at P2:13 (Air Inlet Shutoff Output) and P2:9 defines the hardware requirements and the protocol
(Solenoid Common). of the serial communications. The Caterpillar
Electronic Technician (ET) is an example of one
F. Turn the keyswitch to the OFF/RESET position. of the electronic service tools. Some electronic
dashboards use this data link to receive information.
G, Reinstall the wire to P2:13 (Air Inlet Shutoff Some automatic transmissions also receive
Output). information from this data link.
Expected Result: The ECM provides the following two ATA data link
connection terminals from the ECM vehicle harness
The voltage should be 12.0 + 4.0 VDC. connector Jl:
Results: • J1:9 (J1587 Data Link Negative)
• OK - The ECM is supplying the correct voltage. • J1:8 (J1587 Data Link Positive)
There is an open circuit in the harness.
The vehicle OEM provides twisted pair wiring from
Repair: Repair the circuit. the ECM to the cab data link connector.
Verify that the repair eliminates the problem. Remember that there are potentially several devices
that are installed in the vehicle and remember that
STOR these devices are connected to the ATA data link
at one time. These devices include dash displays,
• Not OK - The ECM is not supplying the correct trip recorders and transmission controls. These
voltage. devices may cause problems with the data link.
These problems can disrupt communications to the
Repair: Verify your results. Replace the ECM. engine ECM and from the engine ECM.
Refer to Troubleshooting, "Replacing the ECM"
before replacing the ECM. Communication
Verify that the repair eliminates the problem. When the ignition key switch is in the OFF
position, the ECM may communicate with ET.
STOR The communications may be disrupted and the
communications may require frequent reconnection.
In order to avoid this problem, turn the ignition key
i01622223
switch to the ON position when ET is being used.
ATA (SAE J1587 / J1708) Data ET may indicate the following error message:
Link Circuit- Test
• The version of the ECM is not recognized and
SMCS Code: 1901-038 the integrity of the changed parameters and
displayed data is not guaranteed.
This message will indicate that the latest version
Use this procedure under the following situation: of ET has not been installed or this message will
indicate that the software in the ECM is newer than
Use this procedure if the Caterpillar Electronic the software for ET.
Technician (ET) will not power up or ET will not
communicate with the ECM through the cab data
link connector.
175
+ BATTERY~--~
- BATTERYI i ~.
ECU
J1587 D L - I " ~ - - X E79~-Bu J!587 DATA LINK NEGATIVE
J1587 DL+I A [794-YL J1587 DATA LINK POSITIVE
Schematic for ATA Data Link with 6-pin connector

and Wiring
J1587 DATA LINK POSITIVE

ooo~,~oooo ooo-'~,x~ J1587 DATA LINK NEGATIVE
II 112...',00 0 0 0 o 0 O 0 0 O141
11113,0000
3t oooo2,1
1111390 o o o IlL S )11 o o o as2 I
1111,7o o o o % ~ s j o o o 04o I
1111570000o o ooooc,81
ECM Side Vehicle Harness Connector P1

1 2 3 4 5 6 n 8 9 10 11 1 2 1 _ ~ J1587 DATA LINK POSITIVE
,hl o o o o o o o G e o o o o 1 J1587 DATA LINK NEGATIVE
lUl"O0000 >~< 00000:':~/
1-1240000 f ~ " x 00003~ I
1 P 0000 (/r.,_ ) ) ) 0000 q
id400000 ~ 0000,,71
II 11~80QO00 QOQO0571
lu40000000000000 J
\ ~,. 58 59 60 61 62 6,3 r:-] 65 66 67 68 69 7 0 j /
II II J
Harness Side
Terminal locations for ECM
A. Thoroughly inspect the following electrical • ATA data link (terminal 8 and terminal 9) in the
connectors: connectors
• ECM vehicle harness connector J1/P1 Refer to Troubleshooting, "Electrical Connectors

- Inspect" for details.
• Cab data link connector
B. Perform a 45 N (10 Ib) pull test on each of the
• Firewall bulkhead connector wires in the ECM connector that are associated
with the ATA data link.
• Electronic service tool connectors
C. Check the ECM connector (Allen Head Screw)
for the proper torque of 6.0 N-m (55 Ib in).
176
D. Check the harness and wiring for abrasion and Results:

pinch points from the connector to the ECM.
Result 1 -There is not a problem with the
Refer to Illustration 56. ATA data link at this time. If an intermittent
condition exists, thoroughly inspect all wiring and
Expected Result: connectors.
All connectors, pins and sockets should be Repair: Perform the following diagnostic
completely coupled and/or inserted and the harness procedure:
or pinch points. Troubleshooting, "Electrical Connectors - Inspect"
Results: STOR
• OK - Proceed to Test Step 2. Result 2 - ET displays an error message. The

ECM is receiving battery power. Proceed to Test
• Not OK Step 5.
Repair: Perform the following repair: • Result 3 -
Repair the connectors or wiring and/or replace Repair: Perform the following diagnostic
the connectors or wiring. Ensure that all of the procedure:
seals are properly in place and ensure that the
connectors are completely coupled. Troubleshooting, "Engine Cranks But Will Not
Start"
STOR
STOP.
• Result 4 -
Test Step 2. Determine the Type of
Problem with the Data Link Repair: Perform the following diagnostic
procedure:
A. Connect ET to the cab data link connector.
Troubleshooting, "Engine Will Not Crank"
B. Start the engine.
STOP.
Expected Result:
• Result 5 - ET does not power up or the
Result 1 The engine starts. The electronic service communications adapter does not power up.
tool powers up and ET communicates without error. Ensure that the ECM is receiving the correct
battery power. Proceed to Test Step 3.
Result 2 The engine starts. ET powers up but an
error is displayed.
Result 3 The engine cranks but the engine will not

start regardless of the condition of ET.
Result 4 The engine will not crank regardless of

the condition of ET.
Result 5 The engine starts but ET does not power

up.
Note: Check the display screen or check the

communication adapter display in order to
determine if ET has powered up. ET will display
information that shows if the tool is getting power.
If ET or the communication adapter powers up, the
cab data link connector is receiving power.
177
Test Step 3. Check the Battery Voltage

Supply to the Cab Data Link Connector
J1587 DATA LINK +

J1587 DATA LINK -
/
-BATTERY +
1
IATTERY
J1567 DATA LINK+
J1587 DATA L -
+BATTERY
-BATTERY
DEUTSCH 6 - T E R M I N A L -BATTERY DEUTSCH J l g 3 g

DASH CONNECTOR J1587 DATALINK+ DASH CONNECTOR
+BATTERY J1587 DATALINK-
DEUTSCH 9 - T E R M T N A L
S E R V I C E TOOL CONNECTOR
g00650354
Illustration 57
ATA Data Link connector
A. Turn the ignition key switch to the ON position. Test Step 4. Change Electronic Service
Tool Components
B. Use a multimeter in order to measure the voltage
from the + Battery terminal of the cab data link A, If another vehicle or another ECM is available
connector to the - Battery terminal of the cab with a Caterpillar electronic engine, connect ET
data link connector. to the other vehicle by using the same cables.
Refer to Illustration 57. B. Turn the ignition key switch to the ON position.
Determine if ET operates correctly on the other
Expected Result: vehicle.
The voltage is between 11.0 and 13.5 VDC for a 12 C. If another engine is not available in the shop, find
Volt system or between 22.0 and 27.0 VDC for a a different set of electronic service tool cables.
24 Volt system. Ensure that the set of electronic service tool
cables is a complete set.
Results:
D. Connect ET to the cab data link connector by
• OK - T h e cab data link connector is currently using the new cables.
receiving the correct voltage. Proceed to Test
Step 4. E. Turn the ignition key switch to the ON position.
• Not OK - T h e cab data link connector is not R If changing cables allows the electronic service
receiving the correct voltage. tool to operate properly, use the following
procedure:
Repair: Inspect the wiring and fuses to the
connector. Repair the wiring or batteries and/or a. Replace the pieces from the old set of cables
replace the wiring or batteries, as required. into the new set of cables that operates.
Send the vehicle to the OEM dealer for repair, if Replace one piece at a time.
necessary.
b. Repower ET after each of the pieces is
Verify that the repair eliminates the problem. replaced. Use this method to find the faulty
piece.
STOR
G. If changing cables does not allow ET to operate
properly, connect another ET.
178
H. Turn the ignition key switch to the ON position.
Expected Result:
Result 1 The original ET works on another vehicle.
Result 2 A different ET works on the original vehicle
while the engine is being tested.
Results:
• Result 1 - Proceed to Test Step 5.
• Result 2
Repair: Send the faulty ET for repairs.
STOP.
Test Step 5. Check the Battery Voltage at

the E C M
130 O O O O O O O O O O O O1
230 O O O O O O14 Breakout T Connector
,310 O O O O O 024
390 O O O O O 032
470000 O0
UNSWITCHED +BATTERY
IGNITION KEY SWZTCH
O ~ O O O O O
-BATTERY
I I
1 2 3 4 ,5 G ~q 8 9 tO 11 12 13~'~
000000000000 Vehicle Harness Connector P1
0000_ 00000
000 A'n',,~'h 0 0 0 0
O O O {( r. ] )) O O O O
000 \"-~-',/ c~c~c')cb UNSWITCHED +BATTERY
III O O O O O * ~ Y Ot50©O._ IGNITION KEY SWITCH
ooooooo o#oo" -BATTERY
~---~5B 59 60 61 62 63 m 65 66 67 68 69 7 0 j
ECM BreakoutT-connector and terminal locationsfor ECM P1
A. Ensure that ET is connected to the cab data link D, Measure the voltage between P1:52 (Unswitched
connector. +Battery) and P1:65 (-Battery).
B. Disconnect vehicle harness connector P1 from E, Measure the voltage between P1:70 (Ignition Key
ECM connector J1 and insert a 70-Terminal Switch) and Pt:65 (-Battery).
breakout T.
Refer to Illustration 58.
C. Turn the ignition key switch to the ON position.
179
E x p e c t e d 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 - T h e ECM is currently receiving the correct

voltage. Proceed to Test Step 6.
• Not OK - T h e 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.
Repair: Perform the following diagnostic

procedure:
Troubleshooting, "Ignition Key Switch Circuit and

Battery Supply Circuit - Test"
STOR
Test S t e p 6. C o n n e c t E T Directly to the

ECM

ECM
RED ~ 20A - - ~ :
-- R 704 IGNITION KEY SWITCH
UNSWlTCHED +BATTERY
IN-LINE FUSE "---1 L R~J53~ UNSWITCH[D +BATTERY
- ~ - - ~ BK'-'t<I65 ~ -BATTERY
t ~ BK._.~<167 -BATTERY
BLACK " ~ GY 1 J1922 DATA LINK NEGATIVE
UNSWITC.ED +BATTERY II, GY--I<tB * J1587 DATA LINK POSITIVE
-BATTERY I e ~ - I I1~ GY---~]9 J1587 DATA LINK NEGATIVE
:J1922 DATA LINK NEGATIVE IE<'t~'~'Z'---~ III, GY'--t<]34~ J1939 DATA LINK POSITIVE
:J1922 DATA LINK POSITIVE ID<'~/~ ~ #"~J III r---Gy--ff<po~ J1939 DATA LINK NEGATIVE
:J1587 DATA LINK POSITIVE IJ III I - - G Y - " ~ ] 42~ J1939 DATA LINK SHIELD
:J1587 DATA LINK NEGATIVE IH<-~ A "\ " "'-J III
:J1939 DATA LINK POSITIVE IG I I ,,
:J1939 DATA LINK NEGATIVE IF ~ J l ""
J1939 DATA LINK SHIELD C J
9-PIN
DATA LINK
CONNECTOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Illustration 59 g0073231B
WARNING
NOTICE
B a t t e r i e s give off flammable f u m e s w h i c h c a n ex- Do Not connect the Bypass Harness to the battery
plode. until the 20 Amp in-line fuse has been removed from
the +Battery line. If the fuse is not removed before
To avoid injury or death, do not strike a match, connection to the battery a spark may result.
c a u s e a spark, or s m o k e in t h e vicinity of a battery.
180
A. Turn the ignition key switch to the ON position.

NOTICE
B. Disconnect vehicle harness connector J1/P1 Do Not connect the Bypass Harness to the battery
from the ECM. until the 20 Amp in-line fuse has been removed from
the +Battery line. If the fuse is not removed before
C. Install an electronic service tool power bypass connection to the battery a spark may result.
cable. Connect a bypass harness to ECM
connector J1.
A. Connect the battery wires from the bypass
Refer to Illustration 59 for the bypass harness. harness to a different battery that is not on the
vehicle.
Note: This bypass directly connects the circuit
for the ignition key switch to the ECM. The ECM Expected Result:
will remain powered until the connection to the
unswitched battery line "+" is disconnected. ET is operating correctly.
Remove the 20 Amp fuse from the in-line fuse
holder to power down the ECM. Do not connect the Results:
bypass to the battery posts without first removing
the 20 Amp in-line fuse or do not remove the bypass • OK - T h e vehicle battery is causing the problem.
from the battery posts without first removing the 20
Amp in-line fuse. Repair: Perform the following diagnostic
procedure:
Expected Result:
Troubleshooting, "Ignition Key Switch Circuit and
ET is operating correctly. Battery Supply Circuit - Test"
Results: STOP.
• OK Not OK
Repair: Perform the following repair: Repair: Perform the following repair:
There is a problem in the vehicle wiring, or 1. Temporarily connect a test ECM.

another device in the vehicle is causing problems
on the data link. Either determine the device that 2. Remove all jumpers and replace all connectors.
is causing the problem or send the vehicle to the
OEM dealer for repair. 3. Recheck the system for active diagnostic
codes.
4. Repeat the Test Step.
STOP.
5. If the problem is resolved with the test ECM,
• Not OK - Verify that the 20 Amp fuse in the reconnect the suspect ECM.
bypass harness is not open. A fuse that is open
is a blown fuse. Proceed to Test Step 7. 6. If the problem returns with the suspect ECM,
replace the ECM.
Test Step 7. Connect ET and the ECM to
Another Battery 7. Verify that the repair eliminates the problem.
STOP.
Batteries give off flammable fumes which can ex- i01622295
plode.
Auxiliary Brake Circuit- Test
To avoid injury or death, do not strike a match,
SMCS Code: 1129-038-AX
cause a spark, or smoke in the vicinity of a battery.

181
Use this procedure in order to determine if the When the cruise control switch is in the ON position,
auxiliary brake circuit is operating properly. two special options allow the engine retarder to
operate only after the driver depresses the service
The following background information is related brake pedal. The customer programmable modes
to this procedure: of operation are listed below:
Auxiliary Brake Operation (Auxiliary Retarder) • Coast mode
The auxiliary brake output circuit is provided by • Latch mode

the ECM in order to indicate that conditions are
acceptable for an auxiliary brake to operate. • Manual mode
Operation of the auxiliary brake output is inhibited
during undesirable engine operating conditions. The The Coast mode engages the engine retarder when
time period of fueling the engine is an undesirable the driver depresses the service brake pedal. The
engine operating condition. The "Auxiliary Brake" retarder disengages when the driver releases the
parameter must be programmed to J1/P1:12 in service brake pedal.
order to enable the auxiliary brake output. The
output will function on the corresponding output The Latch mode engages the retarder when the
that is selected. driver depresses the service brake pedal. The
retarder remains engaged until the control detects a
• ECM connector J1/P1:12 change in a control input. Examples of a change in
a control input are illustrated on the following list:
In typical applications, the auxiliary brake output
circuit operates a relay, which switches battery • Depressing the accelerator pedal
power in order to energize the auxiliary brake
solenoids. An "Engine Brake On" switch will be • Depressing the clutch pedal
wired in series with the relay and the "Engine Brake
On" switch must be ON before the auxiliary brake • The engine speed drops below 800 rpm.
will operate.
The third option for the "Engine Retarder Parameter"
The ECM does not read the OEM installed Auxiliary is Manual mode. In the Manual mode, the retarder
Brake Relay Switches in order to determine operates in the same manner regardless of the
operation. Only the conditions that are listed below position of the cruise control switch. Unlike the
are used to determine operation. The OEM installed Latch mode and the Coast mode, depressing the
auxiliary brake relay switches determine the path of service brake pedal is not required to initiate the
the signal. retarder in the Manual mode.
In order to ensure the proper operation of the Note: Latch mode and Coast mode determine
auxiliary brake, the following conditions must be engine retarder operation only when the cruise
met: control switch is in the ON position. Latch mode
and Coast mode do not determine engine retarder
• Engine speed is above 800 rpm. operation when the engine is active in cruise control.
Latch mode and Coast mode require the initiation of
• The percent of accelerator pedal position is equal the service brake before acting. The initiation of the
to 7 percent or the percent of accelerator pedal service brake disengages cruise control.
position is less than 7 percent.
The "Auto Retarder in Cruise" parameter does not
• The clutch pedal is released. affect the operation of the auxiliary brake output
circuit. The "Auto Retarder in Cruise" parameter is
These conditions must be met regardless of the used only when the retarder is connected to the
following parameters: engine wiring harness.
• Customer Specified Settings for the Engine Note: If the "PTO Configuration" is programmed to
Retarder "Cab Switches", "Remote Switches", or "Remote
Throttle", the Auxiliary Brake Output is disabled
• Auto Retarder in Cruise whenever the PTO On/Off circuit is on. If the vehicle
is equipped with an Anti-Lock Brake System (ABS),
• Engine Retarder Minimum Vehicle Speed the vehicle may have an additional relay in the
switch circuit for the auxiliary brake solenoids. This
Additional operating requirements must be met if is installed so the ABS system can turn off the
the "Cruise/Idle On/Off Switch" is in the ON position. auxiliary brake solenoids, if necessary. The relay
should have normally closed contacts.
Cruise Control Switch in the ON position
182
The "Engine Retarder Minimum Vehicle Speed"

parameter will prevent the operation of the auxiliary
brake output below the programmed vehicle speed
when vehicle speed is present.
The "Engine Retarder Minimum VSL Type"

parameter provides the following two options:
• Hard Limit (default)
• Soft Limit
When the parameter is programmed to the hard

limit, the "Engine Retarder Minimum VSL Type"
does not allow the auxiliary brake to operate under
the following condition:
• The vehicle speed is below the "Engine

Retarder Minimum Vehicle Speed". The "Engine
Retarder Minimum Vehicle Speed" is customer
programmed.
The soft limit also requires the vehicle speed to be

equal to or greater than the programmed "Engine
Retarder Minimum Vehicle Speed" in order to initiate
the activation of the auxiliary brake, but the soft
limit allows the operation of the auxiliary brake to
continue below the programmed "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.
AUXZLTARY BRAKE
AUTO/MANUAL TO VEHICLE
AUXZLZARY BRAKE + BATTERY
AUXZLZARY BRAKE SWTTCH (IN MANUAL) RELAY N\O
SELECTOR SWITCH
-N - - -GY'~
P1 J1
ECM
OUTPUT 13 I
T
AUXILIARY BRAKE
SOLENOZDS
Relay circuit for auxiliary brake
183
1300@,,~ O 0 0 0 0 0 0 0 0
2,:30 O0 ~ 0000014 OUTPUT 3
31OOOO ~'ir/'~}~ O O O O 2 4
39OOOO LL~J 000032
~70 O O O O O O 040
57OOOOO o OOOOO48
70000000000000058

1 2 ,3 4 5 6 r , 8 9 10 11 1 2 1 3 ~ ' ~
O0000000QO 1
00000 >L~
EI< ~ ~ 1 OUTPUT 3
1240000 f ~ m , 00003~1
PO000 (( r. ) )136OOOO cl
,Nooo oooo;; I
' o°8ooo
\X,, 58 59 60 61 62 63 n 65 66 67 68 69 7 0 J
1
Harness Side
Test Step 1. Inspect Electrical Connectors • Not OK - Repair the wiring or replace the wiring,
And Wiring if necessary. Repair the connectors or replace
the connectors, if necessary. Ensure that all of
A. Thoroughly inspect ECM vehicle harness the seals are in the proper place. Ensure that all
connector J1/P1, and the firewall bulkhead of the connectors are connected properly. Verify
connector. Refer to Troubleshooting, "Electrical that the repair eliminates the problem. STOR
Connectors - Inspect" for details.
Test Step 2. Ensure Correct Parameter
B, Perform a 45 N (10 Ib) pull test on P1:12: Programming
Refer to Illustration 61. A. Connect the Caterpillar Electronic Technician
C. Check the ECM Connector (Allen Head Screw)
for the proper torque of 6.0 N.m (55 Ib in). B. Turn the ignition key switch to the ON position.
D. Check the harness and wiring for abrasion and C. Access the customer specified parameter
pinch points from the sensor to the ECM. screen in order to make sure that the ECM is
programmed to use the auxiliary brake output.
Expected Result:
D. Ensure that the auxiliary brake output is
All connectors, pins and sockets should be connected to the programmed output.
and wiring should be free of corrosion, abrasion Expected Result:
or pinch points.
The circuit is connected to the correct ECM terminal
Results: that is selected for the auxiliary brake output.
• OK - Proceed to Test Step 2. Results:

184
• Not OK - Program the customer parameter to the Expected Result:

correct terminal. STOR
The accelerator pedal position is between 3 and
Test Step 3. Check the Parameter for 100 percent, and the clutch pedal position switch
'Engine Retarder Minimum Vehicle indicates that the pedal is being depressed and
Speed" released.
A. Connect ET to the cab data link connector. Note: The clutch pedal position switch is turned on
when the clutch pedal is depressed. The clutch
B. Turn the ignition key switch to the ON position. pedal position switch is turned off when the clutch
pedal is released.
C. Access the customer parameters screen
in order to view the parameter for "Engine Results:
Retarder Minimum Vehicle Speed". Refer
to Troubleshooting, "Customer Specified • OK - Proceed to Test Step 5.
Parameters'for additional information regarding
"Engine Retarder Minimum Vehicle Speed". • Not OK - There is a problem with the accelerator
pedal position.
B, Ensure that the vehicle is not experiencing a
problem due to this parameter. Repair: Perform the following diagnostic
procedure:
Expected Result:
Troubleshooting, "Accelerator Pedal (Throttle)
The problem is due to this parameter. Position Sensor Circuit - Test"
Results: STOR
• OK - Explain the proper operation of the retarder • Not OK -There is a problem with the clutch
and auxiliary retarder solenoids to driver. STOR pedal position.
• Not OK - Proceed to Test Step 4. Repair: Perform the following diagnostic

procedure:
Test Step 4. Use ET to Check the
Accelerator Pedal Position and the Troubleshooting, "Clutch Pedal Position Switch
Clutch Switch Circuit - Test"
A. Connect ET to the cab data link connector. STOR
B. Turn the ignition key switch to the ON position. Test Step 5. Use ET to Check the Relay
and Solenoids
C. Use the following procedure to check the
accelerator pedal position: A. Turn the ignition key switch to the ON position.
a. Access the status screen on ET for the B. Access the "Auxiliary Brake Special Test" on ET.
accelerator pedal position. Access the following display screens in order:
b. While the status screen is being monitored, • "Diagnostics"

depress the accelerator pedal several times
and release the accelerator pedal several • "Diagnostic Tests"
times.
• "Auxiliary Brake Special Tests"
D, Use the following procedure to check the clutch
pedal position switch: C. Turn the dash switches to the "High Braking
Level" for the auxiliary brake. This is not the
a. Access the status screen on ET for the clutch retarder solenoid switches that are connected
pedal position switch. to the ECM vehicle harness connector J1/P1:23
& 40.
b. While the status screen is being monitored,
depress the clutch pedal several times and
release the clutch pedal several times.
185
D. While you listen for the relay and solenoids to Results:

click, cycle the "Auxiliary Brake Special Test"
from the ON position to the OFF position back OK - T h e ECM is operating correctly. The
to the ON position. problem is in the vehicle wiring. Inspect the
vehicle wiring and then repair the vehicle wiring.
Note: You may need to be near the engine in order Otherwise, send the vehicle to the OEM dealer
to hear the click of the relay and solenoids. for repair. Verify that the original condition is
resolved. STOR
Expected Result:
Not OK - Temporarily connect a test ECM. Use
The relay and solenoids are operating. the "Auxiliary Brake Output Special Test" on ET
to check the ECM. If the problem is resolved
Results: with the test ECM, install the suspect ECM. If the
problem returns with the suspect ECM, replace
• OK - T h e ECM is operating correctly. If the the ECM. Verify that the repair eliminates the
auxiliary brake or the relay is not operating, send problem. STOR
the vehicle to the OEM dealer for repair. STOR
i01770843
• Not OK - Proceed to Test Step 6.
Test Step 6. Use ET to Check the ECM

Check Engine Lamp Circuit-
Test
A. Connect ET to the cab data link connector.
SMCS Code: 7431-038
B. Turn the ignition key switch to the OFF position.
C. Disconnect the ECM vehicle harness connector
J1/PI. Use this procedure under the following situation:
D. Connect a 70-Terminal Breakout T between ECM The check engine lamp is suspected of operating
connectors J1 and P1. incorrectly.
E. Connect a voltage test lamp to terminal 65 The check engine lamp is the only standard lamp
(-Battery) and terminal 12 (Output 3) of the on these engines. All other lamps are optional.
Breakout T.
F. Turn the ignition key switch to the ON position. to the following procedure:
G. Access the "Auxiliary Brake Special Test" on ET. Check Engine Lamp
H. While you monitor the voltage test lamp, cycle The check engine lamp is used to provide the
the "Special Test" from the ON position to the following functions:
OFF position back to the ON position.
• Indicate the existence of an active diagnostic
I. Stop the "Special Test". code.
Note: A multimeter can not be used in place of the • Indicate driver alert status of the idle shutdown
voltage test lamp when the ECM outputs are being timer.
tested.
• Read diagnostic flash codes.
Expected Result:
Power Up Lamp Check
The voltage test lamp turns on when the test is
active. The voltage test lamp turns off when the test At powerup, the lamp will turn on for five seconds.
is not active. 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. If certain fault conditions exist, the
lamp will operate in the following manner:
186
• The check engine lamp will turn on for five Electrical Connection of the Check Engine Lamp
seconds.
One terminal of the check engine lamp must be
• The check engine lamp will turn off for a short connected to battery voltage through the vehicle
time. wiring. The other terminal is connected to the ECM
at the vehicle harness connector J1/P1:28 (Check
• The check engine lamp will turn on for another Engine Lamp).
five seconds.
The ECM provides a path to ground in order for the
The check engine lamp will continue to operate in lamp to turn on.
this manner while the fault condition exists.
Indication of the Driver Alert Status of the Idle

Shutdown Timer
During the final 90 seconds of the operation of the

idle shutdown timer, the check engine tamp will
begin to flash. The flashing of the check engine
lamp indicates that an engine shutdown is near.
Flashing Out Diagnostic Flash Codes
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 an indication
of a failure. Flash codes are not as specific as
diagnostic codes. Flash codes only indicate that a
failure has occurred. 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.
Diagnostic flash codes that are active can be

viewed at any time. 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 determined 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.
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).
Note: The check engine lamp should not

continuously flash the diagnostic flash codes. If the
set switch, the resume switch, or the diagnostic
enable switch has not been used, then the circuit is
probably shorted to ground.
187
ECM
J L994-YL
PI J1
CHECK ENGINE LAMP }
CHECK ENGINE LAMP
Illustration 6 2
g00676880
Schematic for Lamp
oooRoo oooooo
00,..',..., o 0 0 0 0 0 1 ~ 1
II IP, O O O e . . _ . .~ o o o o [ , I CHECK ENGINE LAMP
II If ' o o o o lIFo'It o o c} c}~ I
II l i 7 0 0 0 0 [[~.~.1 0 0 0 0 4 0
II I,~;,o o o o o ~ o o o o o,,'el I
II I'~0oo o o o o 6 o o o o o or:sl ~
ECM Side
Vehicle Harness Connector P1

1 Z 3 4 5 6 u 8 9 tO tt t2 t ] - ~
CHECK ENGINE LAMP
' ~ ~(%00
~ D q ~ C"~"~ O00O'~~
~..,. ~8 ,~9 60 61 62 63 i--I 6~ 66 67 68 69 7 0 j
II II J
Harness Side
Illustration 6 3
g00676965
Test Step 1, Inspect Electrical Connectors C. Check the ECM connector (Allen Head Screw)
and Wiring for the proper torque of 6.0 N.m (55 Ib in).
A. Thoroughly inspect J1/P1 ECM vehicle harness D. Check the harness and wiring for abrasion and
connector, the firewall bulkhead connector, pinch points from the battery to the ECM.
and J1:28 (Check Engine Lamp). Refer to
Troubleshooting, "Electrical Connectors- Expected Result:
Inspect" for details.
B. Perform a 45 N (10 Ib) pull test on each of the completely coupled and/or inserted and the harness
wires in the ECM connector that are associated and wiring should be free of corrosion, abrasion
with the check engine lamp: or pinch points.

188
Results:
• 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.
STOR
Test Step 2. Check for Normal Operation

of the Lamp
A. Monitor the check engine lamp.
a. Turn the ignition key switch to the ON position.

The lamp should turn on for five seconds.
Then, the lamp should 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 (Cat ET) in order to read
the active diagnostic code. Troubleshoot the
problem.
Expected Result:
The check engine lamp turns on and the check
engine lamp turns off per the above description.
Results:
• OK - T h e check engine lamp appears to
operating correctly at this time, STOR
Test Step 3. Test the Lamp Circuit
,30 O 0 O 0 0 0 0 0 0 0 0 0 ]
r30 0 0 0 0 o
000 001,
5,000 0.... 00002 CHECK ENGINE LAMP
190 0 0 0 ~i~l 00 00~
~70000 ~ 00004
,70 O 0 0 0 0 0004
'o00 0 ~ . ~ . ~ O O 0 00~
-BATTERY
ECM Side
g00676968
Illustration 64
A. Disconnect ECM vehicle harness connector B. Fabricate a jumper wire 100 mm (4 inch) long.
J1/PI. Crimp a Deutsch pin to both ends of the wire,
189
C. Insert the jumper into P1:28 (Check Engine

Lamp).
D. Connect the other side of the jumper wire to

P1:65 (-Battery).
E. Turn the ignition key switch to the ON position.
F. While the lamp is being watched, insert the

jumper wire and remove the jumper wire.
Expected Result:
Result 1 The check engine lamp turns on while

the jumper is connected to both sockets. Also, the
check engine lamp turns off when the jumper is
removed from one of the sockets.
Result 2 The check engine lamp does not turn on

while the jumper is connected to both sockets.
Result 3 The lamp will stay on while the ECM

vehicle harness connector is disconnected.
Results:
• Result 1 - T h e check engine lamp circuit is

functioning properly. Proceed to Test Step 4.
• Result 2 - T h e lamp did not turn on. The vehicle's

lamp circuit is not functioning properly. The lamp
is probably burned out or there is a problem in
the wiring from the cab to either the ECM or the
+Battery connection. Repair the lamp circuit or
send the vehicle to the OEM dealer for repairs.
STOR
• Result 3

procedure:
The circuit between the ECM and the lamp is

shorted to chassis ground. Repair the circuit or
STOP.
190
Test Step 4. Check ECM Operation of the

Check Engine Lamp
oooooo oooooo h
12~00000 00000~4111
I, ,o o o - II CHECK ENGINE LAMP
i,sgOO0 0
1~70 0 0 0 IIk'-"}ll 0 0 00,~i01 II
I ,,o o o o o lu; ..o o o, 1 II UNSWlTCHED +BATTERY
-BATTERY
ECM Side
ECM Breakout T-connector
A. Disconnect ECM vehicle harness connector Results:

J1/PI.
OK - T h e ECM is operating correctly. There is a
B. Insert a breakout T between ECM vehicle problem in the vehicle wiring or the lamp. Repair
harness connector J1 and ECM vehicle harness the vehicle wiring or the lamp, as required. STOR
connector P1.
Not OK - Temporarily connect a test ECM. Check
C. Connect a voltage test lamp probe to terminal 65 the operation of the check engine lamp when the
(-Battery) and connect the other probe to terminal test ECM is installed. If the problem is resolved
52 (Unswitched +Battery) of the breakout T. with the test ECM, then reconnect the suspect
ECM. If the problem returns with the suspect
D. The test lamp should turn on. If the test lamp ECM, then replace the ECM. STOP.
does not turn on, either the test lamp is faulty or
the wiring to the ECM is faulty. Continue with this
step if the lamp turns on. i01866339
E. Leave the voltage test lamp probe connected to

Clutch Pedal Position Switch
terminal 52 (Unswitched +Battery). Circuit- Test
F. Connect the other probe of the test lamp SMCS Code: 1435-038-P9
to Terminal 28 (Check Engine Lamp) of the
breakout T. System Operation Description:
Refer to Illustration 65. Use this procedure under the following situation:
G. Watch the voltage test lamp. Turn the ignition The clutch pedal position switch is suspected of
key switch to the ON position. preventing normal operation of cruise control, idle
set speed, or PTO operation.
H. The lamp should turn on for five seconds. Then,
the lamp should turn off. The lamp will continue The following switch circuits can also prevent the
flashing if there is an active diagnostic code. If correct operation of the cruise control, idle set
there is an active diagnostic code, connect Cat speed or PTO operation:
ET in order to read the active diagnostic code.
Troubleshoot the problem. • Service Brake Pedal Position (Switch 1)
Expected Result: • Service Brake Pedal Position (Switch 2)
The check engine lamp turns on and the check • Neutral Switch
engine lamp turns off per the above description,
• Cruise Control Set/Resume Switch
191
• Cruise Control On/Off Switch Usage of Transmission Style Switches
• PTO On/Off Switch The "Transmission Style" parameter determines

the switches that will be used. The following
The switches are described in the respective circuit switches can be used with being dependent on the
tests in Troubleshooting. parameter setting:
All of the following customer programmable • Clutch Pedal Position

parameters can affect cruise control, idle set speed,
and PTO operation: • Neutral
• "Low Cruise Control Speed Set Limit" • Service Brake Pedal Position (Switch 1)
• "High Cruise Control Speed Set Limit" • Service Brake Pedal Position (Switch 2)
• "Idle Vehicle Speed Limit" Refer to Table 2 for additional information.
• "Cruise/Idle/PTO Switch Configuration" Table 142

Switch Usage.
• "ldle/PTO Bump rpm" Setting For
Transmission Service Service
• "ldle/PTO rpm Ramp Rate" Style Brake Brake
Parameter Switch Switch Clutch Neutral
1 2
Manual Option X X
The vehicle speed calibration can also affect 1
the cruise control, the idle set speed, and the
Automatic X
PTO if the vehicle speed calibration is incorrectly Option 1
programmed. Refer to Troubleshooting, "Customer
Specified Parameters". Automatic X X
Option 2
Clutch Switch Automatic X X X
Option 3
The clutch pedal position switch is normally closed
when the pedal is released. Depressing the clutch Automatic X X
pedal should open the circuit. This switch is OEM Option 4
supplied. The clutch pedal position switch is Eaton Top 2 X X
typically a limit switch that is mounted near the
pedal. The clutch pedal position switch is usually
adjustable. If the "Transmission Style" parameter is programmed
to one of the following options, the input for the
clutch pedal position switch is not used:
to this procedure:
The kickout switch refers to the switch that is used
to exit the cruise control, the PTO, or the idle set • Automatic Option 2
speed.
The operation of the Caterpillar electronic engine
cruise control is similar to the operation of the • Automatic Option 4
cruise controls that are installed in automobiles.
The operation of idle and PTO are similar to the A Service Brake Pedal Position (Switch 1) is
operation of cruise except that the Idle and the PTO required for all configurations. The Service Brake
govern engine rpm instead of vehicle speed. Pedal Position (Switch 1) connects to the ECM
through connector P1:45. The Service Brake Pedal
Note: Idle in this procedure is an engine idle rpm Position (Switch 2) connects to the ECM through
above the programmed low idle rpm. Idle is set connector P1:64. The clutch pedal position switch
by using the cruise control On/Off switch and the connects to the ECM through connector P1:22.
Set/Resume switch. Refer to Troubleshooting, "PTO The neutral switch connects to the ECM through
Switch Circuit - Test" for additional information Connector P1:62.
regarding the programmable options for the
dedicated PTO.
192
SET/RESUME
~ (SET OFF POSITION)
(RESUME OFF POSITION)
CRUISE CONTROL ON/OFF
I[ ECM
C978-BR--~ SET
CRUiSE OFF POSITIOn) C979-OROR-KI44~]RESUME
SERVICE BRAKE PEDAL POSITIO. r -C992-PU-KI45~SERVICE BRAKE PEDAL POSITION SWITCH
C977"BU-~I22~CLUTCH PEDAL POSITION SWITCH
H795-PK-~ AP SENSOR/SWITCH SENSOR COMMON
/
EDAL RELEASED POSITION) P1 J1

CLUTCH PEDAL POSITION I
I
(PEDAL RELEASED POSITION)
Schematic for cruise control switch, service brake pedal position switch 1 and clutch pedal position switch
Test Step 1. Check the Status for the Test Step 2. Determine the Configuration
"Clutch Pedal Position Switch" of the Clutch Pedal Position Switch
A, Connect the electronic service tool to the data A, Determine if the wiring for the clutch pedal
link connector. position switch is wired directly to the ECM or
through the J1939 data link.
Note: J1/P1:22 can only be used for the clutch
C. Check the status of the "Clutch Pedal Position pedal position switch. If the clutch pedal position
Switch". switch is wired to J1/P1:22, the clutch pedal position
switch is wired directly to the ECM.
D, Depress the clutch.
B. Verify that the "Clutch Pedal Position Switch"
E, Check the status of the "Clutch Pedal Position parameter is programmed to reflect the proper
Switch". wiring.

The status for the "Clutch Pedal Position Switch" The clutch pedal position switch is wired directly
is "Off" when the clutch is released. The status for to the ECM.
the "Clutch Pedal Position Switch" is "On" when the
clutch is depressed. Results:
Results: • OK - T h e clutch pedal position switch is wired
directly to the ECM.
• OK - T h e clutch pedal position switch is
operating correctly. STOR Repair: Verify that the "Clutch Pedal Position
Switch" parameter is programmed to "J1/P1:22".
• Not OK - T h e clutch pedal position switch is not
operating correctly. Proceed to Test Step 2. Proceed to Test Step 3.
• Not OK - T h e clutch pedal position switch uses

the J1939 data link.
193
Repair: Verify that the "Clutch Pedal Position

Switch" parameter is programmed "J 1939 - Body
Controller", "J 1939 - Cab Controller", or "J 1939 -
Instrument Cluster".
Refer to Troubleshooting, "Powertrain Data Link

Circuit - Test".
STOR

and Wiring
AP SENSOR/SWITCH SENSOR COMMON

~5o ~ t ~ o O o o o ~ o o olX CLUTCH PEDAL POSITION SWITCH
!50 O O o O O O O O14
510 O O O ~ O O O 024
390 0 O0 [~0~.~) 0 0 0 0 3 2
470 0 0 O 0 O O 040
570 O O O O o O O O O 048
700 0 0 0 0 0 0 0 0 0 0 0 058
ECM Side Vehicle horness connector P1

1 2 3 4 5A6 ~ 8_9_10_11_12_13~ AP SENSOR/SWITCH SENSOR COMMON
A-] O 0 0 0 t F O 0 0 0 0 O O ~ O CLUTCH PEDAL POSITION SWITCH
U 1 1 4 0 0 0 0 0 ~ O00qF(D~3
-1240000 J~'h, 00003'
PO000 (( r.,_.1 >} 0000
; ooo oooo,r-
',SOOoOOoooSSoOSS
\ X~.58 59 60 6 62 63 Iq 65 66 67 6869 7 0 j /
It II .J
Horness Side
A. Thoroughly inspect the J1/P1 ECM connector, D. Check the harness and wiring for abrasion and
the firewall bulkhead connector and the terminals pinch points from the sensor to the ECM.
for the following switches in the connectors:
Expected Result:
• J1/P1:22 (Clutch Pedal Position Switch)
• J1/P1:5 (AP Sensor/Switch Sensor Common) completely coupled and/or inserted and the harness
Refer to Troubleshooting, "Electrical Connectors or pinch points.
Results:
wires in the ECM connector that are associated • OK - Proceed to Test Step 4.
with the switches.
• Not OK
C. Check the ECM connector (Allen Head Screw) replace the connectors or wiring. Ensure that all
for the proper torque of 6.0 N.m (55 Ib in). of the seals are properly in place and ensure that
194
Verify that the repair eliminates the problem. 2. Remove the breakout T and reconnect the P1
ECM connector to the ECM.
STOP.
Test Step 4. Check the Switch Circuit reconnect the suspect ECM.
A. Turn the key switch to the Off position. 4. If the problem returns with the suspect ECM,
replace the ECM.
B. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wires. 5. Verify that the repair eliminates the problem.
C, Disconnect the P1 ECM connector. STOR
D. Connect a 140-2266 Cable (Seventy-Pin Test Step 5. Insert a Jumper at the Clutch
Breakout) between the J1 and P1 ECM Switch
connectors.
E. Install the jumper into terminal 22 (Clutch Pedal
Position Switch) of the breakout T. Connect B. Find the clutch switch in the vehicle.
the other end of the jumper to terminal 5 (AP
Sensor/Switch Sensor Common) of the breakout C. Disconnect the wires from the clutch switch
T. terminals.
F, Turn the key switch to the On position. D. Turn the key switch to the On position.
G. Connect the electronic service tool to the data E. Connect the electronic service tool to the data
link connector. link connector.
H. Access the status for the "Clutch Pedal Position F. Access the status screen on the electronic
Switch" on the electronic service tool. service tool.
I. While the status for the "Clutch Pedal Position G. While the status for the "Clutch Pedal Position
Switch" is being monitored on the electronic Switch" is being monitored on the electronic
service tool, remove the jumper from terminal 5 service tool, connect the switch wires and
(AP Sensor/Switch Sensor Common). Insert the disconnect the switch wires.
jumper into terminal 5 (AP Sensor/Switch Sensor
Common). Expected Result:
Expected Result: When the switch wires are connected the status for
the "Clutch Pedal Position Switch" is "Off". When
When the jumper wire is installed, the status for the the switch wires are disconnected the status for the
"Clutch Pedal Position Switch" is "Off". When the "Clutch Pedal Position Switch" is "On".
jumper wire is removed, the status for the "Clutch
Pedal Position Switch" is "On". Results:
Results: • OK - T h e wiring between the clutch pedal
position switch and the ECM is OK.
• OK - T h e ECM is functioning properly.
Repair: Replace the faulty switch.
Repair: Remove the breakout T and reconnect the
P1 ECM connector to the ECM. Verify that the repair eliminates the problem.
Proceed to Test Step 5. STOP.
• Not OK - The ECM is not functioning properly. Not OK -There is a problem in the harness
between the switch and the ECM. Proceed to Test
Repair: Perform the following repair: Step 6.
1. Temporarily connect a test ECM

195
Test Step 6. Insert a Jumper at the i01919789

Bulkhead Connector
Coolant Level Sensor Circuit-
A. Turn the key switch to the Off position. Test
B. Fabricate a jumper wire 100 mm (4 inch) long. SMCS Code: 5574-038-CLT
Crimp a Deutsch pin to both ends of the wires.
C. Locate the clutch switch terminal and find the AP
Sensor/Switch Sensor Common terminal on the The coolant level sensor is an OEM installed
engine side of the bulkhead connector. component for the vehicle. This sensor is the
only optional sensor for "Engine Monitoring".
D. Insert the jumper wire between the two terminals "Engine Monitoring" is a programmable feature
in the engine side of the bulkhead connector. of the Caterpillar ECM. The sensor is selectable
through a customer programmable parameter and
E. Turn the key switch to the On position. the customer programmable parameter may be
protected by customer passwords. Some OEM
F. Connect the electronic service tool to the data installed coolant level sensors are not connected
link connector. to the Engine Control Module (ECM). Do not
confuse an OEM installed "Coolant Level Sensor"
G. Access the status for the "Clutch Pedal Position that is independent of "Engine Monitoring" with the
Switch" on the electronic service tool. "Coolant Level Sensor" that is used for "Engine
Monitoring".
H. While the status for the "Clutch Pedal Position
Switch" is being monitored on the electronic The sensor operates as a coolant level sensor. The
service tool, remove the jumper wire between the sensor indicates the presence or the absence of
two terminals and insert the jumper wire between coolant at the sensor probe. There are two options
the two terminals. if a coolant level sensor is installed.
Expected Result: • "4-pin"
When the jumper wire is installed, the status for the • "2-wire Float Sensor"
"Clutch Pedal Position Switch" is "Off". When the
jumper wire is removed, the status for the "Clutch If a coolant level sensor is not installed or the
Pedal Position Switch" is "On". coolant level sensor is independent from the ECM,
the parameter should be programmed to "None".
Results:
"4-pin"
• OK - T h e problem is in the vehicle wiring
between the bulkhead connector and the switch. The sensor is powered from the ECM through the
ECM connector J1/P1:2 (+5 VDC). The signal wires
Repair: Perform the following repair: for the coolant level sensor are connected to pins
J1/P1:54 (Coolant Level Low) and to J1/P1:49
Inspect the vehicle wiring and repair the vehicle (Coolant Level Normal) on the ECM. The sensor
wiring, as required. If the problem still exists with common is connected to the ECM connector
the wiring, send the vehicle to the OEM dealer. J1/P1:5 (AP Sensor/Switch Sensor Common).
STOR If coolant is present at the sensor probe, "Coolant
Level Low" has an output of near 0 VDC. If coolant
• Not OK - The problem is in the vehicle wiring is present at the sensor probe, "Coolant Level
between the bulkhead connector and the ECM. Normal" has an output near +5 VDC. If coolant is
not present at the sensor probe, the "Coolant Level
Repair: Perform the following repair: Low" output would be near +5 VDC. If coolant is
not present at the sensor probe, the "Coolant Level
Inspect the vehicle wiring and repair the vehicle Normal" output would be near 0 VDC.
wiring, as required. If the problem still exists with
the wiring, send the vehicle to the OEM dealer. "2-wire Float Sensor"
STOR The sensor is powered with +5 VDC from the ECM
through ECM connector J1/P1:26. The sensor
is also connected to J1/P1:5 (AP Sensor/Switch
Sensor Common).
196
Resistance through the sensor is varied by the Test Step 2. Determine the type of
coolant level. The voltage at the normal operating Coolant Level Sensor
range is between 0.75 VDC and 1.75 VDC.
A. Check the coolant level sensor in order to
Note: The "Coolant Level Sensor" is set when the determine the type of sensor that is installed on
coolant level sensor is programmed to "4-Pin" or the vehicle.
"2-wire Float Sensor". If this parameter is set and
a sensor is not installed, the following diagnostic Expected Result:
code will be logged:
A "4-pin" or "2-wire Float Sensor" is installed.
• 111-02 Coolant Level signal invalid
Results:
The "Engine Monitoring Lamps" parameter is used
in order to determine if a single warning lamp is • "4-pin" - Proceed to Test Step 3.
used for the engine monitoring system or if discrete
lamps are used for each monitored condition. • "2-wire Float" - Proceed to Test Step 9.
If the "Engine Monitoring Lamps" parameter is
programmed to "Warning Lamp", a single lamp is • None
connected to J1/P1:29. If the "Engine Monitoring
Lamps" parameter is programmed to "Option 1" and Repair: If a coolant level sensor is not installed,
a coolant level sensor is installed, then a discrete change the "Coolant Level Sensor" parameter to
lamp for low coolant level is connected to J1/P1:30. "None".
The "Coolant Level Sensor" parameter must be
programmed for the lamp to operate correctly. Verify that the repair eliminates the problem.
Test Step 1. Check for an Active Coolant STOR

Level Sensor Fault
A. Connect the Caterpillar Electronic Technician
(Cat ET) to the data link connector.
C. Check for active diagnostic codes on Cat ET.
Expected Result:
One of the following diagnostic codes is active.
• 111-03 Coolant Level voltage high
• 111-04 Coolant Level voltage low
Results:
• NotOK - 111-01, 111-11, or 111-14 is active.
Repair: Refer to Troubleshooting, "Troubleshooting

with a Diagnostic Code" for the proper
troubleshooting procedure.
STOR
• No Codes - If none of the specified diagnostic

codes are present, clear all diagnostic codes. If a
problem is still suspected with the coolant level
sensor, proceed to Test Step 2.
197

and Wiring
ECM
*~vF~T~ G879-OR~+SV
COOLANT LEVEL NORMALp D H C983-WH---ICI49~COOLANT LEVEL NORMAL
COOLANT LEVEL LOWp AI;I C 9 8 4 - Y L ~ 1 5 4 4 COOLANT LEVEL LOW
AP SENSOR/SWITCHSENSORCOMMONi~ Bl>l H795-PKpl-~_J~j51AP SENSOR/SWITCHSENSORCOMMON
I
lUustration 68 g00650999
Schematic for "4-pin" coolant level sensor
,--,
ooooooo.' o : I
z,.~O000 0 000
+SV
3,ooo oD
}9O 0 0 0 0 0 0 O32 oooo2,
470 0 0 0 0 0 040
ENGINE COOLANT LEVEL NORMAL
~70 0 0 0 0 0 ~48
ENGINE COOLANT LEVEL Log
'70000000000000058

/ ;-,-2-3u,-5-s-=-8-9-,0ut,-,2-13~ AP SENSOR/SWITCH SENSOR COMMON
D 4 Q( , . ) U ( JQL ) L ) ooQQQQe
>~_!< LJ~J~JL.)LJ231UI +SV
-~40000 f , ~ oooo3~rI
0000 (([ ] ) m O O 0 0 ql
,IOOC)~)C') <'~.,'/ (")0(")(~)47U ENGINE COOLANT LEVEL NORMAL
~,8oe'~oo- oi~:,oo~,lnl ENGINE COOLANT LEVEL LOW
L ooooooooooooo
198
Verify that the repair eliminates the problem. Clear

Coolont Level Low all diagnostic codes.
A
STOR
Test Step 4. Check the Supply Voltage at

the Sensor
Coolont +5 V
Level Sensor
Normol Supply A, Turn the key switch to the OFF position.
B, Disconnect the coolant level sensor from the

harness.
B
Sensor/Switch Common C, Turn the key switch to the ON position.
g00999065
Illustration 70
D, Measure the voltage at the harness connector
Connector for the "4-pin" coolant level sensor between Terminal C (+5 V Sensor Supply) and
Terminal B (AP Sensor/Switch Sensor Common).
A. Thoroughly inspect the J1/P1 ECM connector,
the connector for the coolant level sensor Expected Result:
and the terminals in the connectors. Refer
to Troubleshooting, "Electrical Connectors - The measured voltage is between 4.5 VDC and 5.5
Inspect" for details. VDC.
B. Perform a 45 N (10 Ib) pull test on each of the Results:
wires in the ECM connector that are associated
with the following connections: • OK - T h e voltage is within the proper range.
• J1/P1:2
• Not OK - There is a problem with the sensor
• J1/P1:5 supply. Proceed to Test Step 5.
• J1/P1:49 Test Step 5. Check the Supply Voltage at
the E C M
• J1/P1:54
for the proper torque of 6.0 N.m (55 Ib in). C. Install a 140-2266 Cable (Seventy-Pin Breakout)
between ECM connector J1 and ECM connector
D. Check the harness and wiring for abrasion and P1.
pinch points from the sensor to the ECM.
Note: The P1 ECM connector must be connected
Expected Result: to the breakout T in order for the ECM to receive
battery voltage.
completely coupled and/or inserted and the harness D. Turn the key switch to the ON position.
or pinch points. E. Measure the voltage between Terminal 2 (+5 V
Sensor Supply) and Terminal 5 (AP Sensor/Switch
Results: Sensor Common) at the breakout T.
• OK - Proceed to Test Step 4. Expected Result:
• Not OK The measured voltage is between 4.5 VDC and 5.5
VDC.
replace the connectors or wiring. Ensure that all
199

• OK - T h e problem is located in the harness The status for "Coolant Level" indicates "LOW"
wiring. while the jumper wire is in place. A 111-01 Low
Coolant Level Warning is active while the jumper
Repair: Remove the breakout T. Reconnect the wire is in place.
J1/P1 ECM connectors.
Results:
Measure the voltage between Terminal C and
chassis ground at the connector for the coolant • OK - T h e ECM responded correctly. Proceed to
level sensor on the vehicle harness. Test Step 7.
If the voltage is between 4.5 VDC and 5.5 • Not OK - Proceed to Test Step 8.
VDC, the problem is with the common wire. If
the voltage is not within the proper range, the Test Step 7. Check the Circuit for the
problem is with the supply wire. Coolant Level Low
Repair the wiring or replace the wiring, as A. Turn the key switch to the OFF position.
required.
B. Insert a jumper wire between Terminal A (Coolant
Verify that the repair eliminates the problem. Level Low) and Terminal B (AP Sensor/Switch
Sensor Common) at the harness connector.
STOR
C. Turn the key switch to the ON position.
• Not OK - There may be a problem with the ECM.
D. Check for active diagnostic codes on Cat ET.
Repair: Temporarily connect a test ECM. Ensure
that the "Engine Monitoring" and the "Coolant E. Check the status for "Coolant Level" on Cat ET.
Level Sensor" are programmed to match the old
ECM. Expected Result:
Check the test ECM by measuring the voltage There are no active diagnostic codes while the
between Terminal 2 and Terminal 5 at the jumper wire is in place. The status for "Coolant
breakout T. Level" displays "OK".
If the test ECM fixes the problem, reconnect the Results:

suspect ECM.
• OK - T h e harness and the ECM are working
If the problem returns with the suspect ECM, correctly.
permanently replace the ECM.
Repair: Remove the jumper wire.
Replace the sensor and reconnect the harness
STOR to the sensor.
Test Step 6. Check the Circuit for the Verify that the repair eliminates the problem.
Coolant Level Sensor
STOR
B. Insert a jumper wire between Terminal D (Coolant
Level Normal) and Terminal B (AP Sensor/Switch Test Step 8. Check the ECM for Proper
Sensor Common) at the harness connector. Operation
C. Turn the key switch to the ON position. A. Disconnect the J1/P1 ECM connector.
D. While the jumper wire is in place, access the B. Install a breakout T between the J1 and P1 ECM
status for "Coolant Level" on Cat ET. connectors.
E. Check for active diagnostic codes. C. Fabricate two jumper wires 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of each wire.
R Turn the key switch to the OFF position.
200
E. Monitor the status for "Coolant Level" on Cat Verify that the repair eliminates the problem. Clear
ET. Insert a jumper wire between Terminal 49 all diagnostic codes.
(Coolant Level Normal) and Terminal 5 (AP
Sensor/Switch Sensor Common) of the breakout STOR
T.
• Not OK
F. Monitor the status for "Coolant Level" while the
jumper is being inserted and removed. Wait Repair: Temporarily connect a test ECM. Ensure
for 30 seconds between the insertion of the that the "Engine Monitoring" and the "Coolant
jumper and the removal of the jumper. The status Level Sensor" are programmed to match the old
for "Coolant Level" will display "Low" while ECM.
the jumper wire is in place. Also, the following
diagnostic code should be active: Repeat this Test Step with the test ECM.
• 111-01 Low Coolant Level Warning If the test ECM fixes the problem, reconnect the
suspect ECM.
Note: 111-14 Low Coolant Level Warning will be
active during the first six hours of engine operation. If the problem returns with the suspect ECM,
permanently replace the ECM.
G. Record the result.
H. Monitor the status for "Coolant Level" on Cat
ET. Insert a jumper wire between Terminal STOR
54 (Coolant Level Low) and Terminal 5 (AP
Sensor/Switch Sensor Common) of the breakout
T.
Monitor the status for "Coolant Level" while the

jumper is being inserted and removed. Wait
for 30 seconds between the insertion of the
jumper and the removal of the jumper. The status
for "Coolant Level" will display "OK" while the
jumper wire is in place. Also, there should be no
active diagnostic codes.
Expected Result:
The "Coolant Level" status behaves in the following

manner:
• The status for "Coolant Level" indicates "Low"

when the jumper wire is installed between
Terminal 49 and Terminal 5. Also, 111-01 Low
Coolant Level Warning is active.
Note: 111-14 Low Coolant Level Warning will be

active during the first six hours of engine operation.
• The status for "Coolant Level" indicates "OK"

when the jumper wire is installed between
Terminal 54 and Terminal 5. Also, there are no
active diagnostic codes.
Results:
Repair: Repair the harness or replace the

harness, as required.
201

and Wir,ng
P1/J1 ECM
, @ Coolant Level S e n s o r ~
AP Sensor/Switch Sensor Common~' I~1>I
C455-YL
14795-PK
[~ Input #10
AP Sensor/Switch Sensor Common
Schematic for "2-wireFloatSensor"
f
j-
L__J -"
130000000000000 1 Coolant Level Input
23 0 0 0 0 0 0 0 0 0 0 . ~ 14
310 0 0 0 ~ 0 a~"O 0 24
3900 0 0 ~ 0 0 0032
470 0 0 0 0 0 0 040
5700000 0 0000048
000000000000058
ECM Side
$ 3 (O 5 (O8655(~) 121"3)~
'AP Sensor/Switch Sensor Common
ooo
0000 Coolant Level Input
ccx oooooooo
Harness Side
k. Thoroughly inspect the J1/P1 ECM connector, Refer to Illustration 72.

the connector for the coolant level sensor and
the terminals for the coolant level sensor in the C. Check the ECM connector (allen head screw) for
connectors. Refer to Troubleshooting, "Electrical the proper torque of 6.0 N.m (55 Ib in).
B. Perform a 45 N (10 Ib) pull test on each of the pinch points from the sensor to the ECM.
with the following connections:
• P1/J1:26 (Coolant level input)
• P1/J1:5 (AP sensor/switch sensor common)

202
Expected Result: B, Disconnect the coolant level sensor from the

harness.
completely coupled and/or inserted and the harness C, Use a multimeter to measure the voltage at the
and wiring should be free of corrosion, abrasion harness connector.
or pinch points.
D, Turn the key switch to the ON position.
Results:
Expected Result:
The measured voltage is between 4.5 VDC and 5.5
• Not OK VDC.
Repair: Repair the connectors or wiring and/or Results:

of the seals are properly in place and ensure that • OK - The correct voltage is reaching the sensor.
Repair: Replace the sensor.
Verify that the repair eliminates the problem. Clear
all diagnostic codes. STOP.
STOR • Not OK - Proceed to Test Step 12.
Test Step 10. Verify that the Diagnostic Test Step 12. Disconnect the Terminal
Code is Still Active for the Sensor Supply (+5 VDC) from the
ECM Connector
A, Turn the key switch to the ON position. Wait at
least 15 seconds for activation of the diagnostic AP Sensor/Switch Sensor Common
codes.
Coolant Level Input X
B, Check for active diagnostic codes on Cat ET.
Expected Result:
One of the following diagnostic codes is active. /

o o o o o o
12500000 0 ~ " ~ 0 0 0 0 14
• 111-03 Coolant Level voltage high I oooo II #II 0 0 o o 3 2

1470oo0 k ~ ' ~ p 000040
• 111-04 Coolant Level voltage low 15700000 o 0000048
17o00 0 0 0 0 0 0 0 0 0 0 058
Results:
%
• 111-02 - A fault for the coolant level sensor is
active, Proceed to Test Step 11. ECM SIDE
• 111-03 - A "voltage high" diagnostic code (open Illustration 73 g00884813

circuit) is active at this time. Proceed to Test Step
Terminal locations on the breakout T (2-wire float sensor)
15.
• 111-04 - A "voltage low" diagnostic code (short
circuit) is active at this time. Proceed to Test Step
B, Disconnect the J1/P1 ECM connector.
13.
C, Install a breakout T between ECM connector J1
Test Step 11. Disconnect the Coolant and ECM connector PI.
Level Sensor and Check the Supply
Voltage (+5 VDC) D, Turn the key switch to the ON position.
203
E. Measure the voltage at the breakout T from 2. Verify that the repair eliminates the problem.
terminal 26 to terminal 5.
STOP.
• Not OK - There is still a "voltage low" diagnostic
Expected Result: code (short circuit). Proceed to Test Step 14.
The measured voltage is between 4.5 VDC and 5.5 Test Step 14. Create an Open Circuit at
VDC. the E C M
Results: A. Turn the key switch to the OFF position.
• OK - T h e problem is located in the harness B. Remove the wires from P1:26 and J1:5 in order
wiring. to create an open circuit at the ECM.
Repair: Repair the wiring or replace the wiring, C. Turn the key switch to the ON position. Wait at
as required. least 15 seconds for activation of the diagnostic
codes.
D, Check for active diagnostic codes on Cat ET.
STOR
Expected Result:
• Not OK - The problem is on the ECM side.
111-03 Coolant Level voltage high is now active.
that the "Engine Monitoring" and the "Coolant Results:
Level Sensor" are programmed to match the old
ECM. Check the test ECM by measuring the • OK -There is a short circuit in the harness
voltage at the breakout T from terminal 26 to between the ECM and the coolant level sensor.
terminal 5 again. If the problem is resolved with Proceed to Test Step 17.
the test ECM, reconnect the suspect ECM. If the
problem returns with the suspect ECM, replace • Not OK - The "voltage low" diagnostic code
the ECM. (short circuit) is still present.
STOR Repair: Perform the following procedure:

Test Step 13. Disconnect the Sensor in 1. Temporarily connect a test ECM. Refer to
order to Create an Open Circuit Troubleshooting, "Programming Parameters"
before replacing the ECM.
2. If the test ECM fixes the problem, reconnect
B. Disconnect the coolant level sensor at the sensor the suspect ECM. If the problem returns,
in order to create an open circuit. permanently install the new ECM.
C. Turn the key switch to the ON position. Wait at STOR

least 15 seconds for activation of the diagnostic
codes. Test Step 15. Create a Short Circuit at the
Sensor
D. Check for active diagnostic codes on Cat ET.
Expected Result:
B. Disconnect the coolant level sensor at the sensor.
111-03 Coolant Level voltage high is now active.
C. Fabricate a jumper wire between terminal 1 and
Results: terminal 2 of the connector for the coolant level
sensor in order to create a short circuit.
• OK -There is a "voltage high" diagnostic
code (open circuit) when the connector is D, Turn the key switch to the ON position. Wait at
disconnected. least 15 seconds for activation of the diagnostic
codes.
Repair: There is a short in the coolant level sensor.
E. Check for active diagnostic codes on Cat ET.
1. Repair the sensor or replace the sensor.
204
Expected Result: 2, If the test ECM fixes the problem, reconnect

the suspect ECM. If the problem returns,
111-04 Coolant Level voltage low is now active. permanently install the new ECM.
Results: STOR
• OK -There is an open circuit in the coolant level Test Step 17. Bypass the Harness Wiring
sensor. between the ECM and the Solenoid
Repair: Perform the following procedure: A. Turn the key switch to the OFF position.
1, Repair the coolant level sensor or replace the B, Remove the wires from P1:26 and P1:5. Also
coolant level sensor. remove the wires from the connector for the
coolant level sensor.
2, Verify that the repair eliminates the problem.
C, Fabricate two jumper wires to reach from the
STOR ECM to the connector for the coolant level
sensor. Crimp Deutsch sockets to both ends of
• Not OK - T h e "voltage high" diagnostic code each wire.
(open circuit) is still active. Proceed to Test Step
16. D, Connect one wire between P1:26 and terminal 1
of the coolant level sensor. Connect the other
Test Step 16. Create a Short Circuit at the wire between P1:5 and terminal 2 of the coolant
ECM level sensor.
A. Turn the key switch to the OFF position. E, Turn the key switch to the ON position. Wait at
Bo Remove the wires from P1:26 and P1:5. codes.
C, Fabricate a jumper wire between P1:26 and P1:5 Expected Result:

in order to create a short circuit.
There are no active diagnostic codes.
D, Turn the key switch to the ON position. Wait at
least 15 seconds for activation of the diagnostic Results:
codes.
• OK -There was a problem in the harness.
E, Check for active diagnostic codes on Cat ET.
Expected Result:
1, Permanently replace the faulty wiring.
111-04 Coolant Level voltage low is now active.
2, Clear all diagnostic codes.
Results:
• OK -There is a problem in the harness between
the ECM and the solenoid. Proceed to Test Step STOR
17.
• Not OK - Bypassing the harness did not fix the
• Not OK -There is still a "voltage high" diagnostic problem.
code (open circuit).
Repair: Perform the following procedure: Troubleshooting, "Electrical Connectors- Inspect".
1, Temporarily connect a test ECM. Refer to Restart this procedure and carefully perform each
Troubleshooting, "Programming Parameters" step.
before replacing the ECM.
STOR
205
i01907624 • PTO On/Off Switch

Cooling Fan Circuit and A/C • OEM installed A/C High Pressure Switch
High Pressure Switch Circuit
• Fan Override Switch
- Test
The control unit for the A/C may be connected to
SMCS Code: 1356-038; 1435-038-PX the A/C high pressure switch (Input 11) instead of
a switch.
The output for the cooling fan is intended to connect
Use this procedure under the following situation: directly to the circuit for the cooling fan solenoid.
The solenoid and clutch configuration must be
The cooling fan (Output 5) or the A/C high pressure selected in order for the ECM output to turn the fan
switch (Input 11) is suspected of incorrect operation. "Off". The fan will remain on for a minimum of 30
seconds. The fan will not remain on for 30 seconds
Note: Not all vehicle manufacturers, or all trucks during engine start-up. The fan will not remain on
for a manufacturer use the Caterpillar cooling fan for 30 seconds if the "A/C Pressure Switch Fan On
circuit. Prior to troubleshooting, determine if the Time" is programmed to less than 30 seconds.
vehicle is using the ECM cooling fan circuit. During engine start-up, the ECM will keep the fan
on for two seconds after the engine has reached
Check the following items in order to determine if a the programmed low idle (600 to 750 rpm). The fan
vehicle is using the ECM cooling fan circuit: will be on continuously if the electrical circuit to the
cooling fan air solenoid valve has an open circuit or
• The "Fan Control Type" parameter must be if the ECM fan relay circuit is opened.
programmed to "On/Off", "Three-Speed Fan", or
"Variable Speed Fan Option S". The Caterpillar Cooling Fan On Conditions (On/Off Fan)
factory default is None.
The ECM will turn on the cooling fan, if any of the
• A wire is present in the ECM vehicle harness following conditions are met:
connector J1/P1:11 which is Output 5 (Cooling
Fan Solenoid). This occurs if an "On/Off" type of Engine speed is less than 2250 rpm.
fan is used.
The engine is not running.
• A wire is present in the vehicle harness connector
J1/P1:11 which is Output 5 (Slip Solenoid). A wire The engine is cranking.
is also present in the vehicle harness connector
J1/P1:13 which is Output 4 (Brake Solenoid). This The temperature of the coolant temperature
occurs if a Three-Speed Fan is used. sensor for the C-10 and the C-12 engines is
greater than 96 °C (205 °F).
• Perform the Special Test for the "On/Off Cooling
Fan" or the special tests for the "Three-Speed The temperature of the coolant temperature
Fan". Access each menu in the order that follows: sensor for the 3406E, C-15, C-16 and C-18
"Diagnostics", "Diagnostic Tests", and "Special engines is greater than 102 °C (216 °F).
Test". Activating and then deactivating the circuit
should cause the air solenoid to click if the circuit Active diagnostic code for the coolant temperature
is working properly. sensor
The following background information is related The intake manifold air temperature is greater
to this procedure: than 87 °C (189 °F).
Cooling Fan The intake manifold air temperature is greater
than 72 °C (162 °F) while the boost pressure is
The signal for the cooling fan is provided by the greater than 70 kPa (10 psi).
ECM in order to control the cooling fan. An input
from one of the following items may cause the fan The "Fan with Engine Retarder in High Mode" is
to turn on: programmed to "YES" and the retarder has been
on at least two seconds.
• Engine Coolant Temperature Sensor
The "A/C Switch Fan On-Time" is programmed
• Intake Manifold Air Temperature Sensor to a value above 0 and the A/C high pressure
switch is Open.
• Engine Retarder Switches
206
• The ECM is counting after the A/C high pressure The fan is operating at full speed when the "Direct"
switch has closed. mode is used. The "Slip" mode is used most
often. The "Fan Control Type" parameter must be
• The "PTO Activates Cooling Fan" parameter is programmed to "Three-Speed Fan". Two outputs
programmed to "Continuous" and the PTO On/Off are required for Three-Speed fan control. Output 4
switch is on. is used for the brake solenoid. Output 5 is used
for the slip solenoid. The function of these outputs
• The manual fan override switch is on. is automatically determined by the ECM when the
"Fan Control Type" parameter is programmed to
The last four items in the list are programmed by "Three-Speed Fan". The fan is turned on in the
the customer in the "Configuration" screen on the event of a failure in the output circuit. An example
Caterpillar Electronic Technician (Cat ET). would be an open circuit. The ECM provides the
power in order to turn off the fan. If the power is
Note: With OCT99 and newer software, the ECM will interrupted due to an open circuit, the fan will run
turn the cooling fan "Off" for 10 seconds during an continuously. This provides a fail safe operation.
engine shutdown. The ECM turns Off the output circuit power in order
to turn on the fan. Additional switching devices that
Cooling Fan OFF Conditions are in the circuit create an open circuit in order to
turn the fan "On". Both of the output drivers are in
The cooling fan will be turned off by the ECM if the ON position while the Brake mode is active.
engine rpm exceeds 2300 rpm or when all the However, the fan is off. In Slip mode, Output 4 is
following circumstances are met: off and Output 5 is on. During Direct mode, both
output drivers are off. The fan is on at full speed.
• The engine coolant temperature for the C-10 or The ECM controls the mode for the fan. The mode
the C-12 engines is less than 92 °C (198 °F). is based on the following conditions:
• The engine coolant temperature for the 3406E, • Coolant temperature

C-15, C-16 and C-18 engines is less than 98 °C
(208 °F). • Intake manifold air temperature
• The fan has been on for at least 30 seconds. • Engine operating conditions
• The intake manifold air temperature is less than Cooling Fan Trip Points (Three-Speed Fan)
53 °C (127 °F).
The hysteresis can occur when different modes are
• The "Fan with Engine Retarder in High Mode" selected. The trip points are set at different values.
strategy is not active. The values depend on increasing temperature and
decreasing temperature. The ECM will operate the
• The "A/C High Pressure Switch Strategy" is not cooling fan under the conditions that are listed in
active. the following charts and graphics.
• The "PTO Activates Cooling Fan" strategy is not

active.
• The manual fan override switch is off.
Three-Speed Fan
The Three-Speed Fan operates in three modes:
• Brake
• Slip
• Direct
207
Coolont Temp °C (OF)
90 (194) 9,5 (203)
--Broke ~l~J Slip ,~ Direct

.4-- Broke L., Slip L., Direct
80 (176) 92 (198)
Intoke Air Temp °C (OF) with Boost < 70 kPo

5;3 (127) 81 (17B)
Broke ,-1~1 Slip ~1n Direct
~1-- Broke L,
l-q Slip L.,
i-.~ Direct
0 (32) 53 (127)
Intoke Air Temp °C (OF) with Boost > 70 kPo

53 (127) 65 (149)
Broke ~u'~l Slip ~ Direct
Broke L.,
r-q Slip L.,
i-~ Direct--
0 (32) 55 (127)
Trip Points for a Three-Speed Fan (C-10 and C-12)
Table 143
Trip Points for a Three-Speed Fan (C-10 and C-12)
Intake Manifold Air Intake Manifold Air
Intake Manifold Air Temperature with Temperature with
Mode Coolant Temperature Temperature Boost that is Less Boost that is Greater
Than 70 kPa (10 psi) Than 70 kPa (10 psi)
Brake Mode to Slip °C
Mode 90 (194 °F) 53 °C (127 °F)
Slip Mode to Direct oC

Mode 95 (203 °F) 81 °C (178 °F) 65 °C (149 °F)
Direct Mode to Slip °C

Mode 92 (198 °F) 53 °C (127 °F)
Slip Mode to Brake °C

Mode 80 (176 °F) 0 °C (32 °F)
208
Coolont Temp °C (OF)
90 (194) ~0~ (217)

Broke ,.q==l Slip ~tI Direct --~
41-- Broke It.,
~ Slip L..
i TM
Direct-
80 (176) 97 (207)
Intoke Air Temp O C (OF) with Boost < 70 kPo

53 (127) 81 (178)
Broke =J
,v 1 Slip ~--I Direct
41-- Broke IL. Slip L.,
TM Fw Direct
0 (32) 53 (127)
Intake Air Temp O c (OF) with Boost > 70 kPo

55 (127) 65 (149)
Broke -i"t Slip ~J Direct--I~
<t-- Broke L.,
i-~ Slip L.,
i-~ Direct
0 (32) 53 (127)
Illustration 75 900784050
Trip Points for a Three-Speed Fan (3406E, C-15, C-16 and C-18)
Table 144
Trip Points for a Three-Speed Fan (3406E, C-15, C-16 and C-18)
Intake Manifold Air Intake Manifold Air
Intake Manifold Air Temperature with Temperature with
Mode Coolant Temperature Temperature Boost that is Less Boost that is Greater
Than 70 kPa (10 psi) Than 70 kPa (10 psi)
Brake Mode to Slip °C
Mode 90 (194 °F) 53 °C (127 °F)
Slip Mode to Direct

103 °C (217 °F) 81 °C (178 °F) 65 °C (149 °F)
Mode
Direct Mode to Slip °C
Mode 97 (207 °F) 53 °C (127 °F)
Slip Mode to Brake °C

Mode 80 (176 °F) 0 °C (32 °F)
The following conditions will also cause the • The A/C high pressure switch is active. The "A/C
Three-Speed Fan to operate in Direct Mode: Pressure Switch Fan On-Time" is programmed to
a value that is greater than 0 seconds.
• The engine retarder is on and the engine retarder
selector switch is in the High position. The "Fan Note: There may be an initial delay before the
with Engine Retarder in High Mode" parameter fan is in the Direct mode. Activation of the fan is
must be programmed to "Yes". dependent on the operating conditions.
• The PTO On/Off Switch is on. The "PTO Activates A/C High Pressure Switch Input Connected to
Cooling Fan" parameter is programmed to "Yes". A/C Control Unit.
209
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 Input 11 of the ECM Connector
J1/P1:41. 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

210
ACTUAL CHASSIS
MANUAL FAN DIAGRAM MAY VARY
OVERRIDE SWITCH
ECM
A/C HIGH PRESSURE SWITCH
(N/C) c ~ p (FAN OFF POSITION) G843-OR-~C~TF'~
--INPUT 16
E971-GN--KI INPUT !11
HZ95-PK--KI AP SENSOR/SWITCH SENSOR COMMON
G837-YL~ OUTPUT 15
COOLING FAN
SOLENOID CIRCUIT PI J1
AIR VALVE PROTECTION
NOTE:THE MANUAL FAN OVERRIDE SWITCH MAY
BE PROGRAMMEDTO USE INPUT 14, 15. 16 OR 17-
-g
This schematic representsthe ON/OFFfan with a direct solenoid connection to the ECM and the A/C Pressure Switch connected to
the ECM input.
ACTUAL CHASSIS
DIAGRAM MAY VARY
A/C HIGH CIRCUIT
PRESSURE SWITCH PROTECTION
~ ~ ( F A N OFF SWITCH)
I COOLING FAN ECM

SOLENOID
G837-YL---~ OUTPUT 15
I ~ AIR VALVE CAB MANUAL ,
G844-PK-'I~146~. INPUT 17
' r
._L-
I FAN OVERRIDE SWITCH H795-PK~ AP SENSOR/SWITCH SENSOR COMMON
--=l I P1JI
BE PROGRAMMEDTO USE INPUT 14, IS, 16 OR 17.
This schematic representsthe ON/OFF fan with direct solenoid connection to the ECM and the NC High PressureSwitch not connected to
the ECM input.
211
COOLING FAN CAB MANUAL

SOLENOID FAN OVERRIDE ACTUAL CHASSIS
ATR VALVE SWITCH CIRCUIT OIA6RAH HAY VARY
PROTECTION
A/C ECM
CONTROL
UNIT
G83,-YL--I~ OUTPO,15 I
I I E971-GN-~r<~ I 41N
P1 J1
INPUT !11
OTHER CONNECTIONS TO CONTROL UNIT NOT SHOWN
This schematic representsthe ON/OFF fan with direct solenoid connection to the ECM and the A/C Control Unit is connected to the ECM input.
A/C HIGH CIRCUTT TO VEHICLE

PRESSURE SWITCH PROTECTION +BATTERY
_ ~ ~ (N/O) COOLING FAN

NORMALLY ACTUAL CHASSIS
(,AN o-- ,O,~T~ON~ ~,0~0 .~LA~ DIAepRAM MAY VARY
ECM
GB37-YL-~OUTPUT 15
G 8 4 2 - G ¥ - - - ~ I 4 7 ~ INPUT 15
F H 7 9 5 - P K - ~ - ~ _ 5 ~ A P SENSOR/SWITCH SENSOR COMMON
Pt JI t

BE PROGRAMMED TO USE INPUT 14, 15. 16 OR 17.
This schematic representsthe ON/OFF fan with a normally closed relay and the NC High Pressure Switch not connected to the ECM input.
212
COOLING FAN
NORMALLY
OPEN RELAY CIRCUIT TO VEHICLE
PROTECTION +BATTERY
ACTUAL CHASSIS
DIAGRAM MAY VARY
COOLING FAN
AIR VALVE ECM
A/C HIGH PRESSURE SWITCH
I (N/C)~(FAN OFF POSITION)I OUTPUT 15
INPUT #11
Pt J1
This schematic represents the ON/OFF fan with a normally open relay connection and an NC High Pressure Switch connected to the ECM input.
COOLING FAN
A/C HIGH NORMALLY CIRCUIT TO VEHICLE
PRESSURE SWITCH OPEN R E L A Y PROTECTION +BATTERY
COOLING FAN ACTUAL CHASSIS

SOLENOID AIR VALVE DIAGRAM MAY VARY
: ECM
G837-YL----~ OUTPUT~5
P1 J1 "
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.
213
CAB MANUAL
FANOVERRIDESWITCH
TO VEHICLE
CIRCUIT +BATTERY
PROTECTO
IN
COOLING rAN
NORMALLY
CLOSED RELAY
ACTUAL CHASSIS
DIAGRAM MAY VARY
COOLINGFAN
SOLENOID T
AIR VALVE ECM
A/C HIGHPRESSURESWITCH G837-YL-----F~ ~ OUTPUT15
(NIC)~(FAN OFFPOSITION)
E971-GN'----K141 INPUT111
H795-PK~ APSENSOR/SWITCHSENSORCOMMON
I
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.
ACTUAL CHASSIS
DIAGRAM MAY VARY
MANUAL FAN
OVERRIDE SWITCH
ECM
I A/C HIGHPRESSURESWITCH I INPUT 16
(N/C)~(FAN OFFPOSITION)I INPUT ~11
OUTPUT ~5
OUTPUT 14
COOLING FAN CIRCUIT
SLIP SOLENOID PROTECTION P1 J1
COOLING rAN CIRCUIT NOTE:THE MANUAL FAN OVERRIDE SWITCH MAY

BRAKE SOLENOID PROTECTION BE PROGRAMMED TO USE INPUT 14, t5, 16 OR 17.
_---
Three-Speed Fan with Direct Solenoid Connection
214
Test Step 1. Check the Electrical

Connectors and the Wiring

II l I ' 3 & o
~ o o o o ~ o o o, OUTPUT #5
II 1123oxO o o o o o o o o o1414
OUTPUT #4
IIII 3 1 0 0 0 0 (~1 0 0 0 0 20, 2 4
II II 3 9 o o 0 o IlL U )ll o o o . o 3.032
: INPUT #11 (AIC HIGH PRESSURE SWITCH)
llll'T° o o o k~.) o o ~O'1340
o,{
iiipTooooo o o o o o o 4048
~

/ ff II II
1 2 3 4 54,6 ' ' 8_9 10 11_12_13~,
D]2~0000
oooogoooooeo~ '
OUTPUT #4
~400000 >~< 00C~D023
A'~',% 00003~ OUTPUT #5
3 0 0 . D n (( r_ ) ) } 3 6 o n n n r INPUT ~11 (A/C HIGH PRESSURE SWITCH)
400g'O0 ~ 0000,,,
4800000 O0000s~
0000000000000
Harness Side
Terminal locations for the ECM
A, Thoroughly inspect the ECM Vehicle Harness E. Ensure that the ECM is wired to the cooling fan
Connector J1/P1, the A/C High Pressure Switch on the vehicle and/or the A/C high pressure
Connector, the connections to the Cooling Fan switch. Check for wires that are connected to
Solenoid, and the firewall bulkhead connectors. terminal 11 (Output 5) and for wires that are
Refer to Troubleshooting, " Electrical Connectors connected to terminal 41. Input 11 is the A/C high
- Inspect" for details. pressure switch of vehicle harness connector P1.
If a Three-Speed Fan is used, check for a wire
B. Perform a 45 N (10 Ib) pull test on each of the that is connected to terminal 13 (Output 4).
with the following connections: Refer to Illustration 84 for terminal locations for
the ECM.
• Cooling Fan
Expected Result:
• A/C High Pressure Switch
All connectors, pins, and sockets are completely
C. Check the ECM connector (Allen Head Screw) coupled and/or inserted, and the harness and
for the proper torque of 6.0 N.m (55 Ib in). wiring should be free of corrosion, abrasion or pinch
points.
D. Check the harness and the wiring for abrasion
and pinch points from the battery to the ECM. Results:
Then, check from the key switch to the ECM.
• Not OK
215
Repair: Repair the wiring or replace the wiring, if Note: If the "Fan Control Type" parameter indicates
necessary. Repair the connectors or replace the "None", then the cooling fan driver is not used.
connectors, if necessary. Ensure that all of the
seals are in the proper place. Ensure that all of View the "A/C High Pressure Switch" status on
the connectors are connected properly. Cat ET.
Verify that the repair eliminates the problem. Expected Result:
STOR The status of the A/C high pressure switch indicates

"ON" or "OFF".
• ECM Not Wired To Fan or Switch - If the ECM is
not wired to the cooling fan on the vehicle and/or Results:
the A/C high pressure switch, then the ECM is not
being used for fan control. STOR • OK - The status of the A/C high pressure switch
is on or off. Proceed to Test Step 4.
Test Step 2. Check the Programming of
the "Fan Control Type" Parameter • Not OK - The status of the A/C high pressure
switch is "Unavailable". The ECM is not
A. Connect Cat ET to the data link connector. programmed to use the A/C high pressure switch.
B. Check the "Fan Control Type" parameter. Ensure
that the parameter is programmed to either Test Step 4. Check the Operation of the
"On-Off" or to "Three-Speed Fan", if the ECM AJC Pressure Switch
is used to control the fan. If the parameter
is programmed to "None" and the ECM is A. Connect Cat ET to the data link connector.
connected to the fan, then the fan will always
be ON. B. Turn the key switch to the ON position.
Expected Result: C. Access the "A/C High Pressure Switch" status

screen on Cat ET.
The "Fan Control Type" parameter is programmed
to match the vehicle wiring. This is determined in D. Fabricate a jumper wire 100 mm (4 inch) long.
the previous step. Crimp a Deutsch pin to both ends of the wire.
Results: E, Disconnect the "A/C High Pressure Switch" from

the vehicle harness at the switch and use the
• OK - Proceed to Test Step 3. jumper wire to short the two terminals in the
harness connector together.
• Not OK - Program the "Fan Control Type" to the
correct setting and then recheck the system. If F. Remove the jumper wire and then insert the
conditions are not resolved, then proceed to Test jumper wire. At the same time, view the "A/C
Step 3. High Pressure Switch" status on the service tool
status screen.
Test Step 3. Check the A/C Pressure
Switch Expected Result:
A. Connect Cat ET to the data link connector. The status screen indicates that the "A/C High
Pressure Switch" is turning to the ON position. Then,
B. Turn the key switch to the ON position. the "A/C High Pressure Switch" is turning to the
OFF position.
C. View the following customer specified
parameters. Results:
• "Fan Control Type" • OK - T h e A/C high pressure switch harness is

OK. Proceed to Test Step 6.
• "A/C Switch Fan On-Time"
Ensure that the "A/C Switch Fan On-Time" is
programmed to a greater value than "0". If the Test Step 5. Check Active Codes or
"A/C Switch Fan On-Time" is programmed to Logged Codes
"0", then the "A/C High Pressure Switch Input"
(Input 11) is not used. A. Connect Cat ET to the data link connector.
216
B. Turn the key switch to the ON position. D. Connect a multimeter and measure the
resistance between the two terminals of the A/C
C. Access the "Logged Diagnostic Codes" and the high pressure switch. The switch must be closed
"Active Diagnostic Codes" on Cat ET. in order to check the resistance.
D. Check for the following diagnostic codes. Expected Result:
• 110-00 High Coolant Temperature Warning The resistance measures 10 Ohms or less.
• 110-11 Very High Coolant Temperature Results:

• 110-03 Coolant Temp Sensor Open Circuit • OK - T h e ECM, the A/C high pressure switch,
and the wiring are electrically OK.
• 110-04 Coolant Temp Sensor Short Circuit
Repair: Check the A/C pressure or send the
Record any logged diagnostic codes. Record vehicle to the OEM dealer for repairs.
any active diagnostic codes.
STOR
Expected Result:
• Not OK
Result 1 None of the diagnostic codes that are
listed are logged or active. Repair: Replace the A/C high pressure switch.
Result 2 Diagnostic code 110-00, or 110-11 is Verify that the repair eliminates the problem.
logged or active.
STOR
Result 3 Diagnostic code 110-03 or 110-04 is
logged or active.
Results:
• Result 2 - T h e cooling fan is on because of a

high coolant temperature.

procedure: Testing and Adjusting, "Cooling
System - Check"
STOR
• Result 3 - T h e cooling fan is on because of a

coolant temperature sensor fault.

procedure: Troubleshooting, "Engine Temperature
Sensor Open or Short Circuit - Test"
STOP.
Test Step 6. Check the A/C Pressure

Switch by use of a Voltmeter
A. Connect Cat ET to the data link connector.
B. Turn the key switch to the OFF position.
C, Ensure that the A/C high pressure switch is

disconnected from the vehicle harness at the
switch terminals.
217
Test Step 7. Check the ECM

o o o ooo o o
II 11230 O O O O 0 O O O O O141
1111310000 oooo2,1
II II 3 9 O O O O IK U /11 0 0 0 0 3 2 1 INPUT |11 (A/C HIGH PRESSURE SWITCH)
II II o o o Lt Jj oo I
II II 570 o o o o o o o o o 0,81
Connector for the Breakout T
A. Connect Cat ET to the data link connector. Repair: If a problem still exists, then the problem
is in the OEM wiring. Repair the problem or send
B, Turn the key switch to the OFF position. the vehicle to the OEM dealer for repair. Verify
that the repair eliminates the problem.
C, Disconnect the ECM vehicle harness connector
J1/P1. STOR
D, Remove terminal 41 (Output 11) from the vehicle • Not OK

harness connector P1.
I=. Install a 140-2266 Cable (Seventy-Pin Breakout) that the "A/C Pressure Switch Fan On-Time"
between connectors J1 and P1. parameter is programmed in the same manner as
the suspect ECM. Use Cat ET to check the ECM.
F. Fabricate a jumper wire 100 mm (4 inch) long. If the problem is resolved with the test ECM,
Crimp a Deutsch pin to both ends of the wire. install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM.
G. Connect the jumper wire to terminal 5 (AP
Sensor/Switch Common) and to terminal 41 Verify that the repair eliminates the problem.
(Input 11) of the breakout T.
STOR
Test Step 8. Check Intake Manifold
H. Turn the key switch to the ON position. Air Temperature and the Coolant
Temperature
I, Access the "A/C High Pressure Switch" status
screen on Cat ET. A. Connect Cat ET to the data link connector.
J. Remove the jumper wire and then insert the B, Turn the key switch to the ON position.
jumper wire. At the same time, watch the "A/C
High Pressure Switch" status on Cat ET. C. Monitor the status for "Engine Coolant
Temperature" and "Intake Manifold Air
Expected Result: Temperature" in order to verify that the
temperatures are changing as the engine warms
The status screen indicates that the "A/C High up.
Pressure Switch" status is off when the jumper wire
is in place. The status screen indicates "ON" when Expected Result:
the jumper wire is removed.
The "Engine Coolant Temperature" and the "Intake
Results: Manifold Air Temperature" appear to have the
correct reading.
• OK - T h e ECM is OK.
Results:

218
• Not OK
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.
STOP.
Test Step 9, Check the Circuit for the

Cooling Fan Solenoid
,3%9 oooooooo
oooo
,,1111
OUTPUT 15
iiiioooo Q0 0 0 0 ~ 0
390 O O O
0 0 0
O O O 032
OUTPUT 14
470 0 0 0 0 0 0 04C
570 O O O O O O O O O 048
-BATTERY
o o o o o o o o o
Connector for the breakoutT
A. Connect Cat ET to the data link connector. Results:

B. Turn the key switch to the ON position. • OK - T h e cooling fan circuit from the ECM to the
solenoid is functioning properly at this time.
C. Access the "On-Off Cooling Fan Special Test"
for a fan that cycles "Off" and "On". Access Repair: If a problem still exists, then the problem
the "Three-Speed Fan Slip Output" or the is in the OEM wiring. Repair the problem or send
"Three-Speed Fan Brake Output Special Test" for the vehicle to the OEM dealer for repair.
a Three-Speed Fan. Access each menu in the
order that follows: Diagnostics, Diagnostic Tests, Verify that the repair eliminates the problem.
and Special Test.
STOR
NOTE: If any override switches are installed, the
switch must be in the OFF position. • Not OK - Proceed to Test Step 10.
D. Cycle the "Special Test" to the ON position and Test Step 10. Check the ECM
to the OFF position. Listen for the solenoid to
click. You may need to be near the engine in A. Turn the key switch to the OFF position.
order to hear the click of the solenoid.
B. Disconnect the ECM vehicle harness connector
Expected Result: J1/PI.
An audible clicking is heard, and the solenoid C. Remove terminal 11 (Output 5) from the vehicle
appears to be operating properly. harness connector P1.
D. Connect a breakout T between the J1 and P1

ECM connectors.
219
E. Connect a voltage test lamp between terminal Verify that the repair eliminates the problem.
11 (Output 5) and terminal 67 (Negative Battery)
of the breakout T. STOR
F. Turn the key switch to the ON position.

i01866689
G. For a fan that cycles on and off, access the Cruise Control S w i t c h Circuit
"On/Off Cooling Fan Special Test" on Cat ET.
- Test
Cycle the "On/Off Cooling Fan Special Test" to
the ON position and to the OFF position. At the SMCS Code: 7332-038
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 Use this procedure under the following situation:
Output" in the special tests.
One of the following switches is suspected of
Cycle the "Three-Speed Fan Slip Output" to the preventing normal operation of cruise control, idle
ON position and to the OFF position. At the same set speed, or PTO operation:
time, watch the voltage test lamp.
• Cruise Control On/Off Switch
Connect the voltage test lamp to terminal 13
(Output 4) and terminal 67 (-Battery) of the • Cruise Control Set/Resume Switch
breakout T.
• Cruise Control Pause Switch
Cycle the "Three-Speed Fan Brake Output" to
the ON position and to the OFF position. At the The following switch circuits can also prevent the
same time, watch the voltage test lamp. correct operation of the cruise control, idle set
speed or PTO operation:
Refer to Illustration 86 for the location of Output
4 and Output 5. • Service Brake Pedal Position (Switch 1)
NOTE: A multimeter can not be used in place • Service Brake Pedal Position (Switch 2)
of the voltage test lamp when the ECM output
is tested. • Neutral Switch
Expected Result: • PTO On/Off Switch
The voltage test lamp turns to the ON position when The switches are described in the respective circuit
the test is "Active". The voltage test lamp turns to tests in Troubleshooting.
the OFF position when the test is "Not Active".
All of the following customer programmable
Results: parameters can affect cruise control, idle set speed,
and PTO operation:
• OK - T h e ECM cooling fan relay is functioning
properly. • Adaptive Cruise Control
Repair: If a problem still exists, then the problem • "Low Cruise Control Speed Set Limit"
is in the OEM wiring. Repair the problem or send
the vehicle to the OEM dealer for repair. • "High Cruise Control Speed Set Limit"
Verify that the repair eliminates the problem. • "Idle Vehicle Speed Limit"
STOR • "Cruise/Idle/PTO Switch Configuration"
• Not OK • "ldle/PTO Bump rpm"
Repair: Temporarily connect a test ECM. Use the • "ldle/PTO rpm Ramp Rate"
special test to check the ECM cooling fan circuit.
If the problem is resolved with the test ECM, • "PTO Kickout Vehicle Speed Limit"
install the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM.
220
The vehicle speed calibration can also affect The adaptive cruise control is a J1939 based option.
the cruise control, the idle set speed, and the A radar is used in order to detect vehicles. When a
PTO if the vehicle speed calibration is incorrectly vehicle is detected the cruise control set speed is
programmed. Refer to Troubleshooting, "Customer reduced in order to maintain a following distance.
Specified Parameters". This option must be enabled with the electronic
service tool. Factory passwords are required to
Cruise Control On/Off Switch enable this option.
This switch must be on before cruise control or If a problem is suspected with the adaptive cruise
controlled idle can be activated. This switch is control, the feature can be disabled. Toggle the
on when the switch is closed. When the switch is cruise control switch to the OFF position and to the
closed the following terminals are connected: ON position twice within 10 seconds.
• J1/P1:59 (Cruise Control ON/OFF Switch) The following background information is related
to this procedure:
• J1/P1:5 (AP Sensor/Switch Sensor Common)
The kickout switch refers to the switch that is used
Note: If the vehicle is programmed to use the to exit the cruise control, the PTO, or the idle set
dedicated PTO, the PTO On/Off switch overrides the speed.
cruise control On/Off switch. The PTO On/Off switch
will override the cruise control On/Off switch if the The operation of the Caterpillar electronic engine
vehicle speed is within the programmed range for cruise control is similar to the operation of the
the "PTO Kickout Vehicle Speed Limit" parameter. cruise controls that are installed in automobiles.
The operation of idle and PTO are similar to the
Set/Resume Switch operation of cruise except that the idle and the PTO
govern engine rpm instead of vehicle speed.
While the cruise control On/Off Switch is in the ON
position and the vehicle speed is within the range Note: Idle in this procedure is an engine idle rpm
of the programmed "Low Cruise Control Speed above the programmed low idle rpm. Idle is set with
Set Limit" and the "High Cruise Control Speed Set the cruise control On/Off switch and the Set/Resume
Limit", momentarily pressing the set switch will switch. Refer to Troubleshooting, "PTO Switch
activate the cruise or controlled idle, and the ECM Circuit - Test" for additional information regarding
will maintain the current speed. the programmable options for the dedicated PTO.
Pressing the resume switch will cause the vehicle Usage of Transmission Style Switches
speed to ramp to the last cruise control set speed.
This assumes that the vehicle speed is above the The "Transmission Style" parameter determines
low cruise control speed set limit for cruise control the switches that will be used. The following
or the vehicle speed is below the Idle/PTO vehicle switches can be used with being dependent on the
speed limit for the idle and the PTO. parameter setting:
After a speed has been set, pressing and holding • Clutch Pedal Position
the Set/Resume switch in position will cause the
engine to establish a new set speed. The system's • Neutral
reaction depends on the programming of the
"Cruise/Idle/PTO Switch Configuration". • Service Brake Pedal Position (Switch 1)
When the Set/Resume switch is momentarily • Service Brake Pedal Position (Switch 2)
pressed, the cruise set point will change one
mph. The rate of change is dependent on the Refer to Table 3 for additional information.
programmed "ldle/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

221
Table 145
Switch Usage.
Setting For
Style Brake Brake Clutch Neutral
Parameter Switch Switch
1 2
Manual X X
Automatic
X
Option 1
Automatic
X X
Option 2
Automatic
X X X
Option 3
Automatic
X X
Option 4
Eaton Top 2 X X
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 Options 1
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.
222
SET/RESUME
(SET OFF POSITION)
(RESUME OFF POSITION
ECM
CRUISE CONTROL ON/OFF 0978-BR-~ SET
< ~ C R U I S E OFF POSITION 0979-OR-KI44~ RESUME
i
C975-WH-KI59~ICRUISE CONTROL ON/OFF SWITCH
SERVICE BRAKE PEDAL POSITION C992-PU-KI45~SERVICE BRAKE PEDAL POSITION SWITCH
C977-BU-~122~ CLUTCH PEDAL POSITION SWITCH
%EDAL RELEASED POSITION)
i H795-PK--~_LS_~ AP SENSOR/SWITCH SENSOR COMMON
/
P1 JI i
CLUTCH PEDAL POSITION I
I
(PEDAL RELEASED POSITION)
Schematic for cruise control switch, service brake pedal position switch 1 and clutch pedal position switch
Test Step 1. Check the Status of the B, Monitor the status for the "Cruise Control
Cruise Control On/Off Switch Set/Resume/Accel/Decel Switch J1/P1:35 & 44"
while the Set/Resume switch is cycled.
A, Connect the electronic service tool to the data
link connector. Expected Result:
B, Turn the key switch to the ON position. The status for the "Cruise Control Set/Resume/
Accel/Decel Switch J1/P1:35 & 44" is "Set Switch
(3, Monitor the status for the "Cruise/Idle On-Off On" when the Set/Resume switch is in the Set
Switch" while the cruise control On/Off switch position. The status for the "Cruise Control
is cycled. Set/Resume/Accel/Decel Switch J1/P1:35 & 44" is
"Resume Switch On" when the Set/Resume switch
Expected Result: is in the Resume position.
The status for the "Cruise/Idle On-Off Switch" is Results:

"On" when the cruise control On/Off switch is in the
On position. The status for the "Cruise/Idle On-Off • OK - T h e cruise control Set/Resume switch is
Switch" is "Off" when the cruise control On/Off working properly. STOP.
switch is in the Off position.
• Not OK - T h e cruise control Set/Resume switch
Results: is not working properly. Proceed to Test Step 3.
• OK - T h e cruise control On/Off switch is working Test Step 3. Determine the Configuration
properly. Proceed to Test Step 2. of the Cruise Control Switches
• Not OK - The cruise control On/Off switch is not A, Determine if the wiring for the cruise control
working properly. Proceed to Test Step 3. switches is wired directly to the ECM or through
Test Step 2. Check the Status of the
Set/Resume Switch B, Verify that the "Cruise Control On/Off Switch"
and the "Cruise Control Set/Resume/Accel/Decel
A. Put the cruise control On/Off switch in the On Switch" parameters are programmed to reflect
position. the proper wiring.
223
Expected Result:
The cruise control switches are wired directly to the

ECM.
Results:
• OK - T h e cruise control switches are wired

Repair: Verify that the "Cruise Control

On/Off Switch" and the "Cruise Control
Set/Resume/Accel/Decel Switch" parameters are
programmed correctly.
• Not OK - The cruise control switches are wired

Repair: Verify that the "Cruise Control

On/Off Switch" and the "Cruise Control
Set/Resume/Accel/Decel Switch" parameters are
programmed to "J 1939 - Body Controller", "J 1939
- Cab Controller", or "J1939 - Instrument Cluster".

Circuit - Test".
STOP.

and Wiring

130OOOOO O oo4booo 1
2300 000 o 0000014
310 O OO~--------------~ O , O O O 2 4
SET
390 0 0 O~OIL
o0~ j O~ 0 00 032
470 0 0 040
570 0 0 0 0 0 0 048 RESUME
700 0 0 0 0 0 0 0 0 0 0 O~FOS8 CRUISE CONTROL ON/OFF SWITCH
ECM Side Vehicle harness connector P1
F t 2 3 4 5,=6 rq 8_g_10_11_12_13~, AP SENSOR/SWITCH SENSOR COMMON

O00OfOOOO0000
~400OO0
- 2'0000~.~
0000023
000031
[
SET
ooor(( ( } )) 0 0 0 0 E
4K)O00 ~ 11;00047 RESUME
~ 48000C)0 OC~)C)Q 57 CRUISE CONTROL ON/OFF SWITCH
0e150000000000
~ 5 8 5 9 6 0 61 62 63 n 65 66 67 6 8 6 9 7 0 j
II II J
Harness Side
224

the firewall bulkhead connector and the terminals
for the following switches in the connectors:
• J1/P1:5 (AP Sensor/Switch Sensor Common)
• J1/P1:35 & 44 (Set/Resume Switch)
• J1/P1:59 (Cruise Control On/Off Switch)


with the switches.


Expected Result:

or pinch points.
Results:
• Not OK

STOR
Test Step 5. Check the Switch Circuit at

the E C M
Table 146
Table for Status of the Cruise Control Switch Input
Condition of Switch Circuit Switch Status Circuit
Jumper wire is not installed. OFF Open
Cruise/Idle On/Off Switch terminal 59 connected to ON Shorted
terminal 5.
Set Switch Terminal 35 connected to terminal 5. Set Switch ON Shorted
Resume Switch (Terminal 44) connected to terminal 5. Resume Switch ON Shorted
225
B, Fabricate a jumper wire 100 mm (4 inch) long.

C, Disconnect vehicle harness connector P1 from

the ECM.
D, Connect a 140-2266 Cable (Seventy-Pin

Breakout) between the J1 and P1 ECM
connectors.
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 Common) of the breakout T.
F, Turn the key switch to the ON position.
G, While the status for the suspect switch is being

monitored on the status screen slowly remove
the jumper from terminal 5 and slowly insert the
jumper from terminal 5 (AP Sensor/Switch Sensor
Common) of the breakout T.
Refer to Table 146.
Expected Result:
The switch status changes per the information in

Table 146.
Results:
Repair: Remove the breakout T and reconnect

the J1 and P1 ECM connectors.
• Not OK - The ECM is not functioning properly.
1. Temporarily connect a test ECM.
2. Remove the breakout T and reconnect the J1

and P1 ECM connectors.

reconnect the suspect ECM.
4. If the problem returns with the suspect ECM,

replace the ECM.
5. Verify that the repair eliminates the problem.
STOR
226
T e s t S t e p 6. I n s e r t a J u m p e r at the
Suspect Switch
Table 147

The wires are disconnected. OFF Open
The wires for the Cruise/Idle On/Off Switch are ON Shorted
Connected.
Set Switch wires are Connected. Set Switch ON Shorted
The Resume Switch wires are Connected. Resume Switch ON Shorted
B. Find the suspect switch in the vehicle.
C. Disconnect the wires from the suspect switch

terminals.
E. While the status for the suspect switch is being

monitored on the status screen connect the
suspect switch wires and disconnect the suspect
switch wires.
Refer to Table 147.
Expected Result:

Table 147.
Results:
• OK
Replace the faulty switch.
STOR
• Not OK -There is a problem in the harness

Step 7.
227
Test Step 7. I n s e r t a Jumper at t h e

Bulkhead C o n n e c t o r
Table 148

The wires are disconnected. OFF Open
The wires for the Cruise/Idle On/Off Switch are
Connected. ON Shorted
The Set Switch wires are Connected. Set Switch ON Shorted
The Resume Switch wires are Connected. Resume Switch ON Shorted
A. Turn the key switch to the OFF position. Inspect the vehicle wiring and repair the vehicle
B. Fabricate a jumper wire 100 mm (4 inch) long. the wiring, send the vehicle to the OEM dealer.
Crimp a Deutsch pin on both ends of the wires.
STOR
C. Find the terminal for the suspect switch and
the sensor common on the engine side of the
i01867516
bulkhead connector.
D. Insert the jumper wire between the two terminals

Diagnostic Enable Switch
in the engine side of the bulkhead connector. Circuit- Test
E. Turn the key switch to the ON position. SMCS Code: 7332-038-NQ
F. While the status for the suspect switch is being System Operation Description:
monitored on the status screen remove the
jumper wire between the two terminals, and Use this procedure under the following situation:
insert the jumper wire between the two terminals.
The circuit for the diagnostic enable switch is
Refer to Table 148. suspected of incorrect operation.
Expected Result: Diagnostic Enable Switch
The switch status changes per the information in The diagnostic enable switch is used to
Table 148. prompt diagnostic flash codes on the check
engine lamp. For more information, refer to the
Results: "Flashing Out Diagnostic Flash Codes" section
in Troubleshooting, "Check Engine Lamp Circuit -
• OK - T h e problem is in the vehicle wiring Test". If the "Diagnostic Enable Switch" parameter
between the bulkhead connector and the switch. is programmed to "None" (default), then the feature
is not used. If the "Diagnostic Enable Switch"
Repair: Perform the following repair: parameter is programmed to J1/P1:46, then the
feature is available and the switch circuit should
Inspect the vehicle wiring and repair the vehicle be connected to J1/P1:46 ECM vehicle harness
wiring, as required. If the problem still exists with connector.
the wiring, send the vehicle to the OEM dealer.
STOR
• Not OK - The problem is in the vehicle wiring

between the bulkhead connector and the ECM.

228
DIAGNOSTIC ENABLE
ECM
(;844-PK~ INPUT 1~7

"795-PK-I-<1 ~ <-1AP SENSOR/SWITCH SENSOR COMMON
P1 J1
Schematic for Diagnostic Enable Switch

s O O O O 0 0 0 0 ~ O O O 0 ~ @ ~ 4]] ~]
2sO0000 0 000001
3qO 0 0 O ~ O 0 0 024
sgO 0 0 0 0 0 0 052
~o q o o o o o o401III
~ocs,ooo o ooooo4a//ll Input ~7 (Diagnostic Enable)
,oooooooooooooo~/
ECM SIDE Vehicle Harness Connector P1
5 6 D 8 9 10 11 12 1 5 ~ ~
IVOOOOOOOO
O >~< O O O O O ~
~ 0 0 0 0 ~
( (( 0 )) ) 3 6 0 0 0 0 ~
Input 1117 (Diagnostic Enable)
O OOOO0 ~
OOOOOOO00
32 63 D 65 66 67 68 69 7 0 J
II _J
HARNESS SIDE
Terminal locations for the ECM
Test Step 1. Check the Status of the Expected Result:

"Diagnostic Enable"
The status for "Diagnostic Enable" should indicate
A. Connect the electronic service tool to the data "On" when the switch is in the On position. The
link connector. status for "Diagnostic Enable" should indicate "Off"
when the switch is in the Off position.
B. Turn the key switch to the On position.
Results:
C. Observe the status for "Diagnostic Enable" while
the diagnostic enable switch is operated in the • OK -The switch is operating normally.
On position and the Off position.
Repair: If the check engine lamp is not operating
Note: If the status for the "Diagnostic Enable" correctly, refer to Troubleshooting, "Check Engine
indicates "Not Installed", then the "Diagnostic Lamp Circuit - Test".
Enable" parameter has not been programmed.
STOR
• Not OK - The ECM is not reading the switch

status change. Proceed to Test Step 2.
229
Test Step 2. Determine the Configuration Results:

of the Diagnostic Enable Switch
A. Determine if the wiring for the diagnostic enable
switch is wired directly to the ECM or through • Not OK - Repair the wiring and connectors or
the J1939 data link. replace the wiring or the connectors. Ensure that
all of the seals are properly connected. Verify that
B. Verify that the "Diagnostic Enable" parameter is the repair eliminates the problem. STOP.
programmed to reflect the proper wiring.
Expected Result:
The diagnostic enable switch is wired directly to
the ECM.
Results:
• OK - T h e diagnostic enable switch is wired
directly to the ECM. Proceed to Test Step 3.
• Not OK - The diagnostic enable switch is wired

Repair: Verify that the "Diagnostic Enable"

parameter is programmed to "J1939 - Body

Circuit - Test".
STOR

the connectors, and the firewall bulkhead
connectors. Refer to Troubleshooting, "Electrical

with the suspect switch circuit.


and pinch points from the battery to the ECM.
Then, check from the ignition key switch to the
ECM.
Refer to Illustration 90 for terminal locations for

the ECM.
Expected Result:
coupled and/or inserted, and the harness and
wiring should be free of corrosion, abrasion or pinch
points.
230
Test Step 4. Check the Switch Circuit for

the E C M

130 0 0 0 0 0 0 0 ~11¢00 0 11/]t
zsO0000 o 00000114
SlOOOO ~ 000£024
s90000 ~ 000052
470 ~,~ O O 0 0 040
s70 0 0 o 0 0 0 0 Input ~7 (Diognostic [noble)
~r ~ T ° O O O O O O O O O O O ( r q O ~ /
Connector for breakout T
A. Turn the key switch to the OFF position. Verify that the repair eliminates the problem.
B. Install a 140-2266 Cable (Seventy-Pin Breakout) STOR

between the J1 and P1 ECM connectors.
Test Step 5. Insert a Jumper Wire at the
C. Fabricate a jumper wire 100 mm (4 inch) long. Switch
Crimp a Deutsch pin to both ends of the wire.
D. Insert the jumper wire into terminal 46 (Diagnostic
Enable Switch Input) of the breakout T. Connect B. Fabricate a jumper wire 100 mm (4 inch) long.
the other end of the jumper wire to terminal Crimp a Deutsch pin to each end of the wire.
5 (AP Sensor/Switch Sensor Common) of the
breakout T. C. Insert the jumper wire between the two terminals
of the diagnostic enable switch.
E. Turn the key switch to the On position.
F. While the status for "Diagnostic Enable" is
monitored, remove the jumper wire and insert E. While the status for "Diagnostic Enable" is
the jumper wire from terminal 5. monitored, remove the jumper wire and insert the
jumper wire at the switch terminals.
Expected Result:
Expected Result:
The status for "Diagnostic Enable" is "On" when the
jumper wire is in place. The status for "Diagnostic The status for "Diagnostic Enable" is "On" when the
Enable" is "Off" when the jumper wire is removed. jumper wire is in place. The status for "Diagnostic
Enable" is "Off" when the jumper wire is removed.
Results:
Results:
• OK - The ECM is functioning properly at this time.
• OK
Repair: Remove the breakout T and reconnect the
J1/P1 ECM connector. Repair: Replace the diagnostic enable switch.
Proceed to Test Step 5. Verify that the repair eliminates the problem.
• Not OK - The ECM is not functioning properly. STOR
Repair: Temporarily connect a test ECM. If the • Not OK - There is a problem in the wire harness
problem is resolved with the test ECM, install the between the diagnostic enable switch and the
suspect ECM. If the problem returns with the ECM. Proceed to Test Step 6.
suspect ECM, replace the ECM.
231
Test Step 6. Insert a J u m p e r Wire at the • 55-05 Auxiliary Output #07 current low
Bulkhead Connector
• 55-06 Auxiliary Output #07 current high
• 191-07 Transmission Not Responding
Crimp a Deutsch pin to each end of the wire. The following background information is related
to this procedure:
C. Locate the suspect switch socket in the engine
side of the ECM bulkhead connector. Overview Of The Transmission
D, Insert the wire jumper pin between the switch The engine ECM controls shifts between the top
socket and the sensor common connection. two gears of an Eaton Top 2 transmission. The shift
Install the jumper wire on the engine side of the points are based on engine speed and load for
ECM bulkhead connector. added driving ease. When the transmission is in
the Top 2 gears, the ECM will perform the following
E. Turn the key switch to the ON position. functions:
F. While the status for "Diagnostic Enable" is • Shift the transmission between the top 2 gears
monitored, remove the jumper wire and insert the automatically.
jumper wire at the bulkhead connector.
• Increase or decrease engine speed during a Top
Expected Result: 2 shift.
The status for "Diagnostic Enable" is "On" when the • Momentarily interrupt the cruise control or the
jumper wire is in place. The status for "Diagnostic engine brake during the shift. Then, the cruise
Enable" is "Off" when the jumper wire is removed. control or the engine brake will resume.
Results: Note: Top gear refers to tenth gear in a ten speed

transmission, and top gear refers to thirteenth gear
• OK - T h e problem is in the vehicle wiring in a thirteen speed transmission. Top gear minus
between the bulkhead connector and the switch. one refers to ninth gear in a ten speed transmission,
Inspect the vehicle wiring and then repair the and top gear minus one refers to twelfth gear in a
vehicle wiring. Otherwise, send the vehicle to thirteen speed transmission. Top gear minus two
the OEM dealer for repair. Verify that the original refers to eighth gear in a ten speed transmission,
condition is resolved. STOR and top gear minus two refers to eleventh gear in a
thirteen speed transmission.
between the bulkhead connector and the ECM. Transmission Upshift By The ECM
Inspect the vehicle wiring and then repair the
vehicle wiring. Otherwise, send the vehicle to Upshift the transmission through the shift pattern to
the OEM dealer for repair. Verify that the original top gear minus two. Use double clutching during
condition is resolved. STOR the lever shifts. Break torque during button shifts.
When the engine has reached the shift point use

i01901371
double clutching and move the shift lever into the
Eaton Top 2 Transmission Top Gear Minus One position (automatic position).
Circuit- Test Note: Leave the shift button in the forward position
so that the shift button is ready for downshifting into
SMCS Code: 3174-038 the Top Gear Minus Two position.
System Operation Description: When the engine has reached the upshift point the
ECM will automatically shift the transmission into
Use this procedure under the following situation: Top Gear. The ECM shifts the transmission into Top
Gear by turning on the shift solenoid and turning
The "Transmission Style" parameter is programmed off the lockout solenoid.
to Eaton Top 2 and one of the following diagnostic
codes is active or easily repeatable: Transmission Downshift By The ECM
• 54-05 Auxiliary Output #06 current low

232
Once the engine has reached the shift point, the The control interface between the ECM and the
ECM will automatically downshift the transmission Eaton Top 2 transmission consists of the following
from Top Gear to Top Gear Minus One. The ECM outputs:
downshifts the transmission from Top Gear to Top
Gear Minus One by turning on the lockout solenoid • Eaton Top 2 shift solenoid (No. 7 Output)
and turning off the shift solenoid.
• Eaton Top 2 lockout solenoid (No. 6 Output)
In order to downshift from Top Gear Minus One to
Top Gear Minus Two, make sure that the shift button The ECM will turn on the Eaton Top 2 shift solenoid
is in the forward position. Once the engine has (No. 7 Output) when Top 2 is active in order to
reached the shift point, move the gearshift lever to engage top gear. The ECM will turn off the Eaton
the next lower lever position by double clutching. Top 2 shift solenoid (No. 7 Output) at all other times,
if the "Transmission Style" is programmed to Eaton
Continue downshifting through the shift pattern by Top 2.
double clutching during shifts with the gearshift
lever. Break torque during button shifts. The ECM will turn on the Eaton Top 2 lockout
solenoid (No. 6 Output) when Top 2 is active in
Eaton Top 2 Override with Cruise Control Switch order to engage top gear minus one. The ECM will
turn off the Eaton Top 2 lockout solenoid (No. 6
If this parameter is programmed to YES the cruise Output) at all other times, if the "Transmission Style"
control On/Off switch can be used to disable Top 2 is programmed to Eaton Top 2.
mode. If the cruise control On/Off switch is turned
to the OFF position and the transmission is not Customer Specified Parameters
in Top 2 mode, the Top 2 mode will be disabled.
This condition is applicable to the manual mode of The following parameters must be programmed
operation only. If the cruise control On/Off switch is per the following list in order for the Eaton Top 2
turned to the ON position, the Top 2 mode will be transmission to function properly:
enabled and the transmission will be allowed to shift
automatically in the Top 2 gears. When the vehicle • "Transmission Style" Eaton Top 2
is operating in one of the Top 2 gears and the Top
2 mode is enabled, switching the cruise control • "Top Gear Ratio" Programmed range 0.000 to
On/Off switch to the OFF position will place the 3.750
transmission in hold mode. When the transmission
is in the Hold mode, the transmission will not shift • "Top Gear Minus One Ratio" Programmed range
out of the currently selected gear. When the cruise 0.000 to 3.750
control On/Off switch is returned to the ON position,
the transmission will return to Top 2 mode. When • "Top Gear Minus Two Ratio" Programmed range
the clutch is depressed and the transmission is in 0.000 to 3.750
the hold mode, the Manual mode will be enabled
and the Top 2 will be disabled. • "Eaton Top 2 Override with Cruise Switch" Yes
or No
System Problems
Note: Each gear ratio must be precisely
If the system malfunctions, the transmission will programmed to three decimal places per the
typically default to manual operation. When the following table for the model of transmission that
system is in manual operation, Top 2 is inactive. For is installed:
some malfunctions, the system will detect a failure.
When the system detects a failure, the operator must
allow time out of the timer in the ECM. The ECM will
complete the countdown in nine seconds. 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 the key switch is turned oft.
Wiring Connections Of The ECM

233
Table 149
Transmission Top Top Top
Model Gear Gear Gear
Minus Minus Ratio
Two One
Ratio Ratio
RTLO-XX610B-T2
10 Over 1.352 1.000 0.741
RTL-XX710B-T2
1.825 1.351 1.000
10 Direct
RTLO-XX713A-T2
13 Over 1.000 0.856 0.730
RTLO-XX718B-T2
1.000 0.856 0.730
18 Over
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 N-m
(1400 Ib 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.
ECM
i
G838-BR ~ OUTPUT ~6
G839-BU OUTPUT ~7
..N ...N
TOP 2 TOP 2
P1 J1
LOCKOUT
SOLENOID
SHIFT
SOLENOID
l
Schematic for Eaton Top 2 transmission
P1 ECM Connector
1 2 3 4 ,5 6 u 8 9 10 11 1213~
000000000000 ., ooooooooooooi
0000 >PEI< ~ 0 0 2 ~ Output #6 (Lockout S o l e n o i d ~ o 00000141111
Output #7 (Shift Solenoid>~-------li--i'F~O o o o o4]I II
000 ~ 000031
000 ((E } ) ) ~ 6 0 0 0 0 r IIIpgO o o o II~L# )II o o o us211 II
M400000 ~ 000047 II II47° 0 0 0 \~L~) 0 0 0 04o1111
II 1 1 4 8 0 0 0 0 0 O0000s7 II II57° o o o o o o o o o C4BII II
I~1 0 0 0 0 0 0 0 0 0 0 0 0 0
\k 58 5960 616263 Fq65 66 67 68 6970j
II II J
Harness Side ECM Side
P1 ECM connector
234
Test Step 1. Check for Active/Logged Refer to Illustration 93.

Diagnostic Codes
A. Connect the electronic service tool to the data for the proper torque of 6.0 N.m (55 Ib in).
link connector.
B. Turn the key switch to the ON position. pinch points from the data link connectors back
to the ECM.
C, Monitor the active diagnostic code screen on the
electronic service tool. Expected Result:
D. Check and record active/logged diagnostic All connectors, pins and sockets should be
codes: completely coupled and/or inserted and the harness
• 54-05 Auxiliary Output #06 current low or pinch points.
• 54-06 Auxiliary Output #06 current high Results:

• 55-05 Auxiliary Output #07 current low • OK - Proceed to Test Step 3.
• 55-06 Auxiliary Output #07 current high • Not OK
• 191-07 Transmission Not Responding Repair: Repair the connectors or wiring and/or
Note: If the "Eaton Top 2 Override With Cruise of the seals are properly in place and ensure that
Switch" parameter is programmed to "YES" and the the connectors are completely coupled.
cruise control On/Off switch is in the OFF position,
the operation of Top 2 is disabled. Verify that the repair eliminates the problem.
Expected Result: STOP.
One or more of the listed codes are active or Test Step 3. Check the Solenoids
logged.
A. Connect the electronic service tool to the data
Results: link connector.
• 191-07 Only - Diagnostic code 191-07 is the B. Turn the key switch to the ON position.
only active diagnostic code or the only logged
diagnostic code that is present. Proceed to Test C. Access the customer specified parameters
Step 6. screen on the electronic service tool,
• Any Code - Any single diagnostic code or any B. Verify that the "Transmission Style" is
combination of diagnostic codes is present. programmed to Eaton Top 2.
E. Access the special tests for the "Shift Solenoid"
• No Codes - If a transmission problem is still and the "Lockout Solenoid" on the electronic
suspected, send the vehicle to the OEM dealer service tool. Access the following display
for service to the Eaton transmission. STOR screens in order:
Test Step 2. Inspect Electrical Connectors • "Diagnostics"

and Wiring
• "Diagnostic Tests"
A. Thoroughly inspect ECM vehicle harness
connector J1/P1, the firewall bulkhead connector • "Special Tests"
and the Eaton Top 2 solenoid connector. Refer
to Troubleshooting, "Electrical Connectors - • "Shift Solenoid" and "Lockout Solenoid"
F. Use the following procedure for either of the
B. Perform a 45 N (10 Ib) pull test on each of the following active diagnostic codes or logged
wires in the ECM connector that are associated diagnostic codes:
with the Eaton Top 2 solenoids.
235
• 55-05 Auxiliary Output #07 current low Repair: Clear all logged diagnostic codes.
• 55-06 Auxiliary Output #07 current high STOR
a, Move the splitter button to the rear position. • Not OK - Proceed to Test Step 4.
b, Ensure that the air system pressure is equal Test Step 4. Use the Special Test at the
to or greater than 620 kPa (90 psi). SolenoidConnector
¢, While you listen for the solenoid to shift, cycle A, Turn the key switch to the OFF position.
the special test for the "Shift Solenoid" from
the ON position to the OFF position back to B, Disconnect the Eaton Top 2 solenoid connector.
the ON position.
C, Use the following procedure for either of the
Note: You may need to be near the transmission following active diagnostic codes or logged
in order to hear the shift. diagnostic codes:
G, Use the following procedure for either of the • 55-05 Auxiliary Output #07 current low
following active diagnostic codes or logged
diagnostic codes: • 55-06 Auxiliary Output #07 current high
• 54-05 Auxiliary Output #06 current low a, Connect a voltage test lamp between pin "B"
(Sensor Common) and pin "C" (No. 7 Output)
• 54-06 Auxiliary Output #06 current high on the ECM side of the Eaton Top 2 solenoid
connector.
a, Move the splitter button to the forward
position. D, Connect the electronic service tool to the data
link connector.
b, Ensure that the air system pressure is equal
to or greater than 620 kPa (90 psi). E, Turn the key switch to the ON position.
¢, While you listen for the solenoid to shift, cycle F, Access the special test for the "Shift Solenoid" on
the special test for the "Lockout Solenoid" the electronic service tool. Access the following
from the ON position to the OFF position back display screens in order:
to the ON position.
• "Diagnostics"
Note: You may need to be near the transmission
in order to hear the shift. • "Diagnostic Tests"
Note: 191-07 Transmission Not Responding may • "Special Test"

occur when one of the following diagnostic codes
occurs during vehicle operation: • "Shift Solenoid"
• 54-05 Auxiliary Output #06 current low G. While you monitor the voltage test lamp, cycle
the special test for the "Shift Solenoid" from the
• 54-06 Auxiliary Output #06 current high ON position to the OFF position and back to the
ON position.
• 55-05 Auxiliary Output #07 current low
H. Stop the special test for the "Shift Solenoid".
Note: When the key switch is turned on and the
Expected Result: solenoid connector is disconnected, the following
diagnostic code will occur during performance of
The solenoid is operating correctly when the test the special test for the "Lockout Solenoid":
is activated.
• 54-05 Output #6 Open Circuit (66)
Results:
Clear this logged code when this step is
• OK - T h e ECM, the relay, and the solenoid are completed.
operating correctly.
I. Use the following procedure for either of the
following active diagnostic codes or logged
diagnostic codes:
236
• 54-05 Auxiliary Output #06 current low Repair: Temporarily connect the suspect
solenoids. Clear all logged diagnostic codes.
• 54-06 Auxiliary Output #06 current high Complete a test drive of the truck. If the diagnostic
code is logged after attempting to use the Top 2
a, Connect a voltage test lamp between pin "B" feature, replace the solenoids. Repeat the test
(Sensor Common) and pin "A" (No. 6 Output) drive in order to ensure that the problem has been
on the ECM side of the Eaton Top 2 solenoid corrected. Clear all logged diagnostic codes.
connector.
J, Connect the electronic service tool to the data
link connector. STOR
K, Turn the key switch to the ON position. Not OK - The problem is in the harness wiring or
the ECM. Remove the voltage test lamp. Proceed
L, Access the special test for the "Shift Solenoid" to Test Step 5.
and the "Lockout Solenoid" on the electronic
service tool. Access the following display Test Step 5. Use the Electronic Service
screens in order: Tool to Check the ECM
• "Diagnostics" A, Turn the key switch to the OFF position.
• "Diagnostic Tests" B. Disconnect the ECM vehicle harness connector

J1/P1.
• "Special Test"
C. Connect a 140-2266 Cable (Seventy-Pin
• "Lockout Solenoid" Breakout) to the ECM connector J1.
M, While you monitor the voltage test lamp, cycle D, Use the following procedure for either of the
the special test for the "Lockout Solenoid" from following diagnostic codes:
the ON position to the OFF position and back
to the ON position. • 55-05 Auxiliary Output #07 current low
N, Stop the special test for the "Lockout Solenoid". • 55-06 Auxiliary Output #07 current high
Note: When the key switch is turned on and the a. Remove terminal 20 from vehicle harness
solenoid connector is disconnected, the following connector P1.
diagnostic code will occur during performance of
the special test for the "Lockout Solenoid": b. Connect P1 to the breakout T.
• 55-05 Auxiliary Output #07 current low E. Connect a voltage test lamp to terminal 67
(-Battery) and terminal 20 (No. 7 Output) of the
Clear this logged code when this step is breakout T.
completed.
Note: The No. 7 Output is the shift solenoid.
Expected Result:
F, Connect the electronic service tool to the data
The voltage test lamp behaves in the following link connector.
manner:
G, Turn the key switch to the ON position.
• The voltage test lamp turns on when the test is
active. H. Access the special test for the "Shift Solenoid" on
the electronic service tool. Access the following
• The voltage test lamp turns off when the test is display screens in order:
not active.
• "Diagnostics"
Results:
• OK - T h e engine harness and the ECM are OK.
• "Special Test"
• "Shift Solenoid"
237
I. While you monitor the voltage test lamp, cycle • The key switch is turned on.
the special test for the "Shift Solenoid" from the
ON position to the OFF position and back to the • The ECM connector J1/P1 is disconnected.
ON position.
• The "Transmission Style" is programmed to Eaton
J. Stop the special test for the "Shift Solenoid". Top 2.
K. Use the following procedure for either of the This is normal. Clear these diagnostic codes after
following diagnostic codes: this test step is completed.
• 54-05 Auxiliary Output #06 current low Results:
• 54-06 Auxiliary Output #06 current high • OK
a. Remove terminal 19 from vehicle harness Repair: Clear any diagnostic codes that were
connector P1. caused during this step. Repair the vehicle
harness from the Eaton Top 2 solenoid connector
b. Connect P1 to the breakout T. to ECM connector P1 or replace the vehicle
harness from the Eaton Top 2 solenoid connector
L. Connect a voltage test lamp to terminal 67 to ECM connector P1.
(-Battery) and terminal 19 (No. 6 Output) of the
breakout T. Verify that the repair eliminates the problem.
Note: The No. 6 Output is the lockout solenoid. STOR
M. Connect the electronic service tool to the data • Not OK

link connector.
Repair: Temporarily connect a test ECM. Remove
N. Turn the key switch to the ON position. all jumpers and replace all connectors. Recheck
the system for active diagnostic codes. Repeat
O. Access the special test for the "Lockout this test step. If the problem is resolved with the
Solenoid" on the electronic service tool. Access test ECM, reconnect the suspect ECM. If the
the following display screens in order: problem returns with the suspect ECM, replace
the ECM.
• "Diagnostics"
STOR
• "Special Test"
Test S t e p 6. C h e c k G e a r R a t i o s
• "Lockout Solenoid"
P. While you monitor the voltage test lamp, cycle link connector.
the special test for the "Lockout Solenoid" from
the ON position to the OFF position and back B. Turn the key switch to the ON position.
to the ON position.
C. Access the customer specified parameters
Q. Stop the special test for the "Lockout Solenoid". screen on the electronic service tool.
Expected Result: D. Verify that the three parameters for gear ratios
are correctly programmed.
The voltage test lamp behaves in the following
manner: Refer to Table 149.
• The voltage test lamp turns on when the test is Expected Result:
active.
The parameters for the gear ratios are programmed
• The voltage test lamp turns off when the test is correctly.
not active.
Results:
Note: When all of the following conditions exist a
54-05 and 55-05 diagnostic code will occur: • OK
238
Repair: If a transmission problem is still • Timing

suspected, send the vehicle to the OEM dealer
for service to the Eaton Transmission. These characteristics are programmed into the
personality module at the factory only.
STOR
Microprocessor
• Not OK
The ECM uses a microprocessor to perform the
Repair: Consult the OEM dealer in order to computing that is required to perform the following
determine the proper values for the gear ratios functions:
and program the proper values for the gear ratios.
• Governing
STOR
• Controlling timing
i01906649 • Generating diagnostic codes
ECM Memory- Test • Communicating with service tools
SMCS Code: 1901-038
The microprocessor reads the instructions from the
System Operation Description: software in the personality module.
Use this procedure under the following situation: Programmable Parameters
One of the following diagnostic codes is present: Programmable parameters are stored in permanent
memory. This includes both customer specified
• 252-11 Engine Software Incorrect parameters and system configuration parameters.
Refer to Troubleshooting, "Customer Specified
• 253-02 Check Customer or System Parameters Parameters" for details on customer specified
parameters and refer to Troubleshooting, "System
Also, use this procedure if the integrity of the Configuration Parameters" for details on system
customer parameters or the system parameters in configuration parameters.
the ECM is questionable. Also, use this procedure if
the data for the engine lifetime totals is questionable.

to this procedure:
The engine control module (ECM) is the computer
which controls the Caterpillar electronic truck
engine. The personality module contains the
software that controls the operation of the computer
(ECM).
The personality module software is the instructions

that are used by the ECM to control the engine. For
this reason, updating the personality module to a ':-
different version may cause some engine functions
Engine
to behave in a different manner. Harness OEM
Connector [noine Vehicle
Performance Maps J2/P2 Control Hurness
Module Connector
(ECM) J1/P1
Performance maps define characteristics for various
operating conditions. These characteristics are used g00658319
Illustration94
to achieve optimum performance while emissions ECM and harness connectors
requirements are being met. Examples of these
characteristics are included in the following list: Logged Diagnostics
• Fuel rate
239
Logged diagnostics are stored by the ECM into Repair: Repair the connectors or wiring and/or
memory so a permanent record of the diagnostic replace the connectors or wiring. Ensure that all
code is retained. Logged faults that are not critical of the seals are properly in place and ensure that
are automatically cleared after 100 hours. the connectors are completely coupled.
Input Circuits Verify that the repair eliminates the problem.
Input circuits filter electrical noise for sensor signals. STOR

Also, input circuits protect internal circuits from
potentially damaging voltage levels. Test Step 2. Check for Diagnostic Codes
Output Circuits Connect the Caterpillar Electronic Technician (Cat
E-f) and check for diagnostic codes.
Output circuits provide the voltage or current
that is required to energize components that are Expected Result:
connected to the ECM.
Result 1 The following diagnostic code requires
Power Circuits troubleshooting:
Power circuits provide clean stable electrical power • 252-11 Engine Software Incorrect
to internal circuits and external sensors.
Result 2 The following diagnostic code requires
Test Step 1. Inspect Electrical Connectors troubleshooting:
and Wiring
• 253-02 Check Customer or System Parameters
connector J1/P1 and the battery connections. Result 3 Scrambled parameters or data require
Refer to Troubleshooting, "Electrical Connectors troubleshooting.
Results:
following wires in the ECM connector: • Result 1 - Proceed to Test Step 3.
• Ignition key switch (terminal 70) • Result 2 - Proceed to Test Step 4.
• +Battery (terminals 52 and 53) • Result 3 - Proceed to Test Step 5.
• -Battery (terminals 65 and 67) Test Step 3. Check the Part Number of
the ECM Personality Module
• ATA Data Link (terminals 8 and 9)
for the proper torque of 6.0 N.m (55 Ib in). B. Turn the key switch to the ON position.
D. Check the harness and wiring for abrasion and C. Read the customer specified parameters, Refer
pinch points from the data link connectors back to Troubleshooting, "Programming Parameters".
to the ECM.
D. Ensure that the personality module part number
Expected Result: agrees with the original engine arrangement.
All connectors, pins and sockets should be Expected Result:

and wiring should be free of corrosion, abrasion The correct personality module is installed in the
or pinch points. ECM for the engine.
Results: Results:
• OK - Proceed to Test Step 2. • OK
• Not OK
240
Repair: The diagnostic code 252-11 must be Verify that the repair eliminates the problem.
cleared if the correct personality module has
been installed. Clearing this diagnostic code STOR
requires factory passwords and resetting the
personality module code to zero. Test Step 5. Review Parameters and Data
STOR A. Turn the key switch to the ON position.
• Not OK B. Check for active diagnostic codes and/or logged

diagnostic codes on Cat ET.
Repair: Reprogram the ECM with the correct
personality module. Refer to Troubleshooting, C. Review the customer and system parameters.
"Flash Programming".
D. Review the engine lifetime totals.
Expected Result:
STOR
The parameters and totals are scrambled.
Test Step4. Determine Parameters that
Require Programming Results:
A. Connect Cat ET to the data link connector. • OK
B. Turn the key switch to the ON position. Repair: Try to reprogram the suspect parameter
or parameters. If the ECM does not maintain
C. Check the active diagnostic codes. Note any the parameters, temporarily connect a test
parameters that are listed in the following active ECM. Ensure that the test ECM will allow the
diagnostic code: programming of the parameters. If the test
ECM does not allow the programming of the
• 253-02 Check Customer or System Parameters parameters, the old ECM is OK. Something is
(56) wrong in the vehicle wiring. Check the battery
supply circuit to the ECM and repair, as required.
Expected Result:
The ECM allows the parameters that are listed
under the following active diagnostic code in the STOR
active diagnostic code screen to be programmed:
• Not OK - The ECM is OK. STOR
(56)
i01720712
Results: Electrical Connectors - Inspect

• OK SMCS Code: 7553-040-WW
Repair: Ensure that the cause of all diagnostic System Operation Description:
codes is repaired.
Most electrical problems are caused by poor
STOR connections. The following procedure will assist
in detecting problems due to connectors. If a
• Not OK problem is found in an electrical connector, repair
the connector and verify that the problem does not
Repair: Temporarily connect a test ECM. Ensure return. Do NOT cut connector wires unless terminals
that the test ECM will allow the programming of are being replaced. Repair the connectors with
the parameters. If the test ECM does not allow a 1U-5804 Crimp Tool. The wedges on the DT
the programming of the parameters, the old ECM connectors are easily removed with a 147-6456
is OK. Something is wrong in the vehicle wiring. Removal Tool.
Check the battery supply circuit to the ECM and
repair, as required.
241
Intermittent electrical problems often disappear

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 any
connectors. If the status of a diagnostic code is
changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
likely problems are loose or improperly crimped
terminals, moisture, corrosion, or connectors not
mated securely.
ALWAYS crimp the terminals on the wires with the

1U-5804 Crimp Tool. Do not solder the terminals.
A C >
J2 ~ "
I, e o. . . . . J1
Harness Connector P2 Harness Connector P1
00000000000
III1~00000
III1,,oooo ~
o 00000~1111
00000000000
oooo2,1111
llllz~O0000
IIIPoooo ~
o 00000~41111
oooo2,1111
IIII~ o o o o I L g ] l o o o c ~ l l l l IIII~ o o o o IILgJll oooo=1111
IIIP,OOOO ~ oooc401111 IIIWOOOO ~ oooo,~1111
i i i 1 , , o o o o o o ooooo.1111
i i i p ~ o o o o o o oooo041111
%~ooooooooooomc
~ %~°°m°oooooooo~o
~
ECM Side ECM Side
i ii ill l ii Ill
-c2r
f II II
40 47
Harness Side Harness Side
ECM connectors (AMP)

242
Deutsch DT Connector Receptacles Deutsch DT Connector Plugs
Receptacle Wedge ,1 Plug Wedge
Plug Wedge
Receptocle Wedge
.1 Plug Wedge
Deutsch and AMP Pin Contact Deutsch and AMP Socket Cantact Deutsch and AMP Sealing Plug
Illustration 96
g00675955
Deutsch connector receptaclesand plugs
243
CORRECT CORRECT
Correctly
Inserted
Plug
\ 2
Correctly Routed Harness
AVOID
/ '
Incorrectly
Inserted
Plug
Incorrectly Routed Harness AVOZD
Routing of the Harness and insertion of the plug
(1) Correctly routed harness (3) Incorrectly routed harness
(2) Correctly inserted plug (4) Incorrectly inserted plug
Test Step 1. Check the Locking of the DT Test Step 2. Check the Allen Head Screw
Connector (Deutsch) and Check the Lock on the ECM Connector
Ring of the HD Style Connector (Deutsch)
A. Ensure that the allen head screw is properly
A. Ensure that the connector is properly locked. tightened. Be careful not to overtighten the screw
Also ensure that the two halves of the connector and break the screw.
can not be pulled apart.
B. Do not exceed 6.0 N.m (55 Ib in) of torque on
B. Verify that the latch tab of the connector is the allen head screw.
properly latched. Also verify that the latch tab of
the connector returns to the locked position. Expected Result:
Expected Result: The ECM connector is secure and the allen head
screw is properly torqued.
The connector will securely lock. The connector
and the locking mechanism are without cracks or Results:
breaks.
Results:
• Not OK
Repair: Repair the connector or replace the
• Not OK connector, as required.
Repair: Repair the connector or replace the Verify that the repair eliminates the problem.
connector, as required.
STOP.
STOR
244
Test Step 3. Perform a Pull Test on Each Results:

Wire Terminal Connection
A. Each terminal and each connector should easily
withstand 45 N (10 Ib) of pull and each wire • Not OK
should remain in the connector body. This test
checks whether the wire was properly crimped Repair: Repair the circuit.
in the terminal and whether the terminal was
properly inserted into the connector. Verify that the repair eliminates the problem.
B. The DT connectors use a green wedge to lock STOP.

the terminals in place. Ensure that the green
wedge is not missing and that the green wedge Test Step 5. Check Wires for Nicks or
is installed properly on the DT connectors. Abrasion in the Insulation
Note: Terminals should always be crimped onto the A. Carefully inspect each wire for signs of abrasion,
wires by using a crimp tool. Do not solder terminals. nicks, or cuts.
Use the l U - 5 8 0 4 Crimp Tool.
The following areas are locations that should
Expected Result: be checked:
Each terminal and each connector easily withstands • Exposed insulation

45 N (10 Ib) of pull and each wire remains in the
connector body. • Points of rubbing wire against the engine
Results: • Points of rubbing wire against a sharp point
• OK - Proceed to Test Step 4. B. Check all of the hold down clamps for the
harness in order to verify that the harness is
• Not OK properly clamped. Also check all of the hold
down clamps for the harness in order to verify
Repair: Repair the circuit. that the harness is not compressed by the
clamp. Pull back the harness sleeves in order
Verify that the repair eliminates the problem. to check for a flattened portion of wire. The
flattened portion of wire is caused by the clamp
STOP. that holds the harness.
Test Step 4. Perform the "Wiggle Test" Expected Result:

on Cat ET
The wires are free of abrasion, nicks, or cuts and
A. Select the "Wiggle Test" from the diagnostic tests the harness is properly clamped.
on Cat ET.
Results:
B. Press the "OK" button after you adhere to the
warning. • OK - Proceed to Test Step 6.
C. Choose the appropriate group of parameters to • Not OK

monitor.
Repair: Repair the wires or replace the wires, as
D. Press the "Start" button. Wiggle the wiring required.
harness in order to reproduce intermittent
problems. Verify that the repair eliminates the problem.
E. If an intermittent problem exists, the status will be STOP.

highlighted and an audible beep will be heard.
Expected Result:
No intermittent problems were indicated during the
"Wiggle Test".
245
Test Step 6. Check Connectors for

Moisture or Corrosion
ECM AMP Connectors Deutsch DT Connector Plug
I I
0 0 0 0 0 0 0 0 0 0 0
~/ 0 0 0 0 0
10000 ~
o 0000
000
390 0 0 O 0 0 0 SEAL
1470 0 0 0 0 0 0
I570 O O O O O O O O O 048
O O O O O O O 0 0 0 0 0 0 ) ~ )
I---1 I-1
g00705443
Illustration 98
Connector seals
A. Ensure that the connector seals and the white Moisture can also travel from one connector
sealing plugs are in place. If any of the seals or through the inside of a wire to the ECM
plugs are missing, replace the seal or plug. If Connector. If moisture is found in the ECM
necessary, replace the connector. connector, thoroughly check all connectors and
wires on the harness that connect to the ECM.
B. Check all of the wiring harnesses in order to The ECM is not the source of the moisture. Do
verify that the harness does not make a sharp not replace an ECM if moisture is found in either
bend out of a connector. This will deform the ECM connector.
connector seal and this will create a path for the
entrance of moisture. Note: If corrosion is evident on the pins, sockets or
the connector, use only denatured alcohol to remove
Thoroughly inspect the J1/P1 and J2/P2 ECM the corrosion. Use a cotton swab or a soft brush
connectors for evidence of moisture entry. to remove the corrosion. Do not use any cleaners
that contain 1,1,1 trichloro-ethylene because 1,1,1
Note: It is normal to see some minor seal abrasion trichloro-ethylene may damage the connector.
on the ECM Connector seals. Minor seal abrasion
will not allow the entry of moisture. Expected Result:
C. If moisture or corrosion is evident in the All of the connectors should be completely coupled
connector, the source of the moisture entry and all of the seals should be completely inserted.
must be found and the source of the moisture The harness and the wiring should be free of
entry must be repaired. If the source of the corrosion, abrasion or pinch points.
moisture entry is not repaired, the problem will
reoccur. Simply drying the connector will not fix Results:
the problem. Likely paths for the entrance of
moisture are illustrated in the following list: • OK - Proceed to Test Step 7.
• Missing seals • Not OK
• Improperly installed seals Repair: Repair the connectors or wiring and/or

• Nicks in exposed insulation of the seals are properly in place and ensure that
• Improperly mated connectors
246
Verify that the repair eliminates the problem

by running the engine for several minutes and
by checking 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 that have moisture. These wires may have
moisture that is trapped inside the insulation.
STOR
Test Step 7. Inspect the Connector

Terminals
A. 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.
Results:
• Not OK
Repair: Repair the terminals and/or replace the

terminals, as required.
STOR
247
Test Step 8. C h e c k Individual Pin

Retention into the S o c k e t
-H
--u----q
[ 1
J M \
i
Deutsch ond AMP Pin Contoct Deutsch ond AMP Socket Contoct
1 2
(1) Contact of the pin (2) Contact of the socket
Note: This is especially important for intermittent i01907603

problems.
Engine Pressure Sensor Open
A. Use a new pin. Insert the pin into each socket or Short Circuit - Test
one at a time in order to check for a good grip
on the pin by the socket. SMCS Code: 1917-038; 1923-038; 1924-038
B, Use a new socket. Insert the socket over each System Operation Description:
pin one at a time in order to check for a good
grip on the pin by the socket. The pins are The troubleshooting procedures for the diagnostic
located on the mating side of the connector. codes of each pressure sensor are identical. The
Engine Control Module (ECM) sends a 5 Volt supply
C, The contact terminal should stay connected to terminal A of each sensor. The sensor common
when the connector is held in the position shown connection is connected to terminal B of each
in Illustration 99. The contact terminal is the pin sensor. The signal voltage from terminal C of each
or the socket. sensor is sent to the appropriate terminal at the
J2/P2 ECM connector.
Expected Result:
The pins and the sockets appear to be OK.
Results:
• OK - STOR
• Not OK
Repair: Repair the terminals and/or replace the

terminals.
STOR
248
Enqine
Oil Atmospheric Control Boost
Pressure Pressure Pressure
Module
C-I0 AND C-12 LEFT SIDE VIEW

I
C-10 AND C-12 TOP VIEW

C-10 and C-12 Pressure sensors
Boost Atmosoheric Enoine Oil

Pressure Pressure Control Pressure
Sensor Sensor Module Sensor
3406E LEFT SIDE VIEW 3406E RIGHT SIDE VIEW

3406E Pressure sensors
249
Boost Engine
Pressure Control
Sensor Module
(ECM)
Atmospheric Oil
Pressure Pressure
Sensor Sensor
Ill I
' I O)
LQ
C-15, C-16 and C-18 Pressure sensors
/ l.--.=,~=
ENGINE BOOSTPRESSUREI'--GN--I~I C ~
ENGINE PRESSURE SENSOR COMMON I.-YL-I~.I B ~ - . - -
ENGINE PRESSURE SENSOR +SVt--OR-Iq A'~I~
/
P200 #200
ECM
ENG]NE ATMOSPHERICPRESS.I--GN-~-1"~ ---~ -A746-PK'I2~40~ENG]NE BOOSTPRESSURE
ENGINE PRESSURE SENSOR COMMON I~YL-J~.I B'~t--~ / A747-GY-1<~I14~ENGINEATMOSPHERIC PRESSURE
ENGINE PRESSURE SENSOR +SVI---OR-I~I A ~ ~: z 994-GY'I<t24~ENGINE OIL PRESSURE
-I~G829-GN"I'~IS~ENGINE PRESSURE SENSOR COMMON
P203 J203 -t"-'-G828-WH'~__I2~ENGINE PRESSURE SENSOR +5V
/
ENGENE PRESSURE SENSOR COMMON

ENGINE PRESSURE SENSOR +SV
P201 J201

Schematic for engine pressure sensors
250
ENGINE PRESSURE SENSOR+SV
Z300000 O0
ENGINEPRESSURESENSORCOMMON
3~0000 Q 000~24- ENGINEATMOSPHERICPRESSURE
39o o o o o o o os=~ ENGINEOILPRESSURE
ENGINEBOOSTPRESSURE
470000 0 0 0~0:
570 0 0 0 0 0 0 0 0 048
700 0 0 0 O 0 0 0 O 0 0 0058~J
ECM Side " Engine Harness Connector P2
/ ' ENGINEPRESSURESENSOR+SV
ID 1 4 ~ ~ ~('~C)23;11
>PET< ENGINE PRESSURESENSORCOMMON
-- ~ ~ . - ,-,,-,,',,',-~'~ ENGINEATMOSPHERICPRESSURE
:,4_~L2LX.J /,,'~,,",,
,,..,,Jw~. . . . . . . . . . . .
J 0000 tLU)P~O00 q ..~,.-v,-PRESSURE

40~L'~O(~) k ~ / / O0~Q47b
! 48(~000 0 0 0 0 ~ . ) S71 BOOSTPRESSURE
, 0000000000000 /
Harness Side
Illustration104 900662237
Terminallocationsfor ECM
B. Turn the key switch to the ON position. Wait at
Jack least 15 seconds for activation of the diagnostic
codes.
Pin-B ~ Pin-A
C. Verify if any of the following diagnostic codes
are active:
• 232-03 5 Volt Supply voltage high

\~. J/ ---'-- Pin-C • 232-04 5 Volt Supply voltage low
(Signal)
Plug Expected Result:
Socket-A ~ Socket-B None of the preceding diagnostic codes are active.

(Supply)~ ~ ~(Common)
Results:

Socket-C~ • Not OK
(Signal)
Illustration105 g00810608 Repair: Perform the following diagnostic
Sensorconnector procedure: Troubleshooting, "5 Volt Engine
Pressure Sensor Supply Circuit - Test".
Test Step 1. Check for Active +5 V Sensor STaR
Supply Diagnostic Codes
251
Test Step 2. Inspect Electrical Connectors Expected Result:

And Wirnng
Either a "voltage low" diagnostic code (short circuit)
A. Thoroughly inspect the J2/P2 ECM connector is active or a "voltage high" diagnostic code (open
and the connectors for any suspect sensors. circuit) is active.
- Inspect" for details. Results:
B. Perform a 45 N (10 Ib) pull test on each of the • Voltage Low (Short) - A "voltage low" diagnostic
wires in the ECM connector and the sensor code (short circuit) is active at this time. Proceed
connectors that are associated with the active to Test Step 4.
diagnostic code.
• Voltage High (Open) - A "voltage high" diagnostic
Refer to Illustration 104. code (open circuit) is active at this time. Proceed
to Test Step 7.
for the proper torque of 6.0 N.m (55 Ib in). Test Step 4. Disconnect the Suspect
Sensor
pinch points from the sensors back to the ECM. A. Turn the key switch to the OFF position.
Expected Result: B. Disconnect the sensor with the "voltage low"

diagnostic code (short circuit).
completely coupled and/or inserted and the harness C. Turn the key switch to the ON position. Wait at
and wiring should be free of corrosion, abrasion least 15 seconds for activation of the diagnostic
or pinch points. codes.
Results: D. Check for an active "voltage high" diagnostic

code (open circuit) for the disconnected sensor.
Expected Result:
• Not OK
A "voltage high" diagnostic code (open circuit) for
Repair: Repair the connectors or wiring and/or the disconnected sensor is now active.
of the seals are properly in place and ensure that Results:
OK - A "voltage low" diagnostic code (short
Verify that the repair eliminates the problem. circuit) was active before disconnecting the
sensor. A "voltage high" diagnostic code (open
Clear all logged diagnostic codes. circuit) became active after disconnecting the
sensor.
STOP.
Test Step 3. Determine the Condition that
is Present Check for active diagnostic codes,
A. Turn the key switch to the ON position. Wait at If the new sensor fixes the problem, reconnect
least 15 seconds for activation of the diagnostic the suspect sensor.
codes.
If the problem returns, permanently install the
B. Monitor the active diagnostic code screen on new sensor.
Cat ET.
C. Determine if the problem is related to a "voltage
high" diagnostic code (open circuit) or a "voltage STOR
low" diagnostic code (short circuit).
Not OK - T h e r e is a short circuit between the
sensor and the ECM.
252
Repair: Leave the suspect sensor disconnected. Results:

Proceed to Test Step 5. • OK - The resistance is greater than 20,000
Ohms, or "OL" is displayed on the multimeter.
Test Step 5. Create an Open Circuit at the
ECM Repair: Check the signal wire for a short to
ground.
B. Remove the signal wire of the suspect sensor wiring.
from the P2 ECM connector.
C. Turn the key switch to the ON position.
STOR
D. Check for active diagnostic codes.
Not OK - There is a short between the pressure
Expected Result: sensor common and the signal wire.
A "voltage high" diagnostic code (open circuit) Repair: Locate the short between the pressure
became active after disconnecting the signal wire. sensor common and the signal wire.
Results: Repair the faulty wiring or replace the faulty

wiring.
• OK - A "voltage low" diagnostic code (short
circuit) was active before disconnecting the Verify that the repair eliminates the problem.
sensor. A "voltage high" diagnostic code (open
circuit) became active after disconnecting the STOR
sensor. Proceed to Test Step 6.
Test Step 7. Measure the Sensor Supply
• Not OK -There is still a "voltage low" diagnostic Voltage
code (short circuit).
Repair: Connect a test ECM.
B. Disconnect the suspect sensor.
suspect ECM. C. Turn the key switch to the ON position.
If the problem returns, permanently replace the D. Measure the voltage from terminal A (Pressure
suspect ECM. Sensor +5V) to terminal B (Pressure Sensor
Common).
Expected Result:
STOR
The voltage is 5.0 ± 0.16 VDC.
Test Step 6. Check the Resistance of the
Harness Results:
A. Turn the key switch to the OFF position. • OK - T h e sensor supply voltage is correct.
B. Verify that the suspect sensor is disconnected. Repair: Leave the sensor disconnected.
Co Measure the resistance between terminal B Proceed to Test Step 8.

(Pressure Sensor Common) and terminal C
(Signal) of the connector for the suspect sensor • Not OK - The sensor supply voltage is out of
on the engine harness. the range.
Expected Result: Repair: Check the 5 volt supply wire for an open
circuit.
The resistance is greater than 20,000 Ohms, or
"OL" is displayed on the multimeter. Repair the faulty wiring or replace the faulty
wiring.
253
Verify that the repair eliminates the problem. Note: When the P2 ECM connector is disconnected,
all of the "voltage high" diagnostic codes (open
STOR circuit) for the pressure sensors will be active. This
is normal.
Test Step 8. Create a Short Circuit at the
Sensor E. Install a jumper wire between the terminal for the
signal of the suspect sensor and the pressure
A. Turn the key switch to the ON position. sensor common on the ECM. Wait at least 15
seconds for activation of the "voltage low"
B. Monitor the active diagnostic code screen. diagnostic code (short circuit).
C. Install a jumper wire between terminal C (Signal) Expected Result:

and terminal B (Pressure Sensor Common) of the
sensor connector. Wait at least 15 seconds for A "voltage low" diagnostic code (short circuit) is
activation of the "voltage low" diagnostic code active for the suspect sensor.
(short circuit).
Results:
Expected Result:
• OK - T h e ECM is operating properly.
A "voltage low" diagnostic code (short circuit) is
active when the jumper wire is installed. A "voltage Repair: Leave the P2 ECM connector
high" diagnostic code (open circuit) is active when disconnected.
the jumper wire is removed.
Results:
Not OK - T h e "voltage high" diagnostic code
• OK - T h e engine harness and the ECM are OK. (open circuit) is still active when the jumper wire
is installed.
Repair: Temporarily connect a test ECM.
the suspect sensor. If the test ECM fixes the problem, reconnect the
suspect ECM.
suspect sensor. If the problem returns, permanently replace the
ECM.
STOR
STOR
• Not OK - T h e "voltage high" diagnostic code
(open circuit) remains active when the jumper Test Step 10. Check the Resistance of
wire is installed. the Harness
Repair: Remove the jumper wire. A. Turn the key switch to the OFF position.
Proceed to Test Step 9. B. Verify that the suspect sensor is disconnected.
Test Step 9. Create a Short Circuit at the C. Check the resistance between terminal A
ECM (Pressure Sensor +5V) and terminal C (Signal)
of the connector for the suspect sensor on the
A. Turn the key switch to the OFF position. engine harness.
B. Disconnect the J2/P2 ECM connector. Expected Result:

C. Turn the key switch to the ON position. The resistance is greater than 20,000 Ohms or "OL"
is displayed on the multimeter.
A "voltage high" diagnostic code (open circuit)
should be active for the suspect sensor. Results:
D. Monitor the active diagnostic code screen. Wait • OK -There is an open circuit in the signal wire.
at least 15 seconds for activation of the code.
Repair: Locate the open in the signal wire.
254
Repair the faulty wiring or replace the faulty The "Engine Running Output" activates when the
wiring. engine is running. This can be used to prevent the
engagement of the starter motor while the engine
Verify that the repair eliminates the problem. is running. The ECM can be connected to a relay
that disables the starter. The relay is normally
STOR closed so cranking can be achieved immediately at
powerup. During cranking, the ECM energizes the
• Not OK - There is a short between the 5 volt "Engine Running Output" once engine rpm reaches
supply and the signal wire. 50 rpm below low idle. The output is de-energized
when the engine speed falls by 100 rpm below
Repair: Locate the short between the 5 volt the programmed low idle. The low idle rpm is
supply and the signal wire. programmable. The range for low idle is between
600 rpm and 750 rpm.
wiring.
STOR
i01637520
Engine Running Output Circuit

- Test
SMCS Code: 1901-038
The engine running output circuit is suspected of

incorrect operation.

to this procedure:
Engine Running Output
The "Engine Running Output" can be programmed

to J1/P1:10, J1/P1:12, or J1/P1:13. The "Engine
Running Output" will function on the following
corresponding output that is selected:
• ECM Connector J1/P1:10

255
ENGINE RUNNING TO VEHICLE

OUTPUT RELAY (N/C) + BATTERY
E718-PK OUTPUT #2
OUTPUT ~3
G836-w,-. K I ~3 OUTPUT ~4
P1 J1
NOTE: ENGINE RUNNING OUTPUT PARAMETER MUST BE PROGRAMMED TO THE

OUTPUT SELECTION. OUTPUT 2, 3, OR 4 MAY BE USED.

Circuit for engine running output
I---I '~
OUTPUT 2
, 3 o J t o qr'o o o o o o o o o
230~0 0 0 o 0 0 0 0 014 OUTPUT 3
3,0000 ~ 000024 OUTPUT 4
3~oooo llIUJl oooo~2
470000 ~ 000040
570 O O O O O O O O O 048
70000000000000058

1 2 3 4 5 6 8 9 tOJt 17 1 3 ~ OUTPUT 2
OOOOOOOOOI~OlNI-1 OUTPUT 4
00000 z< ~ 2 3 1
>PEA OUTPUT 3
OOOO f,,~-,,% OOOO3~1
OOOO (( r..])136OOOO [I
oooo oooo; I
\k,~58 59 60 616263 r. t 656667686970.,,/
II II J
Harness Side

Test Step 1. Inspect Electrical Connectors B. Perform a 45 N (10 Ib) pull test on terminal 10,
and Wiring terminal 12, or terminal 13 in the ECM connector.
A. Thoroughly inspect ECM vehicle harness Refer to Illustration 107.

connector J1/P1, and the firewall bulkhead
connector. Refer to Troubleshooting, "Electrical C. Check the ECM connector (allen head screw) for
Connectors - Inspect" for details. the proper torque of 6.0 N.m (55 Ib in).
256
D. Check the harness and wiring for abrasion and C. Begin the "Engine Running Output Special Test"
pinch points from the sensor to the ECM. and listen for the relay to click. You may need to
be near the engine in order to hear the click.
Expected Result:
Expected Result:
completely coupled and/or inserted and the harness The relay will activate when the special test is
and wiring should be free of corrosion, abrasion turned "On".
or pinch points.
Results:
Results:
• OK - T h e ECM and vehicle components are
• OK - Proceed to Test Step 2. operating correctly. STOR
• Not OK - Repair the wiring or replace the wiring, • Not OK - Proceed to Test Step 4.
if necessary. Repair the connectors or replace
the connectors, if necessary. Ensure that all of Test Step 4. Use ET to Check the ECM
the seals are in the proper place. Ensure that all
of the connectors are connected properly. Verify A. Connect ET to the cab data link connector.
that the repair eliminates the problem. STOR
B. Turn the ignition key switch to the OFF position.
Test Step 2. Ensure Correct Parameter
Programming C. Disconnect the ECM vehicle harness connector
JI/P1.
A, Connect the Caterpillar Electronic Technician
(ET) to the cab data link connector. D, Connect a 70-Terminal Breakout T between ECM
connectorsJ1 and P1.
B. Turn the ignition key switch to the ON position.
E. If the "Engine Running Output" is programmed to
C. Access the customer specified parameter J1/P1:10, connect a voltage test lamp to terminal
screen in order to make sure that the ECM 10 (Output 2) and terminal 65 (-Battery) of the
is programmed to use the "Engine Running breakout T.
Output".
F. If the "Engine Running Output" is programmed to
D. Ensure that the "Engine Running Output" circuit J1/P1:12, connect a voltage test lamp to terminal
is connected to the programmed output. 12 (Output 3) and terminal 65 (-Battery) of the
breakout T.
Expected Result:
G. If the "Engine Running Output" is programmed to
The circuit is connected to the correct ECM terminal J1/P1:13, connect a voltage test lamp to terminal
that is selected for the "Engine Running Output". 13 (Output 4) and terminal 65 (-Battery) of the
breakout T.
Results:
H. Turn the ignition key switch to the ON position.
I, Access the appropriate "Engine Running Output
• Not OK - Update the customer specified Special Test" on ET.
parameter in order to match the correct output
terminal. STOR J. Cycle the corresponding "Engine Running Output
Special Test" to the ON position and to the OFF
Test Step 3. Use ET to Check the Relay position and watch the voltage test lamp.
A. Turn the ignition key switch to the ON position. K. Stop the special test.
B. Access the "Engine Running Output Special Note: A multimeter can not be used in place of the
Test" on ET. The "Engine Running Output Special voltage test lamp when the ECM outputs are being
Test" will enable the "Engine Running Output" tested.
when the test is active.
257
Expected Result: The shutdown output allows the ECM to shut

down portions of the vehicle's electrical system
The voltage test lamp turns on when the"Engine at shutdown. This reduces the consumption of
Running Output Special Test" is active. The voltage electrical power (battery draw) after the truck is shut
test lamp also turns off when the "Engine Running down. The system activates a normally open relay
Output Special Test" is not active. (Shutdown Output Relay) when the engine begins
running. This permits the driver to turn the ignition
Results: key switch to the OFF position without causing the
engine to shutdown. When the Idle Shutdown Timer
• OK - T h e ECM is OK. The problem is in the completes the countdown and the Idle Shutdown
vehicle wiring. Inspect the vehicle wiring and then Timer shuts down the engine, the ECM turns off the
repair the vehicle wiring. Otherwise, send the relay. This interrupts the power to the ECM. The
vehicle to the OEM dealer for repair. Verify that current draw on the batteries is then dependent
the original condition is resolved. STOP. on the items that are not powered through the
Shutdown Output Relay Circuit.
• Not OK - Temporarily connect a test ECM. Use
the "Engine Running Output Special Test" on 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. STOR
i01637482
Engine Shutdown Output

Circuit- Test
SMCS Code: 1901-038
The Engine Shutdown Output Circuit is suspected

of incorrect operation.

to this procedure:
Shutdown Output
The "Engine Shutdown Output" can be programmed

to J1/P1:10, J1/P1:12, or J1/P1:13.
The "Engine Shutdown Output" will function on the

corresponding Output that is selected:
• ECM Connector J1/P1 Terminal 10

258
IGNITION I OFF L
KEY SWITCH
TO STARTER
,~~ T O VLEHC
ENGINE
SHUTDOWN
TO VEHICLE
ELECTRICAL
SYSTEMS
ILE
RELAY (N/O)
+ BATTERY I
ECM
J906- B R - - - F r ~ IGNITION KEY SWITCH
--E718-PK---KI 10, OUTPUT 12
.---E991-GY--KI12, OUTPUT 13
ENGINE -G836- WH-~.L13_.: OUTPUT 14
SHUTDOWN
SWITCH (N/C) PI Jt
NOTE: ENGINE SHUTDOWN OUTPUT PARAMETER MUST BE PROGRAMMED TO THE

OUTPUT SELECTION. OUTPUT 2, 3, OR 4 MAY BE USED.
Circuit for shutdown output
OUTPUT 2
OUTPUT 3
OUTPUT 4

f II II
f 1 2 3 4 5 6 u 8 9 10J1 17 13 OUTPUT 2
OOOOOOOOOtrK:~Nl~l OUTPUT 4
OUTPUT 3
240000 f~"~ O000s, I
I OOOO (( r. 3 ) ] 3 6 0 0 0 0
0000000000000 J
~ 5 8 59 60 61 62 63 r~ 65 66 67 68 69 70..,/
Harness Side
Illustration 109 900656156

Test Step 1. Inspect Electrical Connectors B. Perform a 45 N (10 Ib) pull test on terminal 10,
and Wiring terminal 12, or terminal 13 in the ECM connector.
A. Thoroughly inspect ECM vehicle harness Refer to Illustration 109.

connector J1/P1, and the firewall bulkhead
connector. Refer to Troubleshooting, "Electrical
259
C. Check the ECM connector (allen head screw) for C. While you listen for the relay to click, begin the
the proper torque of 6.0 N.m (55 Ib in). "Engine Shutdown Output Special Test".
D. Check the harness and wiring for abrasion and Note: You may need to be near the relay in order to
pinch points from the sensor to the ECM. hear the click.

All connectors, pins, and sockets should be The relay activates when the special test is enabled.
and wiring should be free of corrosion, abrasion, Results:
or pinch points.
Results: operating correctly. STOP.
• OK - Proceed to Test Step 2. • Not OK - Proceed to Test Step 4.
• Not OK - Repair the wiring or replace the wiring, Test Step 4. Use ET to Check the ECM
the connectors, if necessary. Ensure that all of A, Connect ET to the cab data link connector.
of the connectors are connected properly. Verify B. Turn the ignition key switch to the OFF position.
that the repair eliminates the problem. STOP.
Test Step 2. Check the Programmable J1/P1.
Parameters
D. Connect a 70 Terminal Breakout T between
A. Connect the Caterpillar Electronic Technician connectors J1 and P1.
E. If the "Engine Shutdown Output" is programmed
B. Turn the ignition key switch to the ON position. to J1/P1:10, connect a voltage test lamp to
terminal 10 (Output 2) and terminal 65 (-Battery)
C. Access the customer specified parameter of the breakout T.
screen in order to make sure that the ECM is
programmed to use the engine shutdown output. F. If the "Engine Shutdown Output" is programmed
to J1/P1:12, connect a voltage test lamp to
D. Ensure that the circuit for the engine shutdown terminal 12 (Output 3) and terminal 65 (-Battery)
output is connected to the programmed output. of the breakout T.
Expected Result: G. If the "Engine Shutdown Output" is programmed

to J1/P1:13, connect a voltage test lamp to
The circuit is connected to the correct ECM terminal terminal 13 (Output 4) and terminal 65 (-Battery)
that is selected for the "Engine Shutdown Output". of the breakout T.
Results: H. Turn the ignition key switch to the ON position.
• OK - Proceed to Test Step 3. Access the "Engine Shutdown Special Test" on

ET.
• Not OK - Update the customer specified
parameter in order to match the correct output J. While you monitor the voltage test lamp, cycle
terminal. STOR the "Special Test" from the ON position to the
OFF position back to the ON position,
Test Step 3. Connect ET in order to Check
the Relay K. Stop the "Special Test".
A. Turn the ignition key switch to the ON position. Note: A multimeter can not be used in place of the
voltage test lamp when the ECM outputs are being
B. Access the "Engine Shutdown Output Special tested.
Test" on ET. The "Engine Shutdown Output
Special Test" will enable the "Engine Shutdown
Output" when the test is active.
260
Expected Result: Under normal operation, the secondary engine

speed/timing sensor is used to determine timing
The voltage test lamp turns on when the "Engine for starting purposes. The secondary engine
Shutdown Output Special Test" is active. The speed/timing sensor is used to determine when
voltage test lamp turns off when the "Engine the piston in the No. 1 Cylinder is at the top of
Shutdown Output Special Test" is not active. the compression stroke. When the timing has
been established, the primary engine speed/timing
Results: sensor is then used to determine engine speed.
• OK - T h e ECM is operating correctly. The After locating the No. 1 cylinder, the ECM triggers
problem is in the vehicle wiring. Inspect the each injector in the correct firing order and at the
vehicle wiring and then repair the vehicle wiring. correct unit injector timing. The actual timing and
Otherwise, send the vehicle to the OEM dealer duration of each injection is based on engine rpm
for repair. Verify that the original condition is and load. If the engine is running and the signal
resolved. STOP. from the primary engine speed/timing sensor is
lost, a slight change in engine performance will be
• Not OK - Temporarily connect a test ECM. Use noticed when the ECM performs the changeover to
"Engine Shutdown Output Special Test" on ET the secondary engine speed/timing sensor. Loss of
to check the ECM. If the problem is resolved the signal from the secondary engine speed/timing
with the test ECM, install the suspect ECM. If the sensor during engine operation will not result in
problem returns with the suspect ECM, replace any noticeable change in engine performance.
the ECM. Verify that the repair eliminates the However, if the signal from the secondary engine
problem. STOP. speed/timing sensor is not present during start-up
the following conditions may exist:
iO1907625
• The engine may require a slightly longer period
Engine Speed/Timing Sensor of time to start-up.
Circuit- Test • The engine may run rough for a few seconds
until the ECM determines the proper firing order
SMCS Code: 1912-038 by the use of the primary engine speed/timing
sensor only.
The engine will start and the engine will run when
Use this procedure under the following situation: only one sensor signal is present from either of the
sensors. The loss of the signal from both of the
• There is an active diagnostic code or an easily sensors during engine operation will result in the
repeated diagnostic code that is associated with termination of injection and the shutting down the
either the primary engine speed/timing sensor or engine by the ECM. The loss of the signal from
the secondary engine speed/timing sensor. both of the sensors during start-up will prevent the
engine from starting.
• You have been directed to this test from
Troubleshooting, "Troubleshooting without a Both sensors are magnetic sensors. The two
Diagnostic Code". sensors are not interchangeable. Do not switch the
positions of the sensor. If the sensors are replaced,
The following background information is related a timing calibration is NOT necessary for the
to this procedure: engine. Timing calibration is only necessary after
replacing an ECM that will not communicate.
The engine uses two engine speed/timing sensors.
One sensor picks up the camshaft gear and the
other sensor picks up the crankshaft gear. Both
of the engine speed/timing sensors detect the
reference for engine speed and timing from a
unique pattern on the gear. The ECM counts the
time between pulses that is created by the sensor
as the gear rotates in order to determine rpm.
261
Secondary
Engine Engine Secondary
Speed/Timing Control Engine
Module Engine
Sensor Speed/Timing Control
(ECM)
Module
(ECM)
¢ /
1
o
Primary - ~
Engine
Primary Speed/Timing t ~
Engine Sensor
Speed/Timing
Sensor
Illustration 110 900994866 Illustration 112 g00994867
C-10 and C-12 Engine C-15, C-16 and C-18 Engine
Left side engine view Left side engine view
Secondary If a replacement of the ECM is required, the

Engine Engine ECM parameters and the timing calibration can
Speed/Timing Control be transferred from the suspect ECM to the
Sensor Module
(ECM) replacement ECM. Timing calibration will NOT be
necessary. This feature requires the Caterpillar
/ Electronic Technician (Cat ET) and this feature is
only possible if the existing ECM can communicate
with Cat ET. Use the "Copy Configuration - ECM
Replacement" on Cat ET.
When the sensors are being installed, complete
1
all of the following tasks:
• Lubricate the O-ring with oil.

/ Ensure that the sensor has a connector face seal
Primary
Engine inside the connector body. If a seal is damaged
Speed/Timing or missing, replace the seal.
Sensor
• Ensure that the sensor is fully seated into the
Illustration 111 g00995766 engine before tightening the bracket bolt.
3406E Engine • Ensure that the connector is latched on both
Left side engine view sides.
Ensure that the harness is properly secured,

and ensure that the tie-wraps are placed in the
correct location.
Intermittent Faults That Are Due To The Wiring

Harness Terminals
A problem with the engine wiring harness has been

identified. This problem may cause the ECM to
detect several intermittent speed signal conditions
on the following engines:
262
• C-10 (3CS00001-05369) Remove one of the terminals of the harness

socket from the connector for the engine
• 0-12 (2KS00001-15070) speed/timing sensor P401 or P402. The sockets
that are present at the sensor end of the wiring
• 3406E (1MM00390-00838) harness will be one of two types. The socket will
be either a socket that is stamped and formed
• 3406E (2WS08900-20705) or a socket that is machined. The socket that
is stamped and formed will have fingers that
If the intermittent condition occurs, the ECM will log are crimped onto the wire insulation. Refer to
the following diagnostic codes: Illustration 113. The socket that is machined can
only be crimped onto the electrical conductor or
• 190-12 Primary Engine Speed loss of signal wire. Refer to Illustration 114.
• 64-12 Secondary Engine Speed loss of signal If the sockets that are stamped and formed are
present in the sensor harness connectors, the
The occurrence of these faults generally has no sockets must be cut back at the sensor harness
effect on engine performance, although the faults ends of the sensor harness for the engine
are occasionally accompanied by a speed burp of speed/timing sensors, and each socket must
the engine. be replaced by an 8T-8730 Connector Socket
that is machined. The socket terminals in the
Measure the sensor resistance through the engine connector assembly should be removed from
harness, when both of the following conditions are the 2-pin connector. The 2-pin connector is a
met: Deutsch DT-2 connector. The socket terminals
should be changed, and reinserted. Perform this
• The engine falls within the serial number ranges procedure on each wire one at a time in order to
that are listed above. eliminate the chance of reversing the polarity of
the connection. If machined terminals are already
• The engine has logged several 190-12 and/or installed in the sensor harness connectors
64-12 fault codes. for the engine speed/timing sensors, resume
troubleshooting at Test Step 3.
If the speed/timing sensors have the correct
resistance, perform the following procedure in order: There is generally sufficient wire length in the
engine harness in order to perform this repair. Cut
back the socket terminals close to the ends of the
sensor wires. Leave the wire as long as possible.
The wire tie-wraps for the speed-timing sensor

harness can be loosened and the slack in the
harness can be pushed toward the sensor, if
necessary. Maintain at least 1 twist per inch in
Illustration 113
g00660038 the speed-timing sensor harnesses from the ECM
to the sensor.
Socket that is stamped and formed
Ensure that the wiring is not pulled too tightly
at the sensor connector. If the wiring is pulled
too tightly at the sensor connector, intermittent
connections may develop as vibrations occur.
While this service is being performed on the

C-10 and the C-12 engines, ensure that the wire
tie-wrap for the primary engine speed/timing
g00660039
Illustration 114 sensor on the engine front support is snug. This
Socket that is machined tie dampens excessive movement of the sensor
wires during normal engine operation. If the wire
• Ensure that the software that is installed in the tie-wrap for the harness is damaged or missing,
ECM is dated no earlier than March 1999. If install a new tie approximately 102 mm (4 inch)
the software is dated earlier than March 1999, from the sensor.
flash the latest software into the ECM. Clear all
of the fault codes that are related to the engine
speed/timing sensors.
263
• Do Not replace the engine speed/timing sensors.

To check the work that has been performed, start
the engine and disconnect the primary engine
speed/timing sensor. A slight speed burp may
occur when the primary engine speed/timing
sensor is disconnected. If the engine runs
properly and the primary engine speed/timing
sensor is disconnected, the engine repair has
been accomplished without reversing the polarity
of the wiring.
Note: If the above installation is not performed

one wire at a time, the polarity of the wiring can
accidentally be reversed. If the polarity of the wire
for the secondary engine speed/timing sensor is
reversed, the engine may start. The engine will
run adequately until a failure of the primary engine
speed/timing sensor occurs. At this point, the
engine will run poorly. If the polarity of the wire for
the primary engine speed/timing sensor is reversed,
the engine may not start. If the polarities of both
the engine speed/timing sensors are reversed, the
engine will not start.
Primory Engine Speed/Timing Sensor J401/P401

q Primory Speed/Timing - t P2/J2 ECM
Primory Speed/Timing + E963_BK-F]~~ Primary Speed/Timing -
EgO4-wH-1<I48 Primary Speed/Timing +
~E965- BU-1~IS9~ Secondary Speed/Timing -
Secondary Engine Speed/Timing Sensor ~ ~ v "~E966-YL-~_.[_5__~Secondary Speed/Timing +
Secondary Speed/Timing - t
q Secondory Speed/Timing +
Schematic for engine speed/timing sensors
264
• P2 ECM Connector
0000000000001
230 0 0 0 0 ° 0 0 0 0 014
@
!
!
310 0 0 0 0 0 0 024
390 0 0 0 0 0 0 032
Primary Engine Speed/Timing +
470 o o o o o 0/04011 Primary Engine Speed/Timing -
570 o o o o o o o o rsI/
i70o o o o o o o o o o o
r~ ~),/ Secondary Engine Speed/Timing +
Secondary Engine Speed/Timing -
ECM Side
f II II
///~1 2 3 4 5 6 ' ' 8 9 10 11 12 1 3 ~ k
[j 0000000000000
140000 0 >PEI< 0 0 0 0 0 2 s
-240000 /'/~'~"h 00003~
] 0000 ((( ] ) b o O 0 0 0 E Primary Engine Speed/Timing +
4oClO0 0 LN'~J'// 0 0 0 0 4 7 ~ Primary Engine Speed/Timing -
48@0"000 - O0000s7
0000000000 Secondary Engine Speed/Timing +
< 58 ~9 60 61 62 6,.3I-I 65 66 67 68 69 70..,/./
Secondary Engine Speed/Timing -
Harness Side
Illustration 116
g00956357
P2 ECM connector
Test Step 1. Check for Diagnostic Codes Note: If there are occurrences of the 64-12 and
190-12 faults, refer to the following information in
A. Connect the Caterpillar Electronic Technician the System Operation Section:
• Intermittent Faults That Are Due To The Wiring
B. Turn the key switch to the ON position. Harness Terminals
C. Check for one of the following logged diagnostic Expected Result:

codes or active diagnostic codes:
One or more of the diagnostic codes that are listed
• 22-11 Primary to Secondary Engine Speed above are logged or active.
Signal Calibration
Note: If you have been directed here from
• 64-12 Secondary Engine Speed loss of signal Troubleshooting, "Troubleshooting without a
Diagnostic Code" for the following reason, select
• 190-12 Primary Engine Speed loss of signal "No Engine rpm":
Note: If the diagnostic code is logged but not • The engine rpm was not indicated on Cat ET.
active, run the engine until the engine is at normal
operating temperature. The problem may only Results:
occur when the engine is at the normal operating
temperature. If the engine will not start, monitor the • 64-12, 190-12 or 22-11 -There is an active
engine rpm on Cat ET while the engine is being diagnostic code or a logged diagnostic code.
cranked. Cat ET may need to be powered from Proceed to Test Step 3.
another battery while the engine is being cranked.
This is done in order to ensure that Cat ET does • Not OK - If none of the codes that are listed are
not reset. active diagnostic codes or logged diagnostic
codes and the engine is not running properly,
refer to the appropriate symptoms in the service
manual. STOP.
265
• No Engine rpm - Engine rpm is not indicated on 2. Seat the sensor and tighten the bolt.
Cat ET. Proceed to Test Step 2.
If the sensor will not seat, repair the sensor or
Test Step 2. Check the Installation of the replace the sensor, as required.
Sensors and the Bracket
Note: The sensor must not be removed from the
bracket.
Non-Serviceable I-]
Mounting Brocket'~ u Sensor 3. Ensure that the sensor is properly oriented
and that the harness is secured in the proper
location.
STOP.
Test Step 3. Measure the Sensor

Resistance Through the Engine Harness
g00956355 A, Turn the key switch to the OFF position.

Illustration 117
Flange of the sensor and mounting bracket B. Thoroughly inspect the J2/P2 ECM connector.
A. The flange of the sensor should be flush against - Inspect" for details.
the engine in order to ensure proper operation.
C. Perform a 45 N (10 Ib) pull test on the following
B. Inspect the bracket in order to ensure that the wires in the P2 ECM connector that are
installation allows the flange of the sensor to be associated with the engine speed/timing sensors:
flush against the engine.
• Terminal 48
Verify that the bracket is not bent.
• Terminal 49
Note: The bracket cannot be replaced separately.
• Terminal 58
(3. Ensure that one O-ring has been installed on
the sensor, and ensure that the O-ring is free of • Terminal 59
damage.
D. If the following diagnostic code is active, there
may be a problem with the assembly of the D. Ensure that the latch tab on the connector is
engine: properly latched and ensure that the latch tab is
fully latched.
• 22-11 Primary to Secondary Engine Speed
Signal Calibration E. Check the ECM connector (allen head screw) for
the proper torque of 6.0 N-m (55 Ib in).
F. Repair the harness or repair the connector if a
Expected Result: problem is found.
The sensors and the bracket are properly installed. G. Ensure that the wiring harness is correctly routed
and secured at the proper locations.
Results:
H. Ensure that the harness wiring is not pulled
• OK - T h e sensors and the bracket are properly too tightly. When the harness wiring is pulled
installed. Proceed to Test Step 3. too tightly, vibrations or movement can cause
intermittent connections.
• Not OK
Inspect the harness wiring for nicks and
Repair: Perform the following procedure in order abrasions.
to properly install the sensors and the bracket:
J. If the harness and the connector are OK,
1. Loosen the bolt that holds the sensor mounting disconnect ECM connector J2/P2.
bracket to the engine.
266
K. Primary engine speed/timing sensor C. Disconnect the suspect sensor from the engine
harness.
B. Thoroughly inspect J401/P401 or J402/P402
a. Use a multimeter to measure the sensor connectors. Refer to Troubleshooting, "Electrical
resistance (Ohms) between P2:48 (Primary Connectors - Inspect" for details.
Speed/Timing Positive) and P2:49 (Primary
Speed/Timing Negative). E. Primary engine speed/timing sensor
b. Check for an intermittent open circuit or a. Use a multimeter to measure the sensor
short circuit by moving the harness while the resistance (Ohms) between J401:2 (Primary
measurement for resistance is being taken. Speed/Timing Positive) and J401:1 (Primary
Pull the wires that are directly behind the Speed/Timing Negative).
sensors or shake the wires that are directly
behind the sensors. Resistance ...................... 75.0 to 230.0 Ohms
Resistance ..................... 75.0 to 230.0 Ohms F. Secondary engine speed/timing sensor
L. Secondary engine speed/timing sensor a. Use a multimeter to measure the sensor

resistance (Ohms) between J402:2
Refer to Illustration 116. (Secondary Speed/Timing Positive) and
J402:1 (Secondary Speed/Timing Negative).
a. Use a multimeter to measure the sensor
resistance (Ohms) between P2:58 (Secondary Resistance ....................... 600 to 1800 Ohms
Speed/Timing Positive) and P2:59 (Secondary
Speed/Timing Negative). Note: Timing calibration is not necessary following
replacement of the engine speed/timing sensors.
b. Check for an intermittent open circuit or Refer to the information in the System Operation
short circuit by moving the harness while the Section regarding the installation of sensors.
measurement for resistance is being taken.
Pull the wires that are directly behind the Expected Result:
sensors or shake the wires that are directly
behind the sensors. The readings agree with the values that are listed
above.
Resistance ....................... 600 to 1800 Ohms
Results:
Expected Result:
• OK - T h e sensor resistance is correct. Proceed
The readings agree with the values that are listed to Test Step 5.
above.
• Not OK - The sensor resistance is out of the
Results: range.
• OK - Neither a short circuit nor an open circuit is Repair: Perform the following procedure in order
indicated. Proceed to Test Step 5. to check and install the new sensor:
• Not OK - The sensor resistance is not within the . Before installing the new sensor, measure the
acceptable range when the sensor resistance is resistance of the new sensor.
measured through the engine harness. Proceed
to Test Step 4. If the new sensor resistance is in the correct
range, install the new sensor in the engine,
Test Step 4. Measure the Resistance of as follows:
the Sensor at the Sensor
a. Loosen the bolt that holds the sensor
A. Turn the key switch to the OFF position. mounting bracket to the engine.
B. Check the harness and the wiring for abrasion b. Ensure that one O-ring is installed and free
and pinch points from the sensor back to the of damage.
ECM.
c. Seat the sensor and tighten the bolt.
267
If the sensor will not seat, repair the sensor Repair: Verify that the correct terminals have been
or replace the sensor, as required. installed in the correct location of the P2 ECM
connector. If the temporary harness was installed
Note: The sensor must not be removed from the correctly, install the original wiring.
bracket.
d, Ensure that the sensor is properly oriented
and that the harness is secured in the Test Step 6. Check the ECM
proper location.
B, Temporarily connect a test ECM.
STOR
C, Start the engine. Run the engine in order to
Test Step 5. Install the Bypass Harness repeat the conditions when the problem occurs.
for the Engine Speed/Timing Sensors
D, If the problem is resolved with the test ECM,
A, Turn the key switch to the OFF position. reconnect the suspect ECM.
B, Disconnect the J2/P2 ECM connector. E, If the problem returns with the suspect ECM,
replace the ECM.
C, Use the following procedure for the primary
engine speed/timing sensor: Verify that the repair eliminates the problem.
a, Install a 16 AWG wire from J2/P2:48 to P401:2. Expected Result:
b, Install a 16 AWG wire from J2/P2:49 to P401:1. The problem remains with the suspect ECM.
Note: Twisted pair wiring is required. Ensure that the Results:

wires have at least one twist per inch.
• OK
D, Use the following procedure for the secondary
engine speed/timing sensor: Repair: If the problem is resolved with the test
ECM and the problem returns with the suspect
ao Install a 16 AWG wire from J2/P2:58 to P402:2. ECM, replace the ECM.
b, Install a 16 AWG wire from J2/P2:59 to P401:1. Verify that the repair eliminates the problem.
Note: Twisted pair wiring is required. Ensure that the STOR

wires have at least one twist per inch.
• Not OK
E, Reconnect the J2/P2 ECM connector.
Repair: Replace the sensor.
F, Start the engine in order to determine if the
bypass harness repairs the problem. Verify that the repair eliminates the problem.
Expected Result: STOR
The problem is corrected with the installation of the

i01907626
bypass harness.
Results:
Engine Temperature Sensor
Open or Short Circuit - Test
• OK
SMCS Code: 1906-038; 1921-038; 1922-038;
Repair: Permanently install a new section of 1928-038
harness.
STOR
• Not OK
268
There is an active diagnostic code or a diagnostic

code can easily be activated. This procedure
covers open circuit diagnostic codes and short
circuit diagnostic codes that are associated with the
following sensors:
• Coolant Temperature Sensor
• Intake Manifold Air Temperature Sensor
• Fuel Temperature Sensor
• Optional Ambient Air Temperature Sensor

to this procedure:
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.
Fuel Enqine Engine Coolant Intake Manifold

Temperature Control Temperature Air Temperature
Sensor Module Sensor Sensor
• ~ I
LEFT SIDE VIEW TOP VIEW
Illustration 118
g00994858
C-10 and C-12 Temperature s e n s o r s
269
Intake Engine Engine

Fuel Manifold Air Control Coolant
Temperature Temperature Module Temperature
1
Illustration 119
LLf I 51UL V/LW
I
FRONT VIEW
g00995917
3406E Temperature sensors
Intake Manifold
Air Temperature
Sensor
Engine Coolant Fuel
Temperature TemDeroture
Sensor Sensor
L
I
TOP VIEW

C-15, C-16 and C-18 Temperature sensors
270
J100/PIO0 P2/J2 ECM

Engine Coolant T e m p e r o t u r e ~ - ~ 995-BU--~ Engine Coolant Temperature
Engine Temp Sensor Common .cg67-BU~I35~ intoke Manifold Air remp
-A751-YL--t~J33~ i Fuet Temperature
J103/P103 .G833- PK--I-<.118,~ Engine Temp Sensor Common
Intake Manifold Air T e m p l ~ l l > { - - -
Engine Temp Sensor Common
PI/JI
0453-YL~ Ambient Air TemPerature
J105/P105 LgO1-GY--~I18 ~ Tnput Sensor Common #1
Fuel Temperature
Engine Temp Sensor Common
Note A: Input Sensor Common #2 (Terminal 3)

................................ J102/P102 may be used in place of the Input Sensor
', Ambient Air Temoeroture ~ I ]>i Common #1 (Terminal 18).
I Input Sensor Common #I ~2_j~]
L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J ........ DENOTESOPTIONAL SENSOR
121
Illustration
g00970545
Schematic for engine temperature sensors
P2 ECM Connector
"- II ~ II
f l 2 3 4 5 6 8 910111213~'~ L - J
i
0000000000000 Engine Temp Sensor Common
,sooooooooooooo
140000~>PEI< 0000023 23(30000 ~OOOO1
Fuel Temperature s~o o o o ( ~ f - - ~ o oV
z4OC~CDO ff-z~-X 0 0 0 0 3 1 Intake Manifold Air Temperature
02,
] G~O~ (( [ ] ) ) s o O 0 0 0 E Engine Coolant Temperature;
3~,ooo IK U )11~o~3:
~0OOOO ~ 000047 470000 %~---f/JJ) 0 0 0 0 4 (
48OOOOO OOOOO57 570 O O O O o O 0 0 0 O4~
0000000000000 70OOOOOOOOOOOOO5~
85960616263 n 656667686970~
II II ~J
P1 ECM Connector
1 2 3 4 5 6 ~ B 9 10111213~"~"
q--] 0 O O O O © O O O O O O O IF Input Sensor Common #1 ~0013000 O O O O O O O O O
J114OOOOC~'*>PE]< 0 0 0 0 0 2 3 1 1 CO o ~OOOO14
- ~ 2 4 O O ~ A'~',,-"~ 0 0 0 0 3 1 Ambient Air Temperature II II 31° o o o "f / °sLIII
J O O O O {( r. 3 ) ) 3 o 0 0 0 0 r II 1139° o o 0 000C3
~40OOOO ~ 000047 II I147° 0 0 o %~___Jj oooc40t111
[] 4 8 0 0 0 0 0 O0000s7 II II57° o o c o o °°°°Cqlll
- O00000QOQOQO0 O O O O O O O O O C58V/J
"C58596°16'°2103n6560071108097011
122
Illustration
g00970546
P1 and P2 ECM connectors
Test S t e p 1. I n s p e c t Electrical C o n n e c t o r s B. Perform a 45 N (10 Ib) pull test on each of the

and Wiring wires in the sensor connector and the ECM
connector that are associated with the active
A. Thoroughly inspect the J2/P2 ECM connector diagnostic code.
and the suspect sensor connector. Refer to
Troubleshooting, "Electrical Connections -
271
C. Verify that the latch tab of the connector is • Voltage Low (Short) - A "voltage low" diagnostic
properly latched and that the latch tab of the code (short circuit) is active at this time. Proceed
connector has returned to the Fully Latching to Test Step 3.
position.
Test Step 3. Disconnect the Suspect
D. Check the ECM Connector (allen head screw) for Sensor
E. Check the harness and wiring for abrasion and
pinch points from the sensor to the ECM. B. Disconnect the sensor with the "voltage low"
diagnostic code (short circuit).
Expected Result:
C. Turn the key switch to the ON position. Wait at
All connectors, pins, and sockets should be least 15 seconds for activation of the diagnostic
completely coupled and/or inserted and the harness codes.
and wiring should be free of corrosion, abrasion,
or pinch points. D. Check for an active "voltage high" diagnostic
code (open circuit) on the electronic service tool.
Results:
Expected Result:
A "voltage high" diagnostic code (open circuit) for
• Not OK the suspect sensor is now active.
Repair: Repair the connectors or wiring and/or Results:

of the seals are properly in place and ensure that • OK - A "voltage high" diagnostic code (open
the connectors are completely coupled. circuit) for the suspect sensor is now active.
Verify that the repair eliminates the problem. Repair: Temporarily connect a new sensor.
STOR If the new sensor fixes the problem, reconnect

the suspect sensor.
Test Step 2. Determine the Condition that
is Present If the problem returns, permanently replace the
sensor.
link connector. Verify that the repair eliminates the problem.
B. Turn the key switch to the ON position. Wait at STOR

codes. Not OK - T h e r e is a short circuit between the
sensor harness connector and the ECM.
C. Check for active diagnostic codes on the
electronic service tool. Repair: Leave the sensor disconnected.
D. Determine if the problem is related to a "voltage Proceed to Test Step 4.

high" diagnostic code (open circuit) or a "voltage
low" diagnostic code (short circuit). Test Step 4. Disconnect the ECM
Connector
Expected Result:
A "voltage high" diagnostic code (open circuit) or
a "voltage low" diagnostic code (short circuit) is B. Disconnect the J2/P2 ECM connector. Thoroughly
active. inspect both halves of the connector for signs of
corrosion or moisture.
Results:
Note: If the Ambient Air Temperature Sensor is
• Voltage High (Open) - A "voltage high" diagnostic being tested, a 140-2266 Cable (Seventy-Pin
code (open circuit) is active at this time. Proceed Breakout) is required in order to maintain the battery
to Test Step 6. connections.
272
C. Turn the key switch to the ON position. Wait at Repair the faulty wiring or replace the faulty
least 15 seconds for activation of the code. wiring.
D. Check for active diagnostic codes on the Verify that the repair eliminates the problem.
STOP.
Note: When the J2/P2 ECM connector is
disconnected, all of the "voltage high" diagnostic • Not OK -There is a short between the supply
codes (open circuit) for the temperature sensors will wire and the common wire.
be active. This is normal.
Repair: Locate the short between the supply wire
Expected Result: and the common wire.
"Voltage high" diagnostic codes (open circuit) Repair the faulty wiring or replace the faulty
are active when the J2/P2 ECM connector is wiring.
disconnected.
Results:
STOP.
• OK - T h e ECM is working properly.
Test Step 6. Create a Short at the Sensor
Repair: Leave the ECM connector disconnected.
A. Fabricate a jumper wire 150 mm (6 inch) long.
• Not OK - A "voltage low" diagnostic code (short
circuit) is still active for the suspect sensor. C. Monitor the active diagnostic code screen.
Repair: Temporarily connect a test ECM. D. Install the jumper wire between terminal 1 and
terminal 2 of the sensor connector.
suspect ECM. Expected Result:
If the problem returns, permanently replace the A "voltage low" diagnostic code (short circuit)is
suspect ECM. active when the jumper wire is installed.
STOP. • OK - A "voltage low" diagnostic code (short

circuit) is active.
Test Step 5. Check the Resistance
B. Verify that the suspect sensor and the ECM the suspect sensor.
connector are disconnected.
C, Measure the resistance between terminal 1 and suspect sensor.
terminal 2 of the sensor connector.
Expected Result:
STOR
The resistance is greater than 20,000 Ohms or "OL"
is displayed on the multimeter. • Not OK - A "voltage high" diagnostic code (open
circuit) is still active.
Results:
Repair: Remove the jumper wire.
• OK - There is a problem with the supply wire.
Repair: Check the supply wire of the suspect
sensor for a short to ground.
273
Test Step 7. Create a Short at the ECM Verify that the repair eliminates the problem.
A. Turn the key switch to the OFF position. STOR
B. Disconnect the P2 ECM connector. Not OK - The voltage is not within the range.
C. Fabricate a jumper wire 150 mm (6 inch) long. Repair: If the voltage is above 5.5 VDC, check
the supply wire for a short to a voltage source.
D. Install the jumper wire between the terminal for
the sensor supply of the suspect sensor and the If the voltage is below 4.5 VDC, check the supply
terminal for the sensor common. wire for an open circuit.
Expected Result: Repair the faulty wiring or replace the faulty

wiring.
A "voltage low" diagnostic code (short circuit) is
active when the jumper wire is installed. Verify that the repair eliminates the problem.
Results: STOR
• OK - A "voltage low" diagnostic code (short

i01868212
circuit) is active when the jumper wire is installed.
Repair: Reconnect the P2 ECM connector.

Fan Override Switch Circuit-
Test
• Not OK - A "voltage high" diagnostic code (open
circuit) is still active. SMCS Code: 7332-038
Repair: Temporarily connect a test ECM. System Operation Description:
If the test ECM fixes the problem, reconnect the Use this procedure under the following situation:
suspect ECM.
The circuit for the fan override switch is suspected
If the problem returns, permanently replace the of incorrect operation.
suspect ECM.
Note: This procedure is intended for troubleshooting
Verify that the repair eliminates the problem. a fan override switch that is connected to an ECM
input circuit. This procedure is not intended for a
STOR fan override switch that is installed in the cooling
fan output circuit.
Test Step 8. Check the Voltage at the
Sensor Fan Override Switch
A. Turn the key switch to the ON position. The fan override switch is used to turn on the
cooling fan. Using a fan override switch can provide
B, Verify that the sensor is disconnected. the following benefits:
C. Measure the voltage between terminal 1 of the • Helpful for troubleshooting problems with the
sensor connector and chassis ground. cooling fan
Expected Result: • Additional cooling
The voltage should be 5.0 + 0.5 volts. • Additional braking horsepower under certain
operating conditions
Results:
Repair: Check for an open circuit in the common

wire.

wiring.
274
The circuit for the fan override switch can be

installed on four different inputs. Programming of
the "Customer Specified Parameters" is required
to select the desired input for the fan circuit. If the
"Fan Override Switch" parameter is programmed
to "None" (default), this feature is not used. If the
"Fan Override Switch" parameter is programmed to
one of the available options, then the fan override
switch is available. The switch circuit should be
connected to the input that was specified. The
available options that are for the fan override switch
are (J1/P1:7, J1/P1:47, J1/P1:6, J1/P1:46).
Note: The wiring for your particular application may

be slightly different. The circuits for the sensor
common are used interchangeably by the OEM
of the vehicle. The following circuits are common
within the ECM:
• The "Input Sensor Common 1" is terminal 18.
• The "AP Sensor/Switch Sensor Common" is

terminal 5.
ECM
G 8 4 1 - G N ~ INPUT 14
FAN OVERRIDE SWITCH GB42-GY--I-<I47÷INPUT ~5
cpy----c~(SHOWN IN OFF POSITION) GB43-OR--F<I 6+ INPUT 16
, GB44-PK--I-<J46~INPUT 17
H795-PK---~_L5~ AP SENSOR/SWITCH SENSOR COMMON
r-- PI J1
NOTE:INPUT |4,|5,|6 OR 17 MAY BE USED. THE FAN OVERRIDE SWITCH

PARAMETER MUST BE PROGRAMMED TO THE INPUT SELECTION.

Schematic for the fan override switch
275

•oooo Input iS
,oooo oo-II I Input ~4
ooo [~]] o o241 11
0 O0 O 0 0 0321ll Input ~5
111,,e"e,o o k~----------------~J)o o o o , 0 1 III Input ~7
IIp~OOOO o ooooo481111
ECM SIDE Vehicle Harness Connector P1
f II . II -"., AP Sensor/Switch Sensor Common

Input 16
- h---1 Input |4
- 1 2 ~ ~ - ~ - ~~-:-t
:lr d d d d nl=t Input ~5
Input ~7
~-~ II II J
HARNESS SIDE

Terminal Locations for the ECM
Test Step 1. Check the Status of the "Fan Test Step 2. Determine the Configuration
Override Switch" of the Fan Override Switch
A. Connect the electronic service tool to the data A° Determine if the fan override switch is wired
link connector. directly to the ECM or through the J1939 data
link.
Bo Verify that the "Fan Override Switch" parameter
C. Monitor the status for the "Fan Override Switch" is programmed to reflect the proper wiring.
while the fan override switch is moved to the ON
position and the OFF position. Expected Result:
Note: If the status for the "Fan Override Switch" The fan override switch is wired directly to the ECM.
indicates "Not Installed", then the "Fan Override
Switch" parameter has not been programmed. Results:
Expected Result: • OK - T h e fan override switch is wired directly to
the ECM. Proceed to Test Step 3.
The status for the "Fan Override Switch" should be
"On" when the switch is in the On position. The • Not OK - The fan override switch is wired through
status for the "Fan Override Switch" should be "Off" the J1939 data link.
when the switch is in the Off position.
Repair: Verify that the "Fan Override Switch"
Results: parameter is programmed to "J1939 - Body
Controller", "J1939 - Cab Controller", or "J1939 -
• OK - T h e switch is operating normally. STaR Instrument Cluster".
• Not OK - T h e ECM is not reading the change in Refer to Troubleshooting, "Powertrain Data Link
switch status. Proceed to Test Step 2. Circuit - Test".
STOR
276


with the suspect switch circuit.
C. Check the ECM connector (allen head screw) for

D, Check the harness and the wiring for abrasion

Refer to Illustration 124 for terminal locations

for the ECM.
Expected Result:
points.
Results:
• Not OK
Repair: Repair the wiring and connectors or

replace the wiring or the connectors. Ensure that
all of the seals are properly connected.
STOR
277

the E C M

Input ~6
Input |4
]nput ~5
]'nput 1~7
Connector for breakout T
A. Turn the key switch to the OFF position. Verify that the repair eliminates the problem.
B. Install a 140-2266 Cable (Seventy-Pin Breakout) STOR

between the J1 and P1 ECM connectors.
C. Fabricate a jumper wire 100 mm (4 inch) long. Switch
Crimp a Deutsch pin to each end of the wire.
D. Insert the jumper wire into the suspect switch
socket of the breakout T. Connect the other end B. Fabricate a jumper wire 100 mm (4 inch) long.
of the jumper wire to terminal 5 (AP Sensor/Switch Crimp a Deutsch pin to each end of the wire.
Sensor Common) of the breakout T.
C. Insert the jumper wire between the two switch
E. Turn the key switch to the ON position. terminals of the fan override switch.
F. While the status for the "Fan Override Switch" D. Turn the key switch to the ON position.
is monitored, remove the jumper wire and then
insert the jumper wire. E. While the status for the "Fan Override Switch"
is monitored, remove the jumper wire and then
Expected Result: insert the jumper wire.
The status for the "Fan Override Switch" is "On" Expected Result:
when the jumper wire is inserted. The status for the
"Fan Override Switch" is "Off" when the jumper wire The status for the "Fan Override Switch" is "On"
is removed. when the jumper wire is inserted. The status for the
"Fan Override Switch" is "Off" when the jumper wire
Results: is removed.
• OK - The ECM is functioning properly at this time. Results:

Repair: Remove the breakout T and reconnect • OK
the J1 and P1 ECM connectors.
Repair: Replace the fan override switch.
STOR
Repair: Temporarily connect a test ECM. If the
problem is resolved with the test ECM, install the • Not OK - There is a problem in the wire harness
suspect ECM. If the problem returns with the between the fan override switch and the ECM.
suspect ECM, replace the ECM. Proceed to Test Step 6.
278
Test Step 6. Insert a Jumper Wire at the The idle shutdown is suspected of incorrect
Bulkhead Connector operation.
A. Turn the key switch to the OFF position. The following background information is related
to this procedure:
Crimp a Deutsch pin to each end of the wire. "Idle Shutdown Timer"
C. Insert the wire jumper pin between the terminals The "Idle Shutdown Timer" is intended to improve
for the fan override switch on the engine side of fuel economy by limiting idling time.
the ECM bulkhead connector.
The "Idle Shutdown Timer" is a "Customer Specified
D. Turn the key switch to the ON position. Parameter" that may be programmed for any period
from 3 to 1440 minutes.
E. While the status for the "Fan Override Switch"
is monitored, remove the jumper wire and then The timer is activated when all of the following
insert the jumper wire. conditions are met regardless of the position of the
parking brake:
Expected Result:
• The vehicle speed is O.
The status for the "Fan Override Switch" is "On"
when the jumper wire is inserted. The status for the • The engine is not in "Cold Mode" or "Dedicated
"Fan Override Switch" is "Off" when the jumper wire PTO Mode".
is removed.
• The engine is not under load.
Results:
The timer can be reset by moving the vehicle or
• OK - T h e problem is in the vehicle wiring the timer can be reset by quickly depressing the
between the bulkhead connector and the switch. accelerator pedal and releasing the accelerator
pedal.
Repair: Inspect the vehicle wiring and then repair
the vehicle wiring. Otherwise, send the vehicle to The check engine lamp will begin to rapidly flash
the OEM dealer for repair. 90 seconds before the programmed time expires.
During this 90 second time period, the following
Verify that the original condition is resolved. conditions can disable the timer:
STOR • The driver moves the clutch pedal.
• Not OK - The problem is in the vehicle wiring • The driver moves the service brake pedal.
The following event code will be logged when the
Repair: Inspect the vehicle wiring and then repair driver overrides the timer by the use of the clutch
the vehicle wiring. Otherwise, send the vehicle to pedal or the brake pedal during the 90 second
the OEM dealer for repair. period:
Verify that the original condition is resolved. • 71-00 Idle Shutdown Override (01)
STOR 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
i01815718
the brake pedal during the final 90 second period.
Idle Shutdown Timer- Test "YES" is the factory default that is programmed
for the parameter for the "Allow Idle Shutdown
SMCS Code: 1901-038 Override". The allowance of the override is the
default.

279
With OCT99 and newer software, an additional Test Step 1. Verify Activation of the "Idle
parameter can be programmed to allow the timer to Shutdown Timer"
be reset above a specified engine speed. When the
"Idle Shutdown Timer Maximum RPM" parameter A. Connect ET to the cab data link connector.
is programmed to a value below the Top Engine
Limit, the timer can be reset by increasing engine B. Access the "Customer Parameters" on ET.
rpm above a programmed limit. The timer will be
reset until engine rpm drops below the programmed a. Access the following display screens in order:
value. The timer will begin counting again. The
factory default of 2120 rpm disables this feature. • "Service"
The "Top Engine Limit" is 2120 rpm.
• "Configuration"
If the timer is activated and the timer is allowed to
shut down the engine the following event code will b. Record the programmed time for the "Idle
be generated: Shutdown Timer". The "Idle Shutdown Timer"
must be between 3 and 1440 minutes. If the
• 71-01 Idle Shutdown Occurrence (47) "Idle Shutdown Timer" is programmed to 0,
then the timer is disabled.
Code 71-01 records the event and the code does
not indicate an electrical system malfunction or an c, Record the programmed status of the
electronic system malfunction. Disable the timer by parameter for the "Allow Idle Shutdown
programming "Idle Shutdown Timer" to 0 (Caterpillar Override" and the "Idle Shutdown Timer
Factory Default). Maximum RPM".
The ECM will shut down the engine but not the C, Start the engine. Allow the engine to warm up
vehicle electrical system when the "Idle Shutdown until the coolant temperature is 38 °C (100 °F).
Timer" time expires. The "Engine Shutdown Output" Allow the engine to operate at the programmed
can be used to shut down the vehicle electrical low idle and turn off any unnecessary accessory
system after the "Idle Shutdown Timer" time has devices.
expired.
D. Ensure that all unnecessary loads are turned off.
The "Idle Shutdown Timer" feature can be
temporarily disabled by the use of the Caterpillar With OCT99 and newer software, the "Idle
Electronic Technician (ET). The "Idle Shutdown Shutdown Timer Maximum RPM" can be
Timer" feature can be temporarily disabled through programmed to allow the timer to be reset
the "System Troubleshooting Settings" screen by increasing the engine RPM above the
in order to help troubleshoot other problems. programmed limit. Ensure that the accelerator is
Temporarily disabling this feature avoids engine not being depressed so that the rpm increases
shutdowns when you are troubleshooting other beyond the programmed limit.
systems. The use of this method eliminates the
need to temporarily alter the customer specified a. Park the vehicle.
parameter of "Idle Shutdown Timer".
b. Ensure that the "Vehicle Speed" on the status
Note: If the following diagnostic code is active, the screen on ET is 0 km/h (0 mph).
"Idle Shutdown Timer" will not operate.
c. Ensure that the engine speed on the status
• 84-08 Vehicle Speed Out Of Range (36) screen is at "Low Idle".
Note: The timer will be overridden if the following d. Ensure that the clutch pedal is not depressed.
conditions exist. Ensure that the brake pedal is not depressed.
• The "Allow Idle Shutdown Timer Override" is e. Ensure that the status of the PTO On/Off
programmed to "Outside Temperature Based" or Switch is off.
"J1587 Outside Temperature Based".
f. Observe the "Idle Shutdown Status".
• The temperature that is being sensed by the
ECM is below the minimum air temperature that is Expected Result:
programmed or the air temperature is above the
maximum air temperature that is programmed. Result 1 The "idle Shutdown Status" indicates
"Counting".
Result 2 The "Idle Shutdown Status" indicates "Not

Active".
280

• Result 1 - T h e ECM is reading the proper During the 90 second period before the scheduled
conditions for the activation of the "Idle Shutdown shutdown, the status should change from "Counting"
Timer". Proceed to Test Step 2. to "Driver Alert" and the check engine lamp should
flash rapidly. If the "Allow Idle Shutdown Override"
• Result 2 - T h e ECM is not reading the proper is programmed to "YES", the "Idle Shutdown Status"
conditions for activation of the "Idle Shutdown should change to "Override" after the pedals are
Timer". Proceed to Test Step 3. depressed.
Test Step 2. Verify the Driver Alert Result I The "Idle Shutdown Timer" behaves in the
Function for Idle Shutdown and the manner that is described above.
Override Function for Idle Shutdown
Result 2 The check engine lamp did not flash
A. Connect ET to the cab data link connector. during the alert.
B. Access the "Customer Parameters" on ET. Result 3 The ECM did not sense a change in the
status of the service brake.
a. Access the following display screens in order:
Result 4 The ECM did not sense a change in the
• "Service" status of the clutch.
• "Configuration" Results:
b. Record the programmed time for the "Idle • Result I - T h e "Idle Shutdown Timer" is operating
Shutdown Timer". The "Idle Shutdown Timer" properly. STOR
must be between 3 and 1440 minutes. If the
"Idle Shutdown Timer" is programmed to 0, • Result 2 - The check engine lamp did not flash
the timer is disabled. during the alert.
¢. Reprogram the "Idle Shutdown Timer" to 3 Repair: Perform the following diagnostic
minutes for this test. procedure: Troubleshooting, "Check Engine Lamp
Circuit - Test"
C. Observe the following items during the 90 second
period before the programmed shutdown time: STOP.
• Check Engine Lamp • Result 3 - The ECM did not sense a change in
the status of the service brake.
• Idle Shutdown Status
D. If the customer parameter of "Allow Idle procedure: Troubleshooting, "Service Brake Pedal
Shutdown Override" is programmed to "YES", Position (Switch 1) Circuit - Test"
perform either of the following actions in order to
override the shutdown: STOP.
• Press the clutch pedal. • Result 4 - T h e ECM did not sense a change in
the status of the clutch.
• Press the service brake pedal.
Note: This action must be accomplished while the procedure: Troubleshooting, "Clutch Pedal
check engine lamp is flashing. The check engine Position Switch Circuit - Test"
lamp flashes during the 90 second period before
the programmed shutdown time. STOP.
E. Reprogram the "Idle Shutdown Timer" to the Test Step 3. Check the State of the
value that was recorded earlier for this test. Related Conditions when the Vehicle is
Parked
A. Check the state of the following related conditions
when the vehicle is parked:
281
• Ensure that the vehicle speed is 0 km/h i01906643

(0 mph) on ET or the dash display.
Ignition Key Switch Circuit and
• Ensure that the engine is not in cold mode.
(The status screen on ET will indicate that the
Battery Supply Circuit- Test
"Cold Mode" is "Active" in the corner of the SMCS Code: 1401-038; 1553-038
display screen.)
• Ensure that the PTO On/Off switch is OFE
The following diagnostic codes indicate a problem
• Ensure that the engine is at low idle. with the power supply to the ECM:
Expected Result: • 168-02 ECM Battery Power Intermittent
Result 1 Vehicle speed is not indicated as 0 km/h • 43-02 Key Switch Fault
(0 mph).
Note: This code can be generated by rapidly
Result 2 The status screen on ET indicates that the cycling the key switch. Some control modules on the
engine is in cold mode. vehicle require this action in order to prompt flash
codes, If this occurs, clear the logged diagnostic
Result 3 The status of the PTO On/Off switch is codes in order to prevent future confusion or an
not "OFF". incorrect diagnosis.
Result 4 The engine is not at low idle. The following background information is related
to this procedure:
Results:
The ECM receives electrical power (battery voltage)
• Result 1 -Vehicle speed is not indicated as through the wiring that is supplied by the vehicle
0 km/h (0 mph). manufacturer. The ECM input at connector P1:70
(Ignition Key Switch) receives battery voltage from
Repair: Perform the following diagnostic the key switch when the key switch is in the ON
procedure: Troubleshooting, "Vehicle Speed position or the START position. When the ECM
Circuit - Test" detects battery voltage at this input, the ECM will
power up. When battery voltage is removed from
STOR this input, the ECM will power down.
• Result 2 - The status screen on ET indicates that The cause of an intermittent power supply to
the engine is in cold mode. the ECM can occur on either the positive side
("Unswitched +Battery") or the negative side
Repair: The engine must not be in "Cold Mode" ("-Battery"). Both sides are routed from the ECM
operation while this test procedure is being to the battery. The two Unswitched +Battery
performed. Allow the engine to run until the connections should be routed through a dedicated
coolant temperature exceeds 20 °C (68 °F). protection circuit.
Troubleshoot and repair any related conditions.
Some vehicles may be equipped with an engine
STOR protection shutdown system or an idle timer
shutdown system that interrupts electrical power
• Result 3 - The status of the PTO On/Off Switch to the ECM in order to shut down the engine.
is not "OFF". Also, some vehicles may be equipped with an
engine protection shutdown system or an idle timer
Repair: Perform the following diagnostic shutdown system that interrupts electrical power
procedure: Troubleshooting, "PTO Switch Circuit - to the key switch. The engine protection shutdown
Test" system can be an aftermarket device and the idle
timer shutdown system can be external to the ECM.
STOR Some of these systems will not supply power to the
ECM until one of the following conditions is met:
• Result 4 - T h e engine is not at low idle.
• The engine is cranked.
Repair: Return the engine to low idle. Perform the
test procedure again. • The engine oil pressure achieves acceptable
limits.
STOR
• An override button is pressed.
282
Keep in mind that these devices may be the cause

of intermittent power to the ECM.
Usually, battery power to the data link connector

is available and the battery power to the cab
data link connector is independent of the key
switch. Therefore, you will be able to power up
the Caterpillar Electronic Technician (Cat ET), but
you may not be able to communicate with the
engine ECM The engine ECM requires the key
switch to be in the ON position in order to maintain
communications. The ECM may power down a short
time after connecting to Cat ET if the key switch 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 key switch.
r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~
CIRCUITS WITHIN THIS

AREA ARE RECOMMENDATIONS
TO VEHICLE
> COMPONENTS
~T~~"o~GNI
T j~l ON KEY SWITCH
ECM
--JgO6-BR IGNITION KEY SWITCH
101-RD 1<152~ UNSWITCHED +BATTERY
1 2eAr ~14 AWG 101-RD~--~<J53~ UNSWITCHED +BATTERY
229-BK ,--~1§5_<- -BATTERY
[14 AWG 229-BK ; ]<]67~ -BATTERY
P1 Jl
c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
ENGINE BLOCK
Schematicfor ECMbatterycircuit
283
00000000000
III1~00000 0 00000.1111
III1 ,oooo oooo2,1111
IIIPOOOO 1~_2Jl oooo~21111
III p o o o o ~ Unswitched +Battery
11115~oooo~ o ~ooo,~1111 [9nition Key Switch
-Battery
ECM SIDE
f II
/~l 2 $ 4 S s r"me 9 10 11 12 13 ~'~
Unswitched +Battery
Ignition Key Switch

' k, 58 5e 60 61 62 63 I--II (~
-Battery
II
HARNESS SIDE
g00640974
Illustration 127
Terminal locations for E C M
Test Step 1. Inspect Electrical Connectors Results:

and Wiring
• OK, Troubleshooting a 43-02 Code - Proceed to
A. Thoroughly inspect J1/P1 ECM connector, the Test Step 2.
battery connections and the connections to the
key switch. Refer to Troubleshooting, "Electrical • OK, Troubleshooting a 168-02 Code - Proceed
Connectors - Inspect" for details. to Test Step 3.
B. Perform a 45 N (10 Ib) pull test on each of the • Not OK - There is a problem with the connectors
wires in the ECM connector that are associated or wiring.
with the following connections:
• J1/P1:52 & 53 (Unswitched +Battery) replace the connectors or wiring. Ensure that all
• J1/P1:65 & 67 (-Battery) the connectors are completely coupled.
• J1/P1:70 (Ignition Key Switch) STOR
C. Check the ECM connector (allen head screw) for Test Step_2. Check the Status for the
the proper torque of 6.0 N.m (55 Ib in). Ignition Key Switch
D. Check the harness and wiring for abrasion and A. Turn the key switch to the OFF position.
pinch points from the battery to the ECM, and
from the key switch to the ECM. B, Connect Cat ET to the data link connector and
access the status screen that shows the status
Expected Result: for "Ignition Key Switch".
All connectors, pins and sockets should be C. Monitor the status for "Ignition Key Switch" while
completely coupled and/or inserted and the harness the key switch is being cycled slowly from the
and wiring should be free of corrosion, abrasion ON position to the OFF position.
or pinch points.
284
Note: Cat ET may indicate that a new ECM has

been detected. This condition is normal, due to a
powerdown of the ECM with the key switch in the
OFF position.
Note: Cycling the key switch several times may

cause additional 43-02 faults to be logged. This is
normal. Clear any logged faults.
Expected Result:
The status for "Ignition Key Switch" changes from

"On" with the key switch in the ON position to "Off"
with the key switch in the OFF position.
Results:
• OK - T h e key switch input is functioning properly

at this time.
Repair: If an intermittent connection is suspected,

refer to Troubleshooting, "Electrical Connectors
- Inspect". Excessive cycling of the key switch
can cause this fault to be logged. This is normal.
Clear any logged faults.
STOR
Test Step 3. Check the Battery Voltage at

the E C M
Perform Steps A, B, and C if the following
diagnostic code is active or logged:
• 168-02 ECM Battery Power Intermittent
A. Insert a 140-2266 Cable (Seventy-Pin Breakout)

between the J1 and P1 ECM connector.
B. Measure the voltage between P1:52 (Unswitched

+Battery) and P1:65 (-Battery).
0000000000
11112sO0000 0 000
III1,,oooo oo
IIIpOOOO Ill~__JJll o o
III1,~'oooo L.~; oo Unswitched +Bottery
IIIl~,oooor o e'0ooo481111 Ignition Key Switch
-Bottery

285
C. Measure the voltage between P1:53 (Unswitched T e s t S t e p 4. C h e c k t h e B a t t e r i e s

+Battery) and P1:67 (-Battery).
A. Measure no-load battery voltage at the battery
Refer to Illustration 128. posts.
Perform Steps D, E, and F if the following B. Load test the batteries. Use the 4C-4911
diagnostic code is active or logged: Battery Load Tester. Refer to Special Instruction,
SEHS9249, "Use of 4C-4911 Battery Load Tester
• 43-02 Key Switch Fault for 6, 8 and 12 Volt Lead Acid Batteries" and
Special Instruction, SEHS7633, "Battery Test
D. Insert a 140-2266 Cable (Seventy-Pin Breakout) Procedure".
between the J1 and P1 ECM connector.
Expected Result:
The batteries pass the load test. For 12 Volt systems,
F. Measure the voltage between P1:70 (Ignition Key the measured voltage is at least 11.0. For 24 Volt
Switch) and P1:65 (-Battery). systems, the measured voltage is at least 22.0.
Refer to Illustration 128. Results:
Expected Result: • OK
For 12 Volt Systems, the measured voltage is a Repair: Refer to the vehicle service manual for
constant 11.0 to 13.5 VDC with no suspected instructions on troubleshooting the vehicle wiring
intermittent problems at this time. harness. Troubleshoot the vehicle wiring harness
and repair the vehicle wiring harness, as required.
For 24 Volt Systems, the measured voltage is a Verify that the repairs eliminate the problem.
constant 22.0 to 27.0 VDC with no suspected
intermittent problems at this time. STOR
Results: • Not OK
• OK - The ECM is receiving the correct voltage. Repair: Recharge or replace the faulty batteries.
Repair: If an intermittent condition is suspected,
refer to Troubleshooting, "Electrical Connectors STOR
- Inspect".
T e s t S t e p 5. B y p a s s t h e V e h i c l e H a r n e s s
STOR
• Battery Voltage is out of range - Proceed to Test

Step 4.
Batteries give off flammable fumes which can ex-
• Intermittent Or No Voltage - Proceed to Test Step plode.
5.
To avoid injury or death, do not strike a match,
• Key Switch Voltage Out Of Range cause a spark, or smoke in the vicinity of a battery.
Repair: Trace the wiring for the key switch NOTICE

from the ECM through the key switch circuit to Do Not connect the bypass harness to the battery un-
the batteries. Find the problem and repair the til the 20 Amp in-line fuse has been removed from the
problem. Check the circuit protection for the +Battery line. If the fuse is not removed before con-
circuit and the wiring. Refer to the vehicle service nection to the battery, a spark may result.
manual for instructions on troubleshooting the
circuit for the key switch.
Verify that the repairs eliminate the problem.
STOR
286

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECM
IGNITION KEY SWITCH

UNSWlTCHED +BATTERY
IN-LINE FUSE UNSWITCHED +BATTERY
-BATTERY
-BATTERY
J1922 DATA LINK NEGATIVE
UNSWITCHED +BATTERY J1587 DATA LINK POSITIVE
-BATTERY J1587 DATA LINK NEGATIVE
:J1922 DATA LINK NEGATIVE J1939 DATA LINK POSITIVE
:J1922 DATA LINK POSITIVE J1939 DATA LINK NEGATIVE
:J1587 DATA LINK POSITIVE J!939 DATA LINK SHIELD
;J1939 DATA LINK POSITIVE j1
9-PIN
DATA LINK
CONNECTOR
~. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bypass harness
Note: This bypass harness is only for test E. Connect Cat ET to the data link connector of the
applications. This bypass harness may be left only bypass harness and verify that communication
temporarily on the vehicle. The bypass harness can is established.
be used in order to determine if the cause of the
intermittent problem is interruptions in battery power F. Restore all wiring to the original condition after
to the ECM or the key switch circuit. testing.
A. Turn the key switch to the OFF position. Expected Result:
B. Disconnect the J1/P1 ECM connector. Installing the bypass eliminates the problem.
C. Connect a bypass harness to the J1 ECM Note: The status for "Ignition Key Switch" will always
connector. indicate "On" while the bypass harness is installed.
D. Remove the 20 Amp in-line fuse from the Results:

+Battery line of the Bypass Harness and connect
the Unswitched +Battery and - BATTERY LINES OK - The symptoms disappear when the bypass
directly to the battery posts. harness is installed. Also, the symptoms return
when the bypass harness is removed. The
Note: This bypass directly connects the circuit for problem is in the vehicle wiring that supplies
the key switch to the ECM. The ECM will remain power to the ECM. Check for aftermarket engine
powered until the connection to the Unswitched protection switches that interrupt power. Send the
battery line "+" is disconnected. Remove the 20 vehicle to the OEM dealer to repair. STOR
Amp fuse from the in-line fuse holder to power down
the ECM. Do Not connect the bypass to the battery • Not OK
posts without first removing the 20 Amp in-line fuse
or do not remove the bypass from the battery posts Repair: Connect the bypass to another battery
without first removing the 20 Amp in-line fuse. and verify if the problem is resolved. If the
problem is resolved, the problem is with the
vehicle batteries.
287
If the problem still exists, temporarily connect • The "AP Sensor/Switch Sensor Common" is
a test ECM Remove all jumpers and replace terminal 5.
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
STOR
i01632317
Ignore Brake/Clutch Switch

Circuit- Test
SMCS Code: 7332-038-CL
The circuit for the Ignore Brake/Clutch Switch is

suspected of incorrect operation.

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
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.
tf 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 terminal 47 of the J1/P1 ECM vehicle
harness connector.

be slightly different. The circuits for the sensor
common are used interchangeably by the OEM
within the ECM:

288
Ignore Broke/Clutch Switch ECM

GB42-GY--F~ Input
LgO1-GY -'~<'l W 41 Input
I
~5 (Ignore Broke/Clutch Switch) I
Sensor Common ~1
PI Jt
I

Schematic for ignore brake/clutch switch
~00000000 0001 Input Sensor Common ~1
oooo-o
•0 0 0 0 0 o O00w
'0000 ~ 000
000 0000~
o o ooooo 111 Input ~5 (Ignore Broke/Clutch Switch)
OOOOOOO
ECM SIDE Vehicle Horness C o n n e c t o r P1
f II II
(f, ~ ~ , , 0oa ,,o,,,',~"h\
h-1 Input Sensor Common Jl
Input J5 (Ignore Broke/Clutch Switch)
~ 58 ~ eO 6 1 6 2 03 I [ ~ ~
ql
e~ eT(~ 69 7o..~j
II J
HARNESS SIDE

Terminal Locations for ECM
Test Step 1. C h e c k the Electrical Refer to Illustration 131 for terminal locations
C o n n e c t o r s and the Wiring for the ECM.
A. Thoroughly inspect the ECM vehicle harness Expected Result:

connector J1/P1, the connectors, and the firewall
bulkhead connectors. Refer to Troubleshooting, All connectors, pins, and sockets are completely
"Electrical Connectors - Inspect" for details. coupled and/or inserted, and the harness and
B. Perform a 45 N (10 Ib) pull test on each of the points.
with the circuit for the "Ignore Brake/Clutch Results:
Switch".
the proper torque of 6.0 Nom (55 Ib in). • Not OK - Repair the wiring and connectors or
D. Check the harness and the wiring for abrasion all of the seals are properly connected. Verify that
and pinch points from the ignore brake/clutch the repair eliminates the problem. STOP.
switch to the ECM.
289

Ignore Brake/Clutch Switch on ET
A, Connect the Caterpillar Electronic Technician
(ET) at the cab data link connector.
C. Operate the switch in the ON and OFF positions.
D. View the "Ignore Brake/Clutch Switch" status on

ET.
E, If the "Ignore Brake/Clutch Switch" status

indicates "Not Installed", then the "Ignore
Brake/Clutch Switch" parameter has not been
programmed.
Expected Result:
The "Status" screen should indicate "On" if the
switch is turned on. The "Status" screen should
indicate "Off" if the switch is turned off.
Results:
• OK - T h e switch is operating normally. Continue
troubleshooting if the original condition is not
resolved. STOR
• Not OK - T h e ECM is not reading the change in

switch status. Proceed to Test Step 3.

the E C M
ooooooooooo
I,,ooooo o #ooo0-1111 Input Sensor Common il
I,,oooo oooo2,1111
I oooo IIl, JJll oooo 21111
I, OOO oooo 1111
• ~0~0 O0 o 0000048 Input 15 (Ignore Broke/Clutch Switch)
Connector for Breakout T
A. Turn the ignition key switch to the OFF position. D, Insert the jumper wire into terminal 18 (Input
Sensor Common #1) of the breakout T. Insert the
B. Install a 70 terminal breakout T to the ECM other end of the jumper wire into terminal 47
vehicle harness connector J1/PI. (Ignore Brake/Clutch Switch) of the breakout T.
C. Fabricate a jumper wire 100 mm (4 inch) long. E. Connect ET to the cab data link connector.
F, Turn the ignition key switch to the ON position.
290
G. Alternately remove the jumper wire and insert Expected Result:

the jumper wire at terminal 18 while you monitor
the status screen on ET. The switch status changes to "ON" with the jumper
wire in place to "OFF" when the jumper wire is
Expected Result: removed.
The switch status changes from "ON" with the Results:

jumper wire in place to "OFF" when the jumper wire
is removed. • OK
Results: Repair: Replace the ignore brake/clutch switch.
• OK - T h e ECM is functioning properly at this Verify that the repair eliminates the problem.
time. Proceed to Test Step 4.
STOR
Not OK - There is a problem in the wire harness
Repair: Perform the following repair: between the Ignore Brake/Clutch Switch and the
1, Temporarily connect a test ECM.
2, Remove all jumpers and replace all connectors. Bulkhead Connector
3, Recheck the system for active diagnostic A. Turn the ignition key switch to the OFF position.
codes.
4, Repeat the Test Step. Crimp a Deutsch pin to both ends of the wire.
5, If the problem is resolved with the test ECM, C. Insert the jumper wire between the two terminals
reconnect the suspect ECM. for the ignore brake/clutch switch on the engine
side of the ECM bulkhead connector.
6, If the problem returns with the suspect ECM,
replace the ECM. D. Turn the ignition key switch to the ON position.
7, Verify that the repair eliminates the problem. E, Alternately connect and then disconnect the
jumper wire. At the same time, monitor the status
STOR screen on ET.
Test Step 4. Insert a Jumper Wire at the Expected Result:

Switch
The switch status changes from "ON" with the
A. Turn the ignition key switch to the OFF position. jumper wire in place to "OFF" when the jumper wire
is removed.
B, Reconnect the ECM vehicle harness connector
JI/P1. Results:
C, Fabricate a jumper wire 100 mm (4 inch) long. • OK - T h e problem is in the vehicle wiring
Crimp a Deutsch pin to both ends of the wire. between the bulkhead connector and the switch.
D, Insert the jumper wire between the two terminals Repair: Inspect the vehicle wiring and then repair
of the ignore brake/clutch switch. the vehicle wiring. Otherwise, send the vehicle to
the OEM dealer for repair.
E, Turn the ignition key switch to the ON position.
Verify that the original condition is resolved.
F, Alternately remove the jumper wire and then
insert the jumper wire at the switch terminals. At STOR
the same time, watch the status screen on ET.
291
Repair: Inspect the vehicle wiring and then repair

the vehicle wiring. Otherwise, send the vehicle to
the OEM dealer for repair.
Verify that the original condition is resolved.
STOR
i01907627
Injector Solenoid Circuit- Test

SMCS Code: 1290-038
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
g00735975
loads). Illustration 133
Electronic Unit Injector
to this procedure:
These engines have Electronic Unit Injectors

that are mechanically actuated and electronically
energized. The engine control module 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 then enable the
solenoid. If the short circuit remains this sequence
of events will be repeated until the problem is
corrected.
Some personality modules require the injector

codes to be programmed. 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:
When an injector is replaced, program the injector

code that is etched on the injector. The injector
code is a four digit number. If the ECM is replaced,
all six injector codes must be programmed into the
new ECM. Refer to Troubleshooting, "Injector Code
- Calibrate".
292
Injector Injector
Cylinder Cylinder
No. 2 No. 1
J300/P300 P2/J2 ECM

--D789-WH-~12 >F-L983-WH--~ 44<- Injector Common Cylinders 1 & 2
A7OI-GY- >F--A7OI-GY-- ~ 36<-- Injector Cylinder 1
Injector Cylinder 2
D 9o-oR- ,0 ,5<- Injector Common Cylinders 3 & 4
Injector Cylinder 3
Injector Injector Injector Cylinder 4
Cylinder Cylinder
No. 4 No. 3 Injector Common Cylinders 5 & 6
]njector Cylinder 5
Injector Cylinder 6
Injector Injector
Cylinder Cylinder
No. 6 No. 5

Schematic for electronic unit injector
293
~INJECTOR CYLINDER 4
~INJECTOR COMMON CYLINDERS 1&2
INJECTOR CYLINDER 6
ECM Side Engine Harness Connector P2

fl 2 3 4 5 6 w 8 9 10 11 12113
OOOOOOOOOO~OO INJECTOR CYLINDER 1
t4C)~ t O(DO00 INJECTOR CYLINDER 2
INJECTOR CYLINDER 3
INJECTOR CYLINDER 4
INJECTOR COMMON CYLINDERS 5&6
INJECTOR COMMON CYLINDERS 3&4
OOOOOOOO~ ~ G INJECTOR CYLINDER 6
, 58 5 9 6 0 6 1 6 2 6 3 , 6 4 6 5 6 6 1 c-~, ; '. INJECTOR COMMON CYLINDERS 5&6
INJECTOR CYLINDER 5
Harness Side
P2 ECM connector
Test Step 1. Inspect Electrical Connectors F. Check the harness and wiring for abrasion and
and Wir,ng pinch points from the injectors to the ECM.
Expected Result:
All connectors, pins, and sockets should be

Electrical shock hazard. The electronic unit injec- completely coupled and/or inserted and the harness
tor system uses 90-120 volts. and wiring should be free of corrosion, abrasion,
or pinch points.
A. Turn the key switch to the OFF position, A strong
electrical shock hazard is present if the key Results:
switch is not turned off.
B. Thoroughly inspect the ECM engine harness
connector J2/P2 and the solenoid connector for • Not OK
the Injector J300/P300. Refer to Troubleshooting,
"Electrical Connectors - Inspect" for details. Repair: Perform the following repair:
C. Perform a 45 N (10 Ib) pull test on each of Repair the connectors or wiring and/or replace
the wires in the J2/P2 ECM connector and the connectors or wiring. Ensure that all of the
the J300/P300 valve cover connector that are seals are properly in place and ensure that the
associated with injector solenoids. connectors are completely coupled.
Refer to Illustration 135. Verify that the repair eliminates the problem.
D. Check the ECM connector (allen head screw) for STOR

Test Step 2. Check for Logged Diagnostic
E. Check the J300/P300 valve cover connector Codes Regarding Injector Solenoids
in order to ensure the proper mating of the
connector. A. Connect the Caterpillar Electronic Technician
(ET) to the data link connector.
294
C. Monitor the logged diagnostic code screen on

Cat ET.
Expected Result:
One or more diagnostic codes for the injectors have
been logged:
Results:
Test Step 3. Check the Variation of the

Injectors from a Cylinder to a Cylinder
-Select Cylinder Cutout Test i [Engine Speed

4 - Cylinder Cutout Test [default) :~ 1OO9 r m
(primary test for troubleshooting)
Fuel Position
1 - Cylinder Colout Test 6.74 mm
(used when diagnosing n rough running engine)
Engine Coolant
Temperature
5 - Cylinder Cutout Test
|used when traublcshooting engine]
Cooling Fan
Fan Off
Click the Continue button to proceed with the test.
g00663575
Illustration 136
"Automated Cylinder Cutout Test" screen in Caterpillar Electronic Technician (Cat ET)
A. Connect Cat ET to the data link connector. E. After the engine is warmed to operating
temperature, access the "Cylinder Cutout Test"
B. When possible, put the truck on a dynamometer. by accessing the following display screens in
order:
C. Start the engine.
• "Diagnostics"
D. Allow the engine to warm up to normal operating
temperature 77 °C (171 °F). • "Diagnostic Tests"
• "Cylinder Cutout Test"

295
F. 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.
G. Shut off all parasitic loads such as the air

conditioning and the air compressors which
could affect the results of the test.
H. Set the engine speed to 1000 + 20 rpm.
I. Select the start button at the bottom of the

screen for the "Cylinder Cutout Test".
J. Select the "4 Cylinder Cutout Test" which is the

default test.
K. Follow the instructions that are provided in the

Cylinder Cutout Test. The Cylinder Cutout Test
is 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 Cat ET 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.
Expected Result:
All cylinders indicate "OK" on Cat ET.
Results:
• OK
Repair: If the engine is misfiring or if the

engine has low power, refer to Troubleshooting,
"Engine Misfires, Runs Rough or Is Unstable"
and Troubleshooting, "Low Power/Poor or No
Response to Throttle".
If a diagnostic code results from running the

Cylinder Cutout Test, proceed to Test Step 4.

296
Test Stejp 4. Use the Injector Solenoid

Test to Test the Injector Solenoids
Cylinder 4 Powered
Cylinder 5 Powered
Cylinder 6 Powered
"Injector Solenoid Test" screen in Caterpillar Electronic Technician (Cat ET)
A. Start the engine. Note: Do not confuse the Injector Solenoid Test with
the Cylinder Cutout Test. The Cylinder Cutout Test
B. Allow the engine to warm up to 77 °C (171 °F) is used to shut off fuel to a specific cylinder while
which is the normal operating temperature. the engine is running. The Injector Solenoid Test
is used in order to actuate the injector solenoids.
C. Turn the key switch to the OFF position. This allows the click of the injector solenoids to be
heard when the engine is not running in order to
D. Connect Cat ET to the data link connector. determine that the circuit is functioning properly.
E. Turn the key switch to the ON position. H, As each solenoid is energized by the ECM an
audible click can be heard at the valve cover.
F. After the engine is warmed to operating Listen for a click at each valve cover. A black
temperature, access the "Injector Solenoid Test" square will appear over the cylinder number
by accessing the following display screens in when the cylinder is being fired.
order:
I. Perform the Injector Solenoid Test at least two
• "Diagnostics" times.
• "Diagnostic Tests" Expected Result:

• "Injector Solenoid Test" All cylinders indicate "OK".
G, Activate the test. Results:

• OK -There is not an electronic problem with the
injectors at this time.
297
Repair: If the Cylinder Cutout Test returned a "NOT

OK" for any injector, refer to Troubleshooting,
"Engine Misfires, Runs Rough or Is Unstable".
STOR
• Not OK - Note the cylinders that indicate "OPEN"

and/or "SHORT". Proceed to Test Step 5.
Test Step 5. Use the Injector Solenoid

Test to Check the Engine Harness from
P2 to P300 for Short Circuits
Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.
A, Turn the key switch to the OFF position. A strong

electrical shock hazard is present if the key
B, Disconnect the J300/P300 injector connector.
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".
Results:
• Not OK - Note the cylinders that indicate a short

circuit. Proceed to Test Step 7.
298

Test to Check the Engine Harness from
P2 to P300 for an Open Circuit
INJECTOR COMMON INJECTOR COMMON INJECTOR COMMON

CYLINDERS 1&2 CYLINDERS 5&4 ~ CYLINDERS 5&6
CYLINDER 1 ~ / CYLINDER 6
INJECTOR INJECTOR INJECTOR INJECTOR

CYLINDER 2 CYLINDER 3 CYLINDER 4 CYLINDER 5

Injector connectorfor Engine harness
Expected Result:
Cat ET displays "SHORT" for the cylinder with the
Electrical shock hazard. The electronic unit injec- jumper wire.
Results:
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key • OK - Proceed to Test Step 8.
B. Disconnect injector connector J300/P300.
C. Turn the key switch to the ON position. Test to Check the ECM for Short Circuits
E. Insert one end of the jumper wire into the tor system uses 90-120 volts.
"Injector Common" socket of the problem injector.
Insert the other end of the jumper wire into the
socket of injector connector P300 that goes to A. Turn the key switch to the OFF position. A strong
the problem injector. For example, if Injector 5 electrical shock hazard is present if the key
is the problem injector, insert the jumper from switch is not turned off.
terminal 5 of the injector connector P300 to
terminal 8 of the injector connector P300. B. Disconnect the J2/P2 ECM connector from the
ECM and check for evidence of moisture entry.
F. Perform the Injector Solenoid Test at least two
times. C. Turn the key switch to the ON position.
G. Repeat this test for each suspect Injector. Ensure D. Perform the Injector Solenoid Test at least two
that the Injector Solenoid Test is disabled before times.
handling the jumper wires.
299
Expected Result: Result 3 Test Step 6 indicated that two injectors

that share an injector common line are shorted.
All cylinders indicate "OPEN" when the P2 ECM
connector is disconnected from the ECM. Results:
Note: When the engine harness is disconnected all • Result 1 - Proceed to Test Step 10.
of the diagnostic codes for supply voltage to the
sensors will be active. This is normal. Clear all of • Result 2 - Proceed to Test Step 11.
these diagnostic codes after completing this test
step. • Result 3 - Proceed to Test Step 12.
Results: Test Step 9. C h e c k the E C M for an O p e n

Circuit
• OK - T h e short circuit is in the engine harness.

Repair the engine harness or replace the engine
harness, as required. Clear all diagnostic codes
after completing this test step.
Verify that the repair eliminates the problem. electrical shock hazard is present if the key
STOR
B. Disconnect the J2/P2 ECM connector. Connect a
• Not OK 140-2266 Cable (Seventy-Pin Breakout) to the
ECM. Do not connect the engine harness to the
Repair: Perform the following repair: breakout T.
1. Temporarily connect a test ECM. C. Use a jumper wire to short between the socket
of the injector and the common socket of the
2. Remove all jumpers and replace all connectors. suspect injector.
3. Recheck the system for active diagnostic D. Turn the key switch to the ON position.
codes.
E. Perform the Injector Solenoid Test at least two
4. Repeat the Test Step. times.
5. If the problem is resolved with the test ECM, Expected Result:

ET displays "SHORT" for the cylinder with the
6. If the problem returns with the suspect ECM, jumper wire.
replace the ECM
Note: When the engine harness is disconnected all
7. Verify that the repair eliminates the problem. of the diagnostic codes for supply voltage to the
sensors will be active. This is normal. Clear all of
STOR these diagnostic codes after completing this test
step.
Test Step 8. Evaluate the S y m p t o m s
Results:
Expected Result:
• OK - T h e ECM is OK.
Choose from these possible results:
Result 1 Test Step 6 indicated that only one injector
had an "OPEN" or "SHORT", or that one injector Replace the engine harness or repair the engine
had an "OPEN" but the other injector on the injector harness, as required.
common line had a "SHORT".
Result 2 Test Step 6 indicated that two injectors
that share an injector common line are open. STOR
• Not OK
300
Repair: Perform the following repair: Repair: Perform the following repair:
1. Temporarily connect a test ECM. Replace the faulty injector. Restore the wiring to
the proper injectors.
2. Remove all jumpers and replace all connectors.
3. Recheck the system for active diagnostic
codes. STOR
4. Repeat the Test Step. Not OK -
5. If the problem is resolved with the test ECM, Repair: Perform the following repair:
Replace the injector harness under the valve
6. If the problem returns with the suspect ECM, cover.
replace the ECM.
STOR
STOR
Test Step 10. C h e c k the Injector H a r n e s s

U n d e r the Valve Cover


B. Remove the valve cover.
C. Disconnect the harness from the problem

injector. Disconnect the harness from the other
injector that has the same injector common line.
D. Thoroughly clean the terminals of both injectors

and the harness.
E. Exchange the harness between the two injectors

that share the common line.
G. Perform the Injector Solenoid Test at least two

times.
Expected Result:
Exchanging the harness between the two injectors

caused the problem to move to the other injector
on Cat ET.
Results:
• OK
301
Test Step 11. Check the Engine Harness

Under the Valve Cover for an Open Circuit
in the Common Line
Attach Jumper
Wire #1 Here
Attach Jum
Wire #2 He
Harness terminals of Electronic Unit Injector
1. Replace the engine harness under the valve

cover.
2. Use the Injector Solenoid Test to check the
A. Turn the key switch to the OFF position. A strong installation of the new harness before installing
electrical shock hazard is present if the key the valve covers.
STOP.
C. Disconnect each of the injectors that indicate an
"OPEN" from the wiring harness. Ensure that each • Not OK - Both injectors indicate "SHORT".
of the connectors from the disconnected injector
harness does not touch other components and Repair: Perform the following repair:
short to ground.
Both injectors indicate "SHORT". Replace Both
D. Attach a jumper wire to both terminals of the injectors.
injector harness for the two injectors that share
an injector common line. Verify that the repair eliminates the problem.
E. Turn the key switch to the ON position. STOP.
F. Perform the Injector Solenoid Test at least two Test Step 12. Check the Engine Harness
times. Under the Valve Cover for Short Circuits
in the Injector Wires
Expected Result:
The cylinders with the short in place indicate an
"OPEN".
Results: tor system uses 90-120 volts.
• OK
302
A. Turn the key switch to the OFF position. A strong Expected Result:
switch is not turned off. The multimeter indicates that the resistance is
greater than 10 Ohms.
Results:
C. Disconnect each of the injectors that indicate a
"SHORT" from the wiring harness. Ensure that • OK - Reconnect the engine harness to the ECM.
each of the connectors from the disconnected Proceed to Test Step 14.
injector harness does not touch other
components and short to ground. • Not OK
D. Turn the key switch to the ON position. Repair: Perform the following repair:
E. Perform the Injector Solenoid Test at least two Replace the injector harness under the valve
times. cover.
Expected Result: Verify that the repair eliminates the problem.
Both cylinders indicate an "OPEN". STOR
Results: Test Step 14. C h e c k for a Short Circuit in

the Injector
• OK - Leave the injector wires disconnected.
Neither of the injector wires are shorted to the
engine. Proceed to Test Step 13.
• Not OK Electrical shock hazard. The electronic unit injec-

Replace the injector harness under the valve electrical shock hazard is present if the key
cover. switch is not turned off.
Verify that the repair eliminates the problem. S. Reconnect one of the two disconnected injectors.
STOR C. Turn the key switch to the ON position.

Test Step 13. C h e c k for a Short Circuit in D. Perform the Injector Solenoid Test at least two
the Injector C o m m o n Line to the E n g i n e times.
Expected Result:
The reconnected injector indicates a "SHORT".

tor system uses 90-120 volts. Results:
A. Turn the key switch to the OFF position. A strong • OK

switch is not turned off. Repair: Perform the following repair:
B. Disconnect the J2/P2 ECM connector. Replace the Injector.
C. Locate the common line for the problem injector Verify that the repair eliminates the problem.
in the P2 connector. Measure the resistance
from the terminal to the engine ground stud STOP.
connection.
• Not OK - The injector is OK. Proceed to Test
Step 15.
303
Test Step 15. Check for a Short Circuit The multitorque feature is an optional feature. This
in the Other Injector feature requires unique software. The multitorque
feature provides an otherwise standard engine with
two different torque curves. The torque curve for the
lower gears functions as a standard engine. The
torque curve for the top gears provides additional
Electrical shock hazard. The electronic unit injec- torque. The transmission ratio determines the
tor system uses 90-120 volts. top gears. In the top gears, the engine provides
additional torque. This additional torque is typically
A. Turn the key switch to the OFF position. A strong 136 N.m (100 Ib ft).
switch is not turned off. The ECM determines when the vehicle is in the
top gears by sensing the ratio of engine speed to
B. Reconnect the other disconnected injector. vehicle speed. The engine will operate with the
higher torque curve if the ratio of engine speed to
C. Turn the key switch to the ON position. vehicle speed is within the specified range.
D. Perform the Injector Solenoid Test at least two The engine ratings are based on the trip point.
times. Additional torque is made available at the trip
points. The three options are listed below.
Expected Result:
• MT-4 ratio is 71.5 rpm/mph & below (Top 4 Gears)
The reconnected injector indicates a "SHORT".
• MT-2 ratio is 37.6 rpm/mph & below (Top 2 Gears)
Results:
• MT-1 ratio is 27.9 rpm/mph & below (Top 1 Gear)
• OK -
With OCT99 and newer software, the "Multitorque
Repair: Perform the following repair: Ratio" parameter was added. This allows the
selection of the desired ratio turn on trip point (MT-1,
Replace the faulty injector. Restore the wiring to MT-2, or MT-4). "Multitorque Ratio" is used rather
the proper injectors. than requiring three different ratings that are based
only on the different ratio trip points. With older
Verify that the repair eliminates the problem. software, the engine rating determined the specific
ratio that was used for the vehicle application.
STOR
The multitorque feature differs from the PTO torque
• Not OK - This injector is OK. STOP. limit. The PTO torque limit requires a torque limit
switch. Multitorque software provides a second
torque curve. The engine will not exceed the PTO
i01815762 torque limit. The ECM essentially removes the top
of the torque curve at the programmed PTO torque
Multi-Torque- Test limit. The PTO torque limit is used only for temporary
protection of equipment.
SMCS Code: 1901-038
Test Step 1. Repair all Diagnostic Codes
System Operation Description: and Other Problems
Use this procedure under the following situation: A. Make sure that there are no active diagnostic
codes and make sure that there are no logged
The multitorque software is suspected of operating diagnostic codes that affect engine performance.
incorrectly. Access the Instantaneous Screen if
the vehicle is equipped with the (CAT ID) Driver B. Refer to the procedure that best describes
Information Display. This screen will show the status the symptom if there are any other complaints
of the multitorque feature in order to determine if the or symptoms. Refer to Troubleshooting
multitorque feature is activating.
for troubleshooting information on specific
symptoms, or the relationship between
Background of the multitorque feature
diagnostic codes and possible performance
related complaints.
Expected Result:
No other detectable problems exist.

304
Results: Repair: Verify that the vehicle specifications are

compatible with the multitorque feature. The ratio
• OK - Proceed to Test Step 2. of engine speed to vehicle speed should be less
than 71.5 in top gear. The ratio of engine speed
• Not OK - Repair any other problems, as required. to vehicle speed should be less than 44.7 when
Proceed to Test Step 2. metric vehicle speed is used.
Test Step 2. Verify that the Software is With OCT99 and newer software, verify that the
Installed "Multitorque Ratio" parameter is programmed to
the correct setting.
(ET) to the cab data link connector. Verify that the repair eliminates the problem.
B. Turn the ignition key switch to the ON position. STOR
Expected Result:
i01859775
The rating type in the customer specified

parameters indicates "Multitorque".
Neutral Switch Circuit- Test
SMCS Code: 1435-038
Results:
Use this procedure to determine if the neutral switch
• Not OK - T h e engine is not equipped with the is preventing normal operation of cruise control, idle
multitorque feature. STOR set speed, or PTO operation:
Test Step 3. Verify a Change in the Rated The following switch circuits can also prevent the
Fuel Limit correct operation of the cruise control, idle set
A. Put the vehicle on a dynamometer or take the
vehicle for a road test. • Service Brake Pedal Position (Switch 1)
B. Operate the vehicle in the lower gears at an • Service Brake Pedal Position (Switch 2)
approximate engine speed of 1200 rpm. A load
on the engine is not required. • Cruise Control Set/Resume Switch
C. Read the "Rated Fuel Limit" and record the • Cruise Control On/Off Switch
"Rated Fuel Limit" from the status screen on ET.
• PTO On/Off Switch
D. Operate the vehicle in the top gear at 1200
rpm. Read the "Rated Fuel Limit" and record the The switches are described in the respective circuit
"Rated Fuel Limit". tests in Troubleshooting.
Expected Result: All of the following customer programmable
The "Rated Fuel Limit" in the top gear is greater and PTO operation:
than the "Rated Fuel Limit" in the lower gears.
• "Low Cruise Control Speed Set Limit"
Results:
• "High Cruise Control Speed Set Limit"
• OK -The multitorque feature is operating
correctly. STOR • "Idle Vehicle Speed Limit"
• Not OK • "Cruise/Idle/PTO Switch Configuration"
• "ldle/PTO Bump rpm"
• "ldle/PTO rpm Ramp Rate"

305
• "PTO Vehicle Speed Limit" A service brake pedal position (Switch 1)is required
for all configurations. The service brake pedal
The vehicle speed calibration can also affect position (Switch 1) connects to the ECM through
the cruise control, the idle set speed, and the connector P1:45. The service brake pedal position
PTO if the vehicle speed calibration is incorrectly (Switch 2) connects to the ECM through connector
programmed. Refer to Troubleshooting, "Customer P1:64. The neutral switch connects to the ECM
Specified Parameters". through connector P1:62.
Transmission Neutral Switch
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.
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
The "Transmission Style" parameter determines

the switches that will be used. The following
switches can be used with being dependent on the
parameter setting:
• Clutch Pedal Position
• Neutral
• Service Brake Pedal Position (Switch 1)
Refer to Table 150 for additional information.

Table 150
Switch Usage.
Setting For
Style Brake Brake
Clutch Neutral
Parameter Switch Switch
1 2
Manual
X X
Option 1
Automatic
Option 1 X
Automatic
X X
Option 2
Automatic
Option 3
X X X
Automatic
Option 4
X X
Eaton Top 2 X X
306
TRANSMISSION NEUTRALSWITCH ECM

----~(IN GEARPOSITION)
409-0R--~--<-[62~ INPUT ~12
P1 J1

Schematic for transmission neutral switch
Test Step 1. Determine the Type of Expected Result:

Problem
The problem is due to a parameter setting or the
A. Connect the electronic service tool to the data problem is due to a normal kickout.
link connector.
Results:
B, Turn the key switch to the ON position.
• OK - Explain the proper operation of system to
C, If the vehicle will not allow setting a cruise the driver. STOR
speed, an idle speed or a PTO speed, check the
following customer parameters: • Not OK
Cruise Control Parameters Repair: If a problem is still suspected with the

neutral switch circuit perform the following
• "Low Cruise Control Speed Set Limit" procedure:
• "High Cruise Control Speed Set Limit" Proceed to Test Step 2.
Idle Parameters
• "Idle RPM Limit"
• "Top Engine Limit" (TEL)
PTO Parameters
• "PTO Configuration"
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
307

and Wiring
13000000000000
230 O O O O o O 0 0 0 O14
310 O O O ~ O 0 0 024
390 0 O0 ~ 0 ~ 000032
47OOOO 000040
570 0 0 0 0 o 0 0 0 O 048
INPUT 12 (TRANSMISSION NEUTRAL SWITCH)
700 0 0 0 0 0 0 0 ~ 0 O 0 058
~-. ~
1 2 3 4 5 6 [~ 8 9 10 1112 13~"~
A-I 0 0 0 0 0 0 0 0 0 0 0 0 0
UI14000QO ~ OOQOQ23
-1:'40000 /.~-x~ 00003'
p oooo oooo
lu' o o o o o . . - INPUT 12 (TRANSMISSION NEUTRAL SWITCH)
OOOOt~OOOOO00O ,
\ ~.58 59 60 61 62 63 r-q 65 66 67 6869 70 j /
II II J
Harness Side
A. Thoroughly inspect the J1/P1 ECM connector, • Not OK

for the following switches in the connectors: Repair: Repair the connectors or wiring and/or
• J1/P1:62 (Neutral Switch) of the seals are properly in place and ensure that
- Inspect" for details. Verify that the repair eliminates the problem.
B. Perform a 45 N (10 Ib) pull test on each of the STOR

with the switches.


Expected Result:
All connectors, pins, and sockets should be

or pinch points.
Results:

308
Test Step 3. C h e c k the Status of the

"Transmission Neutral Switch"
Table 151
"Transmission Neutral Switch" Status
Switch Position Switch Status Circuit
The Transmissionis m Neutral. ON Closed
The Transmissionis in Gear. ' OFF Open
A. Access the status screen on the electronic B. For an intermittent idle kickout, talk to the driver
service tool. in order to determine the conditions when the
kickout occurs. A topic of examination could be
B. Turn the key switch to the ON position. the following example:
C. Shift the transmission into the Neutral position • Specific engine rpm
while the status for the "Transmission Neutral
Switch" is being observed. Also, shift out of Start the engine. Duplicate these conditions and
neutral while the status for the "Transmission set the idle rpm. Operate the vehicle in idle until
Neutral Switch" is being observed. the problem reoccurs.
Note: If the status indicates "Not Installed", check Note: The status screen on the electronic service
the programming of the "Transmission Style" tool will only indicate the last kickout. The status
parameter. The "Transmission Style" must be screen on the electronic service tool will lose this
programmed to "Automatic Option 3" or "Automatic information if the key switch is turned OFE
Option 4".
C. Connect the electronic service tool and check
Expected Result: the status screen for the last cause of the kickout.
The switch status changes per the information in D. If the status screen on the electronic service tool
Table 151. is blank, then either there was no kickout of the
cruise control, or the power to the ECM was
Results: turned off before the information could be read.
Repeat this test step.
• OK - T h e switch is operating normally. STOR
Note: A status screen that is blank indicates No
• Intermittent Problem Suspected - Proceed to Test Occurrence.
Step 4.
Expected Result:
• Not OK - T h e ECM is not reading the switch
status change. Proceed to Test Step 5. RESULT 1 The status for the kickout displays the
following result:
Test Step 4. O p e r a t e the Vehicle and
C h e c k the Kickout Status P a r a m e t e r • "Neutral"
A. For an intermittent cruise control kickout, talk to RESULT 2 The status for the kickout displays the
the driver in order to determine the conditions following result:
when the kickout occurs. Topics of examination
could be the following examples: • "Switch Turned Off"
• Specific Speed RESULT 3 The status for the kickout displays the
following result:
• Road Conditions
• "Brake"
• Weather Conditions
RESULT 4 The status for the kickout displays the
Take the vehicle for a road test in order to following result:
duplicate these conditions and set the cruise
control. Operate the vehicle in cruise control until • "Vehicle Speed < Limit"
the problem reoccurs.
309
• "Bad Vehicle Speed" Repair: Perform the following diagnostic

procedure:
• "Vehicle Speed _> Limit"
Troubleshooting, "Clutch Pedal Position Switch
RESULT 5 The status for the kickout displays the Circuit - Test"
following result:
STOR
• "PTO Switch ON"
• Result 7
RESULT 6 The status for the kickout displays the
following result: Repair: Perform the following diagnostic
procedure:
• "Clutch"
Troubleshooting, "Engine Speed/Timing Circuit -
RESULT 7 The status for the kickout displays the Test"
following result:
STOR
• "No Engine Speed"
Results: the E C M
• Result 1 - Proceed to Test Step 5. A. Turn the key switch to the OFF position.
• Result 2 B. Fabricate a jumper wire 100 mm (4 inch) long.

procedure: (3. Disconnect the P1 ECM connector from the ECM.
Troubleshooting, "Cruise Control Switch Circuit - D. Connect a 140-2266 Cable (Seventy-Pin

Test" Breakout) between the P1 ECM connector and
the ECM.
STOR
E. Install the jumper into terminal 62 (Neutral
• Result 3 Switch) of the breakout T. Connect the other
end of the jumper to terminal 52 (Unswitched
Repair: Perform the following diagnostic +Battery) of the breakout T.
procedure:
Troubleshooting, "Service Brake Pedal Position
(Switch 1) Circuit - Test" G. Connect the electronic service tool to the data
link connector.
STOR
H. Access the status screen on the electronic
• Result 4 service tool.
Repair: Perform the following diagnostic While the status for the "Transmission Neutral
procedure: Switch" is being monitored on the status screen
slowly remove the jumper from terminal 52
Troubleshooting, "Vehicle Speed Circuit - Test" (Unswitched +Battery). Now, slowly insert the
jumper into terminal 52 (Unswitched +Battery).
STOR
Expected Result:
• Result 5
When the jumper wire is installed, the status for
Repair: Perform the following diagnostic the "Transmission Neutral Switch" is "On". When
procedure: the jumper wire is removed, the status for the
"Transmission Neutral Switch" is "Off".
Troubleshooting, "PTO Switch Circuit - Test"
Results:
STOR
• OK - T h e ECM is functioning properly. Proceed
• Result 6 to Test Step 6.
310
• Not OK - The ECM is not functioning properly. Replace the faulty switch.
Repair: Perform the following repair: Verify that the repair eliminates the problem.
1. Temporarily connect a test ECM. STOR
2. Remove all jumpers and replace all connectors. Not OK - T h e r e is a problem in the harness
3. Recheck the system for active diagnostic Step 7.
codes.
Test Step 7. Insert a Jumper at the
4. Repeat the Test Step. Bulkhead Connector
5. If the problem is resolved with the test ECM, A. Turn the key switch to the OFF position.
6. If the problem returns with the suspect ECM, Crimp a Deutsch pin to each end of the wires.
replace the ECM.
C. Find the neutral switch terminal and the +Battery
7, Verify that the repair eliminates the problem. connection in the engine side of the bulkhead
connector for the vehicle harness.
STOR
D. Insert the jumper wire between the two terminals
Test Step 6. Insert a Jumper at the Neutral in the engine side of the bulkhead connector.
Switch
F. Connect the electronic service tool to the data
B. Ensure that the J1/P1 ECM connector is link connector.
connected.
G. Access the status screen on the electronic
C. Find the neutral switch in the vehicle. service tool.
D. Disconnect the wires from the neutral switch H. While the switch status is being monitored,
terminals. alternately remove the jumper wire between the
two terminals, and alternately insert the jumper
E. Turn the key switch to the ON position. wire between the two terminals.
F. Connect the electronic service tool to the data Expected Result:

link connector.
When the jumper wire is installed, the status for
G. Access the status screen on the electronic the "Transmission Neutral Switch" is "On". When
service tool. the jumper wire is removed, the status for the
"Transmission Neutral Switch" is "Off".
H. While the status for the "Transmission Neutral
Switch" is being monitored, connect the switch Results:
wires and disconnect the switch wires.
Expected Result: between the bulkhead connector and the switch.
When the switch wires are connected, the status for Repair: Perform the following repair:
the "Transmission Neutral Switch" is "On". When the
switch wires are disconnected, the status for the Inspect the vehicle wiring and repair the vehicle
"Transmission Neutral Switch" is "Off". wiring, as required. If the problem still exists with
Results:
STOP.
• OK - T h e switch is not functioning properly.
Repair: Perform the following repair: between the bulkhead connector and the ECM.
311
Repair: Perform the following repair: • J1922
Inspect the vehicle wiring and repair the vehicle • J1939

the wiring, send the vehicle to the OEM dealer. • J1922 and J1939
STOR • None
Anti-Lock Brake Systems (ABS)

i01909566
Powertrain Data Link Circuit- The "Powertrain Data Link" may be used by an
anti-lock brake system (ABS) in order to disable the
Test engine retarder when the anti-lock brake control
determines that the engine retarder should be
SMCS Code: 1901-038 disabled. This is usually achieved when the ABS
system is active.
Traction Control Systems
Power train Data Links
Loss of traction is determined by sensors on the
Power train data links are designed to facilitate vehicle that are mounted near the wheels. These
communication and control between electronically sensors are also used by the ABS system. Typically,
controlled Anti-Lock Brakes (ABS), traction control a system with traction control includes Anti-Lock
systems, transmissions, and engines. Typical control brakes.
would include a momentary reduction of engine
rpm and/or engine torque, that is triggered by a Transmission Control
signal from an off-engine control module such as
the ABS, the traction control, or the transmission. An The following characteristics are determined by a
off-engine control module is a control module that is vehicle speed sensor in the transmission:
not part of the Caterpillar engine control system.
• Transmission shift points
Any combination of the following systems may be
installed together on a vehicle: • Engine rpm
• Traction Control • Load
• Transmission Control The sensors for power train control provide signals
to the vehicle control module of the "Powertrain Data
• ABS Link". The vehicle control module of the "Powertrain
Data Link" then communicates with the engine
The required components are installed at the OEM ECM. The engine ECM receives a request from the
when the vehicle is built. "Powertrain Data Link". The engine ECM responds
by momentarily limiting the following characteristics:
Powertrain data link wiring, off-engine control
modules, and wiring are installed by the vehicle • Engine rpm
OEM. Questions that are related to the hardware
configuration, software, and installation should be • Torque
directed to the vehicle OEM.
• Both Engine rpm and Torque
The following two power train data links are
available: The presence of an active J 1922 data link circuit can
be determined by observing the "Powertrain Status"
• SAE J1922 screen on the Caterpillar Electronic Technician (Cat
ET). The status screen will display "Installed" if the
• SAE J 1939 proper software is installed in the ECM, and there
is no action that is being requested at that time by
The J1922 and J1939 refers to the standard any of the control modules on the data link.
for data link communications of the Society
of Automotive Engineers Inc.. The ECM has a
customer programmable parameter that is called
"Powertrain Data Link" which can be programmed
to any one of the following options:
312
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.
J1922 Data Link
SAE J1922 is standard with all software.
Note: The J1922 data link wires are a twisted pair.

The twisted pair is used to reduce electromagnetic
interference. If a section of wiring must be replaced,
the new wires should also be a twisted pair. Use
care to maintain the polarity of the original wire
when the pins and the sockets are being installed
into the connectors.
J1939 Data Link
SAE J1939 is standard with all software.
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.
ECM
TOJ1922 DATALINKCONNECTOR( . E721-WH ~ J1922DATA LINK +
TOJ1922 DATALINKCONNECTOR~. ~>~ ~>~ ~ /Y~---[ 720-PK J1922DATA LINK-
TO Jt939 DATALINKCONNECTOR( A249-BK J1939 DATA LINK SHIELD
TOJ,939 DATALINKCONNECTOR( ~ ~ > ~ K99O-G;" Jt939 DATA LINK -
TOJ1939 DATALINKCONNECTOR( v v KgOO-YL Jt939 DATA LINK +
PI J1

Schematic for Power train data link
313
J1939 DATA LINK -

JIF9319LDDATALINK J1939 DATA LINK
s ,.o
J1939 DATA LINK - ~ BATTERY ~H'~\- // "tBATI'ERY

J1587 DATA LINK
J1939 DATA LINK +~ ~ J1587 DATA LINK + / \
+BA'B'ERY J1587 DATA LINK- J1,587 DATA LINK - -BATTERY
DEUTSCH 9-TERMINALCONNECTOR DEUTSCH J1939 CAB CONNECTOR

Does not require an Adapter Harness for Requires 157-4829 Adapter Harness for
connection to the Service Tool Cable connection to the Service Tool Cable
g00714306
Illustration 143
ECM pin locations
Test Step 1. Inspect Electrical Connectors Results:

and Wirnng
the firewall bulkhead connector, the connectors • Not OK
for the power train control module, and the
connector terminals for the SAE J1922 data Repair: Perform the following repair:
link or the connector terminals for the J1939
data link. Refer to Troubleshooting, "Electrical Repair the connectors or wiring and/or replace
Connectors - Inspect" for details. the connectors or wiring. Ensure that all of the
B, Perform a 45 N (10 Ib) pull test on each of the connectors are completely coupled.
with the SAE J1922 data link or the J1939 data Verify that the repair eliminates the problem.
link.
STOR
Test Step 2. Check for Active Diagnostic
C. Check the ECM connector (allen head screw) for Codes
D, Check the harness and wiring for abrasion and
pinch points from the data link connectors back B, Turn the key switch to the ON position.
to the ECM.
C, Monitor the active diagnostic code screen on Cat
Expected Result: ET. Check and record active diagnostic codes.
All connectors, pins, and sockets should be Expected Result:

and wiring should be free of corrosion, abrasion, There is an active diagnostic code for the SAE
or pinch points. J1922 data link or the SAE J1939 data link.
314
Note: The "Powertrain Data Link" parameter is a • No - T h e ECM is not receiving messages from
customer parameter that must not be programmed the devices that are installed on the vehicle.
to J1939, or J1922 and J1939, unless the J1939
data link is being used. Repair: The devices that can be programmed to
use the J1939 data link can be circuits with two
Results: wires or circuits with three wires. Bad connections
are the most frequent problem. Repair the suspect
• J1939 - Proceed to Test Step 3. component or replace the suspect component.
This may include the connectors, the wiring,
• J1922 - Proceed to Test Step 5. and/or the device. Ensure that the connectors are
free of corrosion.
STOR
Test Step 3. Check the Devices on the
J1939 Data Link.
B, Access the special test "J1939 Receive

Communication Status". The special tests are
located under the Diagnostic menu.
C. Cat ET will display the J1939 sources that have

transmitted at least one good message that
has been successfully received by the ECM. If
the ECM has not received any messages from
a source, that source will not be displayed.
Examples of devices that can use the J1939
data link include the following switches:
• Switches that are programmed to "Instrument

Cluster"
• Switches that are programmed to "Body

Controller"
• Switches that are programmed to "Cab

Controller"
D, Cat ET will display the J1939 source in the

"Description" column. The "Status" column
displays the status of the device.
E. If an expected message is not received from a

device, Cat ET will display "Not Receiving".
F. The status screen on Cat ET can be set to

display the status of a device that is not working.
The status screen will display "No Comm" if a
message is not received from the device.
Expected Result:
Cat ET displays the devices that are used on the
vehicle and the ECM is receiving messages from
the devices.
Results:
• Yes - T h e ECM is receiving messages from the
devices that are installed on the vehicle. STOR
315
Test Step 4. Check the Power Train Status

Screen
........................................................................................................................................................................................................................... i~,~.............
,~,~,i~ii!
I
® I........N
.........[NNINNI
.......................................N..... ...................................................... I
t 34°6E Truck (1BG23456) , ............................................................................................................................................................................................... ::iii ..................................... iiii .......
I No Engine Speed I
-341~E Truck Group 9

3406E Truck(2WS14269)
1720 RPM EngineSpeed
47% Percent Torque
Traction Control PowertrainStatus
Torque Limit TC Status
TC Speed
4~,~ TC Torque
No Communication TransmissionStatus
TransmissionOutputSpeed
TransmissionTorque
No Communication ABS Status
Illustration 144 gOO714416
Table 152
Powertrain Status Group Definition Table
Heading On Status Screen Displayed Message Definition of Message
Engine Speed Actual Engine rpm of the engine
Percent Torque Current engine torque during operation
that is expressed as a percent of peak
torque
Powertrain Status "Not Installed", "ABS Control", "Traction Communication of the Power Train
Control", "Traction and ABS Control", control module
'q-rans Control", 'q-rans and ABS
Control", "Trans and Traction Control",
"Trans and Traction and ABS"
(continued)
316
Table 152, contd)

Powertrain Status Group Definition Table
Heading On Status Screen Displayed Message Definition of Message
TC Status or Transmission Status "No Communication" Communication from the vehicle control
is not being received by the ECM. One
of the following conditions exists: The
vehicle does not support this feature.
The vehicle control is not currently
powered, or the wiring is damaged or
disconnected.
"Not Active" No requests from the Vehicle Power
Train ECU (Electronic Control Unit)
"Speed Command" Engine rpm is being controlled by a
Vehicle ECU.
"Torque Command" Engine torque is being controlled by a
Vehicle ECU.
"Speed and Torque Limit" Engine rpm and torque is being
determined by a Vehicle ECU,
"Torque Limit" The Torque limit is being determined by
a Vehicle ECU.
"Speed Limit" The rpm limit is being determined by a
Vehicle ECU.
TC Speed The TC Speed is the desired engine
rpm setpoint or the engine rpm limit
that is being requested by the Vehicle's
Traction Control ECU.
TC Torque The TC Torque is the desired percent of
torque or the desired percent of torque
limit that is being requested by the
Vehicle's Traction Control ECU.
Transmission Output Speed The Transmission Output Speed is the
desired engine rpm setpoint or the
engine rpm limit that is being requested
by the Vehicle's Traction Control ECU.
Transmission Torque The Transmission Torque is the desired
percent of torque or the percent of
torque limit that is being requested by
the Vehicle's Traction Control ECU.
ABS Status "No Communication" The ECM is not receiving
communication from the vehicle's
ABS/Traction Control System. One of
the following conditions exists: The
vehicle does not support this feature.
The vehicle's ABS/Traction Control
System is not currently powered. The
wiring is damaged or disconnected.
"Not Active" There are no requests from the
ABS/-I-raction Control ECU.
"Disable Retarder" This is a request from the ABS/Traction
Control ECU to the ECM. The
ABS/Traction Control System requests
the disabling of the Engine Retarder
operation.
A. Connect Cat ET to the data link connector. B. While the vehicle is being driven by someone
else, monitor Cat ET. Use the following procedure:
317
a, Access the status screen on Cat ET. Select the

"Powertrain Status" screen. The "Powertrain
Status" screen relates to the J1922 data link
and J1939 data link.
b. While the vehicle is being operated, monitor

the "Powertrain Status" screen.
Refer to Table 152 for an explanation of the

headings that are displayed in the "Powertrain
Status" screen on Cat ET.
Note: Transmission shifts and/or a momentary loss

of traction should trigger the appropriate action by
the ECM when the correct sensors, controls and
wiring are installed on the vehicle.
Expected Result:
The status screen indicates that the ECM is

responding to a power train control.
Note: Some power train control modules have test

modes that are available by activating diagnostic
switches. Ensure that the Caterpillar ECM is not
reacting to a test by the power train control module
if the problem is related to power train control
operation and you believe that the system should
not be active.
Results:
• OK - I f the response is abnormal, send the

vehicle to the OEM dealer for repairs. STOR
• Not OK

procedure:
Troubleshooting, "Troubleshooting without a

Diagnostic Code"
STOR
318
Test Step 5. Disconnect the Data Link

Lines from the ECM Connector
~ 0000000000000~2~4" J1922 DATA LINK POSITIVE

500000~0000 J1922 DATA LINK NEGATIVE
310000 009 J1939 DATA LINK NEGATIVE
ooo o ,Co o 2j J1939 DATA LINK SHIELD
470 0 0 0 0 qF~) O40J
570 0 0 0 0 o 0 0 ~ O41~
700 0 0 0 0 0 0 O 0 0 0 0 058'

--f 1--~2-3"4-5-6 ,7 8-9-10 Ij11-12-15~'~ J1922 DATA LINK POSITIVE
J~"bNMNNNNMNN J1922 DATA LINK NEGATIVE
,4qirOOOO ; @ OOOO0231LII
2 4 0 0 0 0 ~ - - ~ c,,c~'~ns,m J1939 DATA LINK NEGATIVE
,088¢8
,aOC: O " - " 00000571111
0000000000000 I-~
k~58 59 60 6162 63 m 65 66 67 68 69 7 0 . ~ /
II II J
Horness Side
Illustration145 900652192
A. Turn the key switch to the OFF position. • 249-11 J1922 Data Link Fault (58)
B, Remove the wires from J1/P1:14 (J1922 Data Results:

Link Negative) and J1/P1:1 (J1922 Data Link
Positive). This may require disconnection of • OK
J1/P1 from the ECM.
C, Reconnect vehicle harness connector P1 to the procedure:
ECM when the wires are disconnected.
1. Use the following procedure if the vehicle is
D. Turn the key switch to the ON position. not using the J1922 data link for power train
control:
E, Monitor the active diagnostic code screen on Cat
ET. Check and record active diagnostic codes. a, Leave the pins for the data link
disconnected from the ECM.
Expected Result:
b. Fill the unused cavities of connector P1 with
The following diagnostic code is active: Deutsch plugs.
• 249-11 J1922 Data Link Fault (58) c. Program the parameter for the "Powertrain
Data Link" to "None".
Note: If the J1922 data link is not being used
for the vehicle's power train control, program 2. Use the following procedure if the vehicle
the "Powertrain Data Link" parameter to "None". is using the J1922 data link for power train
After the "Powertrain Data Link" parameter is control:
programmed to "None", the following active
diagnostic code should be repaired: a, Temporarily connect a test ECM.
319
b. Repeat the Test Step. The ECM can use various inputs in a number
c. If the problem is resolved with the test ECM, programming. Certain features are available on
reconnect the suspect ECM. several different inputs. The configuration for the
d. If the problem returns with the suspect order for the switch to function properly.
ECM, replace the ECM.
Switch for "PTO Engine RPM Set Speed Input A"
STOR
The switch for the "PTO Engine RPM Set Speed
• Not OK - The ECM is OK. Input A" is used to control engine RPM during
PTO operation. The "PTO Engine RPM Set Speed
Repair: Perform the following diagnostic A" parameter requires an engine RPM to be
procedure: programmed. The "PTO Engine RPM Set Speed
A" parameter is located in the "Dedicated PTO
1. Use the following procedure if the vehicle is Parameter Group". The "PTO Engine RPM Set
not using the J1922 data link for power train Speed Input A" status is located in the "Input
control: Selections Parameter Group". The engine will ramp
up to the engine rpm that is programmed under
a. Leave the pins of the data link disconnected the following conditions:
from the ECM.
• The switch for the "PTO Engine RPM Set Speed
b. Fill the unused cavities of connector P1 with Input A" is in the ON position and the PTO On/Off
Deutsch plugs. switch is then turned on.
c. Program the parameter for the "Powertrain • The switch for the "PTO Engine RPM Set Speed
Data Link" to "OFF". Input A" is turned to the ON position when the
PTO On/Off switch is on.
d. Verify that the repair eliminates the problem.
The "PTO Configuration" must be programmed to
2. Use the following procedure if the vehicle "Cab Switches", "Remote Switches", or "Remote
is using the J1922 data link for power train Throttle" for this feature to function. The PTO On/Off
control: switch or the switch for the "PTO Engine RPM
Set Speed Input A" must be cycled from the OFF
a. Send the vehicle to the OEM dealer for position to the ON position in order to return to the
repair. programmed engine rpm if the PTO operation is
disabled. If the "PTO Engine RPM Set Speed Input
b. Verify that the repair eliminates the problem. A" parameter is programmed to None (default), this
feature is not used. If the "PTO Engine RPM Set
STOR Speed Input A" parameter is programmed to one of
the available inputs (J1/P1:6, J1/P1:46, J1/P1:58,
J1/P1:60), the feature is available. Also, the switch
i01625471
circuit should be connected to the same input.
PTO Engine RPM Set Speed Switch for the "PTO Engine RPM Set Speed Input
(Input A and Input B) Circuit - B"
Test
SMCS Code: 1901-038
Use this procedure to determine if the circuit for the

PTO Engine RPM Set Speed "Input A" and "Input
B" is operating correctly. This feature is available on
NOV99 and newer software.

to this procedure:
320
The switch for the "PTO Engine RPM Set Speed

Input B" is used to control engine RPM during
PTO operation. The "PTO Engine RPM Set Speed
B" parameter requires an engine RPM to be
programmed. The "PTO Engine RPM Set Speed
B" parameter is located in the "Dedicated PTO
Parameter Group". The "PTO Engine RPM Set
Speed Input B" status is located in the "Input
Selections Parameter Group". The function of the
switch for the "PTO Engine RPM Set Speed Input B"
is similar to the function of the switch for the "PTO
Engine RPM Set Speed Input A". The engine will
operate at set speed "A" when both of the switches
are on. If the "PTO Engine RPM Set Speed Input B"
parameter is programmed to "None" (default), this
feature is not used. If the "PTO Engine RPM Set
Speed Input B" parameter is programmed to one of
the available inputs (J1/P1:6, J1/P1:46, J1/P1:58,
J1/P1:60), then the feature is available. Also, the
switch circuit should be connected to the same
input option.

be slightly different. The sensor common circuits are
used interchangeably by the OEM of the vehicle.
The following circuits are common within the ECM:
• The "input Sensor Common 1" is terminal 18.
• The "A/P Sensor/Switch Sensor Common" is

terminal 5.
ECM
PTO ENGINE RPM K980-PK~ INPUT 12

SPEED INPUT A SWITCH K982-YL--FI60 INPUT 13
I ~ (SHOWN IN POSITION)I
OFF GS 3-OR--t-<I6÷ INPUT
G844-PK--F<I46÷ INPUT
16
17
H795-PK--~_JS_~_ AP SENSOR/SWITCH SENSOR COMMON
Pl J1
NOTE:INPUT 12,13,~6 OR 17 MAY BE USED. THE PTO ENGINE RPM SET SPEED INPUT A
g00683014
Illustration 146
This illustration represents the schematic for the "PTO Engine RPM Set Speed InputA" switch circuit.
321
ECM
PTO ENGINE RPM K980-PK--~ INPUT ~2

SPEED INPUT B SWITCH .82-YL-f<I6O~ INPUT ~3
c~--~(SHOWN IN OFF POSITION) G843-OR-J-<I6 INPUT ~6
• G 8 4 4 - P K - - ~ I 4 6 ~ INPUT ~7
I i-- H 7 9 5 - P K - - ~ _ I ~- AP SENSOR/SWITCH SENSOR COMMON
PI J1
NOTE:INPUT ~2,~3,J6 OR ~7 MAY BE USED. THE PTO ENGINE RPM SET SPEED INPUT B

This illustrationrepresentsthe schematicfor the "PTO Engine RPM Set Speed Input B" switch circuit.
d~ ,,
~ooooooo~ooooo4]
2300000
] o 00000~
INPUT ~6
510 0 0 0 ~ 0 00024,/
5~)000 <k.~J 000032/
470 ~ 0 0 0 00040 H
INPUT J7
[,570 0 0 0 0 0 000004
INPUT J2
~7o0O 0 0 0 0 0 0 0 0 q O ~5
INPUT ~3
ECM SIDE VEHICLE HARNESS CONNECTOR PI

II II ~'.
//"~1 2 3 4 5 6 ' ' 8 9 10 11 12 13 ~ \ INPUT |6
n---I O 0 0 0 0 e O 0 0 0 0 0 0 h-'l
L l l u O 0 0 0 0 >PEI<0 0 0 0 0 2 : IJI
- 1 2 ' 0 0 0 0 //n'x-h 00003~--I
Is 0 0 0 0 (( ( ) ))360000 E/
400000 ~ 00~047 INPUT 17
~:°8S0000 00000571-tl INPUT ~2
u--I g O e O 0 0 0 0 0 0 0 0 0 U-el INPUT ~3
\ k...5859 60 61 62 63 ri 6566 676869 7 0 / /
HARNESS SIDE

Terminal Locationsfor ECM
Test Step 1. Check the Electrical D. Check the harness and the wiring for abrasion
Connectors and the Wiring and pinch points from the battery to the ECM.
A. Thoroughly inspect the ECM vehicle harness ECM.
bulkhead connectors. Refer to Troubleshooting, Refer to Illustration 148 for terminal locations
"Electrical Connectors - Inspect" for details. for the ECM.
B. Perform a 45 N (10 Ib) pull test on each of the Expected Result:

with the suspect switch circuit. All connectors, pins, and sockets are completely
C. Check the ECM connector (allen head screw) for wiring should be free of corrosion, abrasion or pinch
the proper torque of 6.0 N.m (55 Ib in). points.
322
Results:
• Not OK
Repair: Repair the wiring and connectors or

all of the seals are properly connected.
STOP.
Test Step 2. Check the Status of the "PTO

Engine RPM Set Speed Input A" and
"PTO Engine RPM Set Speed Input B"
on ET
D. View the switch status on ET.
E. If the "PTO Engine RPM Set Speed Input

A" status indicates "Not Installed", then the
parameter has not been programmed. If the
"PTO Engine RPM Set Speed Input B" status
indicates "Not Installed", then the parameter has
not been programmed.
Expected Result:
The status screen should indicate "ON" if the switch

is turned on. The status screen should indicate
"OFF" if the switch is off.
Results:

resolved. STOP.

323

the E C M
Input 16
t3OOOOOOOdi~O0000 1
2 3 0 0 0 0 0 o..~_Q~ 0 O 0 014
s~O000 / ~ l 000024
~90 0 0 0 O 0 00~2
470 9 0 0 0 0 0 040
Input 1~7
OOOO o 0000048
Input 12
00 0 0 O0 0 O0 0~0 I~"s~
Input |5
A. Turn the ignition key switch to the OFF position. 3. If the problem is resolved with the test ECM,
B, Install a 70 terminal breakout T to the ECM
vehicle harness connector J1/P1. 4. If the problem returns with the suspect ECM,
replace the ECM.
C. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wire. STOR
D. Insert the jumper wire into the suspect switch Test Step 4. Insert a Jumper Wire at the
socket of the breakout T. Connect the other Switch
end of the jumper wire to terminal 5 (AP
Sensor/Switch Common) in the breakout T. A. Turn the ignition key switch to the OFF position.
E, Connect ET to the cab data link connector. B, Reconnect the ECM vehicle harness connector
J1/P1.
F. Turn the ignition key switch to the ON position.
C, Fabricate a jumper wire 100 mm (4 inch) long.
G. Alternately remove the jumper wire and then Crimp a Deutsch pin to both ends of the wire.
insert the jumper wire from terminal 5. At the
same time, monitor the status screen on ET. D, Insert the jumper wire between the two switch
terminals.
Expected Result:
The switch status changes to "ON" with the jumper
wire in place. The switch status changes to "OFF" F. Alternately remove the jumper wire and then
when the jumper wire is removed. insert the jumper wire at the switch terminals. At
the same time, watch the status screen on ET.
Results:
Expected Result:
• OK - The ECM is functioning properly at this
time. Proceed to Test Step 4. The switch status changes to "ON" with the jumper
wire in place. The switch status changes to "OFF"
• Not OK - The ECM is not functioning properly. when the jumper wire is removed.
Repair: Perform the following repair: Results:

1. Temporarily connect a test ECM. Only connect • OK
ECM harness J1/P1.
2. Recheck for an +5 V diagnostic code when procedure:
the engine harness is disconnected.
324
Replace the switch. Verify that the repair i01903372

eliminates the problem.
P T O S h u t d o w n T i m e r - Test
STOR
SMCS Code: 1901-038
• Not OK - There is a problem in the wire harness
between the switch and the ECM Proceed to Test System Operation Description:
Step 5.
Bulkhead Connector Use this procedure to determine if the PTO
Shutdown is operating correctly.
A. Turn the ignition key switch to the OFF position.
B. Fabricate a jumper wire 100 mm (4 inch) long. to this procedure:
PTO Shutdown Timer
C. Locate the suspect switch socket in the engine
side of the ECM bulkhead connector. A programmable parameter for the PTO Shutdown
Timer is provided. This timer will shut down the
D. Insert the wire jumper pin between the switch engine when all of the following conditions are met:
socket and the sensor common connection.
Install the jumper wire on the engine side of the • The PTO shutdown time that is programmed has
ECM bulkhead connector. expired.
E. Turn the ignition key switch to the ON position. • The ECM is programmed to use "Dedicated PTO"
parameters.
F. Alternately connect and then disconnect the
jumper wire. At the same time, monitor the status • The PTO on/off switch is ON and the ECM is in
screen on ET. the dedicated PTO mode.
Expected Result: • The engine is not in the Cold Mode.
The switch status changes from "ON" with the During the last 90 seconds of the PTO Shutdown
jumper wire in place. The switch status changes to Timer, the check engine lamp will begin flashing. If
"OFF" when the jumper wire is removed. the vehicle is equipped with a PTO switch on lamp,
the PTO switch on lamp will begin flashing during
Results: the last 90 seconds.
• OK - The problem is in the vehicle wiring If the PTO shutdown timer is activated and the timer
between the bulkhead connector and the switch. stops the engine, the following event code will be
Inspect the vehicle wiring and then repair the generated.
vehicle wiring. Otherwise, send the vehicle to
the OEM dealer for repair. Verify that the original • 71-14 PTO Shutdown (47)
condition is resolved. STOR
Note: Fuel rates are not monitored while the PTO
• Not OK - The problem is in the vehicle wiring shutdown timer is active. Shutdown will occur
between the bulkhead connector and the ECM. regardless of load. Unlike the idle shutdown timer,
Inspect the vehicle wiring and then repair the the PTO shutdown timer cannot be overridden by
vehicle wiring. Otherwise, send the vehicle to using the clutch pedal or the brake pedal.
the OEM dealer for repair. Verify that the original
condition is resolved. STOR Test Step 1. Verify Activation of the PTO
Shutdown Timer
link connector.
B. Access the Customer Parameters on the

electronic service tool. Access the following
display screens in order:
325
• "Service" • "Configuration"
• "Configuration" b. Record the programmed PTO shutdown time.

The PTO shutdown time must be between 3
a. Record the programmed PTO shutdown time. and 1440 minutes. If the PTO shutdown time
The PTO shutdown Time must be between 3 is programmed to 0, the timer is disabled.
and 1440 minutes. If the PTO shutdown time
is programmed to 0, the timer is disabled. c. Reprogram the PTO shutdown time to 3
minutes for this test.
C. Start the engine. Allow the engine to warm up
until the coolant temperature is 38 °C (100 °F). C, Observe the following items during the 90 second
Allow the engine to operate at the programmed period before the programmed shutdown time:
low idle and turn off any unnecessary accessory
devices. • Check engine lamp
D. Ensure that all unnecessary loads are turned off. • Status of the PTO shutdown timer
E. Use the following procedure in order to check • PTO switch on lamp

the operation of the PTO shutdown:
During the 90 second period before the
a, Park the vehicle. scheduled shutdown, the status should change
from "COUNTING" to "DRIVER ALERT". The
b. Ensure that the PTO configuration is check engine lamp and the PTO switch on lamp
programmed to "Cab Switches", "Remote should flash rapidly.
Switches" or "Remote Throttle".
Note: A PTO switch on lamp is an optional feature
C, Ensure that the status of the PTO on/off switch and the PTO switch on lamp may not be installed.
is on.
D. Reprogram the PTO shutdown timer to the value
d, Observe the status of the "PTO Shutdown". that was recorded earlier for this test,
Result 1 The status of the parameter for "PTO Result 1 The driver alert function of the PTO
Shutdown" indicates "COUNTING". shutdown operates in the manner that is described
above.
Result 2 The ECM is not reading the proper
conditions for activation of the timer. Result 2 The PTO switch on lamp did not flash.
Results: Result 3 The check engine lamp did not flash.
• Result 1 - T h e ECM is reading the proper Results:

conditions for the activation of the PTO shutdown
timer. Proceed to Test Step 2. Result 1 - T h e PTO shutdown timer is operating
properly. Clear all diagnostic codes. STOR
Result 2 - The PTQ switch on lamp did not flash
Test Step 2. Use the Electronic Service during the driver alert.
Tool to Verify the Driver Alert Function of
the PTO Shutdown Repair: Perform the following diagnostic
procedure: Troubleshooting, "PTO Switch ON
A. Connect the electronic service tool to the data Lamp Circuit - Test"
link connector.
STOR
B. Use the following procedure in order to activate
the PTO shutdown timer: Result 3 - The check engine lamp did not flash
during the driver alert.
a. Access the "Customer Parameters" on the
electronic service tool. Access the following Repair: Perform the following diagnostic
display screens in order: procedure:
• "Service"
326
Troubleshooting, "Check Engine Lamp Circuit- i01877667

Test"
PTO Switch Circuit- Test
STOR
SMCS Code: 7332-038
Test Step 3. Check the State of the
Related Conditions w h e n the Vehicle is System Operation Description:
Parked
A. Check the state of the following related conditions
when the vehicle is parked: Use this procedure to determine that the vehicle
wiring and the ECM are functioning properly for the
a. Ensure that the vehicle speed is 0 km/h features of Dedicated PTO.
(0 mph) on the electronic service tool or the
dash display. The following background information is related
to this procedure:
b. Ensure that the engine is not in cold mode.
INPUT 1
Note: The electronic service tool status screen will
indicate if the cold mode is active. J1/P1:56 Input 1 is used for the circuit for the
PTO on/off switch when the PTO Configuration is
c. Ensure that the PTO on/off switch is on. programmed to "Cab Switches", "Remote Switches",
or "Remote Throttle".
Expected Result:
When the PTO on/off switch is on, the ECM will be
Result I Vehicle speed is not indicated as 0 km/h in Dedicated PTO mode.
(0 mph).
When the ECM is in the Dedicated PTO mode the
Result 2 The electronic service tool status screen PTO Top Engine Limit (TEL) is activated. The engine
indicates that the engine is in the cold mode. may proceed directly to the PTO engine rpm set
speed if the parameter is programmed. If a PTO
Result 3 The PTO on/off switch is not on. switch on lamp is connected to the J1/P1:30 Output
1, the PTO switch on lamp will turn on whenever the
Results: PTO on/off circuit is on.
• Result 1 - Continue by testing the vehicle speed If the problem is with undetermined PTO kickouts,
circuit. use the following procedure:
Repair: Perform the following diagnostic Operate the vehicle in PTO mode.
procedure: Troubleshooting, "Vehicle Speed
Circuit - Test" After the kickout, review the status parameter
onthe electronic service tool. The status parameter
STOR indicates the cause of the kickout. This must be
performed before the ignition key switch is turned
• Result 2 - T h e engine must not be in cold mode off. It is important to remember that the parameter
operation while this test procedure is being will only indicate the last kickout since the ECM has
performed. Allow the engine to run until the been powered by the ignition key switch.
coolant temperature exceeds 38 °C (100 °F).
Troubleshoot and repair any related conditions. This parameter is blank when the ECM is first
STOR powered up. If this parameter is blank "Not Kicked
Out" is indicated. This parameter remains blank
• Result 3 - Continue by testing the circuit for the until the ECM detects the use of the PTO mode.
PTO on/off switch. Also, this parameter remains blank until the ECM
detects the disengagement of PTO mode. Refer to
Repair: Perform the following diagnostic Table 153 in order to interpret the status parameter.
procedure: Troubleshooting, "PTO Switch Circuit -
Test" The following kickout status parameter is available:
STOP. • PTO kickout

327
PTO interlocks may also be connected in series with • Clutch pedal position switch
the PTO on/off switch. The interlocks are intended
to prevent the PTO on/off circuit from activating • Neutral switch
unless certain conditions are met.
• Accelerator pedal position sensor
INPUT 2
• Cruise control set/resume switch that is located
J1/P1:58 Input 2 is used for the PTO set switch in the cab
when the "PTO Configuration" is programmed to
"Remote Switches" or "Remote Throttle". The PTO A remote accelerator pedal position sensor is
set switch can also be used to increase engine rpm. connected to J1/P1:68 Input 8 when the "PTO
Configuration" is programmed to "Remote Throttle".
INPUT 3
J1/P1:60 Input 3 is used for the PTO resume switch be slightly different. The circuits for the sensor
when the "PTO Configuration" is programmed to common are used interchangeably by the OEM
"Remote Switches" or "Remote Throttle". The PTO of the vehicle. The following circuits are common
resume switch can also be used to decrease engine within the ECM:
rpm.
• J1/P1:18 (sensor common 1)
The PTO Configuration Is Set To Cab Switches.
• J1/P1:3 (sensor common 2)
When the "PTO Configuration" is programmed to
"Cab Switches" and the PTO on/off switch is on, the • J1/P1:5 (AP sensor/switch sensor common)
following circuits can be used to interrupt a set rpm:
• Cruise control set/resume switch
• Service brake pedal position switch 1
• Clutch pedal position switch
• Neutral switch
• Cruise Control Pause Switch

"Cab Switches" and the PTO on/off switch is on, the
accelerator pedal position sensor that is located
in the cab can be limited to one of the following
settings by using the "PTO Cab Throttle RPM Limit"
parameter:
• Low idle
• PTO Top Engine Limit
• Top engine limit
The "PTO Configuration" Is Programmed To

"Remote Switches" or "Remote Throttle".

"Remote Switches" or "Remote Throttle" and the
PTO on/off switch is on, the following circuits are
ignored:

328
Table 153
Table For The PTO Kickout Status Screen On The Electronic Service Tool
Cat ET Meaning or Possible Cause Troubleshooting
Intermittent engine speed signal or lost Refer to Troubleshooting, "Speed/Timing
"No Engine Speed" engine speed signal. Circuit - Test".
The PTO On/Off switch is turned OFF or the Proceed with this test procedure.
"Switch Turned Off"
switch circuit has an open circuit condition.
The cruise control pause switch is Refer to Troubleshooting, "Powertrain Data
"Cruise Control PAUSE
Switch" depressed or there is an illegal message on Link Circuit - Test".
The service brake pedal is depressed or the Refer to Troubleshooting, "Service Brake
"Brake Pedal Depressed" circuit for the service brake switch has an Pedal Position Switch 1 Circuit - Test".
open circuit condition.
The clutch pedal is depressed or the circuit Refer to Troubleshooting, "Clutch Pedal
for the clutch pedal switch has an open Position Switch Circuit - Test".
"Clutch Pedal Depressed" circuit condition. Also, the switch could be
incorrectly adjusted.
The vehicle speed has exceeded the speed Refer to Troubleshooting, "Vehicle Speed
that is programmed into the "PTO Vehicle Circuit - Test" if a problem with the signal
"Vehicle Speed _>Limit"
Speed Limit" parameter or the vehicle exists.
speed signal is erratic or intermittent.
The transmission is not in neutral or the Refer to Troubleshooting, "Neutral Switch
"Neutral" transmission neutral switch circuit has an Circuit - Test".
open circuit condition.
The PTO has not been enabled since the Operate the vehicle in the PTO mode in
"Not Kicked Out"
ECM has been powered up. order to create the problem again.
~ PTO SWITCH ON LAMP

SET/RESUME
(SET OFF POSITION) 11
(RESUME OFF POSITION) ECM
OUTPUT 11
SERVICE BRAKE PEDAL POSITION
EDAL RELEASED POSI TION)

,
]¢ - -
!!!!:-!! SET
RESUME
CLUTCH PEDAL POSITION SWITCH
INPUT |1
"----~C;~(PEDALRELEASEDPOSITION) INPUT SENSOR COMMON ~2
PTO ON/OFF PTO INTERLOCK P1 J1
(PTO OFF POSITION)

Circuit schematic for "Cab Switches" configuration
329
REMOTE PTO SWITCH ON LAMP

SM•ITCH
PTO SET/RESUME
__~(SET OFF POSITION)
(RESUME OFF POSITION) ECM
PTO ON/OFF PTO INTERLOCK

[J _ _ . K998-BU--~--l-~
KgBO-PK-J-<I58~
KgB2-YL--KI60~
993-BR--~1 3~
OUTPUT !1
INPUT J2
INPUT 13
INPUT SENSOR COMMON 12
K999-GN__~ INPUT !1
(PTO OFF POSITION) P1 J1

Circuit schematicfor "Remote Switches"configuration
CAB PTO SWITCH ON L ~ REMOTE PTO SWITCH ON LAMP
PTO SET/RESUME
(SET OFF POSITION)
ECM
PTO INTERLOCK OUTPUT !1
INPUT 12
INPUT |3
INPUT !1
INPUT SENSOR COMMON 12
t INPUT 18
REMOTE PTO ACCELERATORPOSITION SENSOR I/ P1 Jl
~--} --- B'-'--'-'---~T+ER-'~-~+
R D ~ I
I I INPUT SENSOR COMMON t21-BK--~IB<--I - - I
U ACCELERATORPOSITIONF WH--~l C < - } ~

Circuit schematicfor "RemoteThrottle" configuration
Test Step 1. Use the Electronic Service Expected Result:

Tool to Check the Programming of the
Parameter "DedicatedPTO Parameters" The "PTO Configuration" is programmed to "Cab
Switches", "Remote Switches", or "Remote Throttle".
link connector. Results:
B. Turn the ignition key switch to the ON position. • Yes - Proceed to Test Step 2.
C. Access the "Dedicated PTO Parameters" on the • No - T h e Dedicated PTO features are not
electronic service tool. Note the programming of programmed for this engine. If PTO operation
the parameter "PTO Configuration". is desired, the "PTO Configuration" must be
programmed to "Cab Switches", "Remote
Switches", or "Remote Throttle". STOR
330
Test Step 2. Determine the Truck OEM

Wiring Installation of the PTO
A, From the programming of the parameter for the
"PTO Configuration", review the truck wiring in
order to determine the method of installation of
the wiring. Talk to the driver about the use of the
PTO.
B, Check the cab glove box for any information

regarding the installation of the PTO. It is
important to understand the location and the
function of the interlock switches for the PTO.
C. Contact the installer of the components that are

used for the PTO, if necessary.
D, Determine the schematic that most closely

matches the installation. Review the schematics
in this procedure for each of the options for the
specific "PTO Configuration "of the truck.
E. Record the "PTO Configuration".
Expected Result:
The requirements for the installation and the
application have been reviewed.
Results:
331

and Wiring
rb,oooooooooo ,.,0,
1123ooooo o ooooo1411 II ......
113'o ~ ~ ~ uu,ru, ~1 (PTO SWITCH ON LAMP)
11 9o o o o lit • )11 o o o o3211 II

]1470 0 0 INPUT #1 (PTO ON/OFF SWITCH)
I IS70 0 " 0 0 0 o 0 0 0 ~ INPUT |3 (REMOTE PTO RESUME SWITCH)
~ 700 0 ~ 0 0 0 0 0 0 ~'0 ~ INPUT

INPUT
~2 (REMOTE PTO SET SWITCH)
i~8 (REMOTE PTO ACCELERATOR)

1 2 3 4 5 6 n 8 9 10 11 12 13~"k
INPUT SENSOR COMMON|2
o booooooooQ 1
OOOO ~ 00000231 OUTPUT ~1 (PTO SWITCH ON LAMP)
-1240000 f~-'-,, OOe'03~ I
d,0ooRR .' C.RRo_,R,o.,,,

I II ' 80,@',---"-.-,"----' 'J~,,~'"l
INPUT
INPUT
l1
|3
(PTO ON/OFF SWITCH)
(REMOTE PTO RESUME SWITCH)
INPUT ~2 (REMOTE PTO SET SWITCH)
INPUT ~8 (REMOTE PTO ACCELERATOR)
Harness Side
A. Thoroughly inspect ECM connector J1/P1, Refer to Illustration 153.

the firewall bulkhead connectors, and any
connectors that are used by the PTO. C. Check the ECM connector (allen head screw) for
the proper torque of 6.0 n.m (55 Ib in).
- Inspect" for details. D. Check the harness and wiring for abrasion and
wires in the ECM connector that are associated E x p e c t e d Result:
with the connections for the PTO. The following
connections should be tested if the connections All connectors, pins and sockets should be
are used: completely coupled and/or inserted and the harness
• P1/J1:3 or pinch points.
• P1/J1:5 Results:
• P1/J1:30 • OK - Proceed to Test Step 4.
• P1/J1:35 • Not OK
• P1/J1:44 Repair: Perform the following diagnostic

procedure:
• P1/J1:56
Repair the connectors or wiring and/or replace
• P1/J1:58 the connectors or wiring. Ensure that all of the
• P1/JI:60 connectors are completely coupled.
• P1/J1:68
332
Verify that the repair eliminates the problem. Test Step 5. Use the electronic service
tool to Check the Status of the
STOR Set/Resume Input
Test Step 4. Use the Electronic Service Note: The set/resume input increases the engine
Tool to Check the Circuit for the PTO rpm and the set/resume input decreases the engine
On/Off Switch rpm.
A. Turn the ignition key switch to the ON position. A. Find the PTO set switch. If the "PTO
Configuration" is programmed to "Cab Switches",
B. For the input 1 (PTO on/off switch), access the the cruise control set/resume switch will be
electronic service tool status screens that display used. If the "PTO Configuration" is programmed
the following status parameters: to "Remote Switches" or "Remote Throttle", a
dedicated PTO set switch will be used.
• "PTO Config"
The "PTO Configuration" is programmed to
• "PTO On/Off Switch" "Cab Switches".
C. Verify that each of the interlocks for the PTO are Look at the status for the "Cruise Control
set. Then, while the electronic service tool status Set/Resume Switch" parameter on the electronic
screen is being monitored move the PTO on/off service tool. The parameter is located on the
switch to the ON position and move the PTQ same status screen as the idle switch.
on/off switch to the OFF position.
B. Monitor the status screen of the electronic service
An example of an interlock for the PTO would be tool. Perform the following procedure in order:
a parking brake that is intended to allow the PTO
to control the engine under specific conditions. Put the cruise control set/resume switch in the
Set position.
Expected Result:
Release the cruise control set/resume switch
Result I The status of the PTO on/off switch on the from the Set position.
electronic service tool changes from "OFF" to "ON"
when the PTO on/off switch is turned to the OFF Put the cruise control set/resume switch in the
position and the ON position, but the set/resume Resume position.
switch is not operating correctly.
Release the cruise control set/resume switch
Result 2 The status of the PTO on/off switch on the from the Resume position.
electronic service tool changes from "OFF" to "ON"
when the PTO on/off switch is turned to the OFF The "PTO Configuration" is programmed to
position and the ON position. However, the remote "Remote Switches" or "Remote Throttle".
accelerator is not operating correctly.
View the status parameter on the electronic
Result 3 The status of the PTO on/off switch on the service tool for the "Remote PTO Set Switch" and
electronic service tool does not change from "OFF" the "Remote PTO Resume Switch".
to "ON" when the PTO on/off switch is turned to the
OFF position and the ON position. C. While the status screen of the electronic service
tool for the switch is being monitored, perform
Results: the following procedure in order:
• Result 1 - Proceed to Test Step 5. • Put the remote PTO set/resume switch in the
Set position.
• Result 2
• Release the remote PTO set/resume switch
Repair: Perform the following diagnostic from the Set position.
procedure: Troubleshooting, "Remote PTO
Accelerator Position Sensor Circuit - Test" • Put the remote PTO set/resume switch in the
Resume position.
STOP.
• Release the remote PTO set/resume switch
• Result 3 - Proceed to Test Step 6. from the Resume position.
333
Expected Result: Test Step 6. Use the Electronic Service

Tool to Check the Status of the PTO
When the "PTO Configuration" is programmed to On/Off Switch
"Cab Switches", the status parameter for the cruise
control set/resume switch onthe electronic service Input Sensor Common ~2
tool behaves in the following manner:
• The status of the cruise control set/resume switch

,,\\
will display "OFF" when the set switch is released. o o o o o o o o
i~ooooo o ooooo141111
changes from "OFF" to set switch "ON" when the
1310000 0000241111
switch is moved to the SET position.
I oooo IIt JII °ooo3:111/
i,Toooo L~--,~-p 0o0o401111
changes from set switch "ON" to resume switch
Ill
"ON" when the resume switch is moved to the
RESUME position.
Input ~1 (PTO On/Off Switch)
"Remote Switches" or "Remote Throttle", the status
parameter for the remote PTO set switch behaves
in the following manner:
• The status screen for the remote PTO set switch Illustration 154 g00768799
displays "OFF" when the remote PTO set switch
ECM breakout T-connector
is released.
• The status of the remote PTO resume switch
displays "OFF" when the remote PTO resume
switch is released.
• The status of the remote PTO set switch changes
C. Disconnect vehicle harness connector P1 from
from "OFF" to set switch "ON" when the remote
the ECM.
PTO set switch is moved to the SET position.
• The status of the remote PTO resume switch D. Connect a breakout T to ECM connector J1 and
connect P1 to the breakout T.
changes from "OFF" to resume switch "ON" when
the remote PTO resume switch is moved to the
E. Connect the electronic service tool to the data
RESUME position.
link connector.
Results:
• Yes - T h e set circuit and the resume circuit are
functioning correctly. The inputs for the PTO are G. Access the "PTO On/Off Switch" status on Cat
functioning properly. Continue troubleshooting if ET.
the original condition is not resolved. STOP.
H. While the switch status is being observed on the
• No (programmed to "Cab Switches") - The "PTO electronic service tool, install the jumper into
Configuration" is programmed to "Cab Switches". the breakout T between J1/P1:56 (input 1) and
J1/P1:3 (input sensor common 2).
• No (programmed to "Remote Switches" or The input 1 is the PTO on/off switch.

"Remote Throttle") - The "PTO Configuration" is
programmed to "Remote Switches" or "Remote Refer to Illustration 154.
Throttle". Proceed to Test Step 8.
Expected Result:
The switch status of the "PTO On/Off Switch" onthe
electronic service tool behaves in the following
manner:
334
• The switch status changes from "OFF" to "ON" Test Step 7. Use the Electronic Service
when the jumper is in place. Tool to Check the Status of the Cruise
Control Set/Resume Switch
• The switch status is "OFF" when the jumper is
removed.
AP Sensor/Switch Sensor C o ~
Results:
• Yes - T h e input 1 (PTO on/off switch) of the ECM
is functioning correctly. The problem is in the 0000 0000"~1
switches of the vehicle or the problem is in the 12..s0 0 0 0 0 0 0000014
wiring of the vehicle. I~0000 ~ 000024
I IIt _PJil ooo32
Repair: Inspect the wiring. Select one of the I,,-,ooo qooo40
following options: i :,ooyoo o 00\00048
[7oO C/O O O O O O O O\O O 058
• Repair the wiring or replace the wiring.
• Send the vehicle to the OEM dealer for repair.
Verify that the repair eliminates the problem. Cruise Control Resume Cruise Control Set
STOR
• No - T h e ECM is not reading the switch status Illustration 155

g00768798
change.

procedure: A. Turn the ignition key switch to the OFF position.
1, Temporarily connect a test ECM. B, Fabricate a jumper wire 100 mm (4 inch) long.
2, Ensure that the "PTO Configuration" of the test
ECM matches the "PTO Configuration" of the C, Disconnect vehicle harness connector P1 from
the ECM.
suspect ECM.
3, Remove all jumpers and replace all connectors. B, Connect a breakout T to ECM connector J1 and
connect P1 to the breakout T.
4, Recheck the system for active diagnostic
E, Connect the electronic service tool to the data
codes.
link connector.
5, Repeat the test step.
F, Turn the ignition key switch to the ON position,
6, If the problem is resolved with the test ECM, while the engine is off.
G. Access the status of the cruise control set/resume
7, If the problem returns with the suspect ECM, switch on the electronic service tool.
replace the ECM.
H. While the switch status is being observed on the
8. Verify that the repair eliminates the problem. electronic service tool, install the jumper into the
breakout T in order to connect P1/J1:35 (Set)
STOR to P1/Jl:5 (AP sensor/switch sensor common).
Also, while the switch status is being observed
on the electronic service tool remove the jumper
from the breakout T in order to disconnect
P1/J1:35 (Set) fromP1/Jl:5 (AP sensor/switch
sensor common).
335
I. While the switch status is being observed on the 3. Remove all jumpers and replace all connectors.
electronic service tool, install the jumper into
the breakout T. This connects P1/J1:44 (resume) 4. Recheck the system for active diagnostic
to P1/J1:5 (AP sensor/switch sensor common). codes.
Also, while the switch status is being observed
on the electronic service tool, remove the jumper 5. Repeat the test step.
from the breakout T. This will disconnect P1/J1:44
(resume) from P1/1:5 (AP sensor/switch sensor 6. If the problem is resolved with the test ECM,
common). reconnect the suspect ECM.
Refer to Illustration 155. 7. If the problem returns with the suspect ECM,
replace the ECM.
Expected Result:
The switch status of the cruise control set/resume
switch onthe electronic service tool behaves in the STOR
following manner:
Test Step 8. Use the Electronic Service
• The switch status of the cruise control set/resume Tool to Check the Status of the Remote
switch changes from "OFF" to set switch "ON" PTO Set Switch and the Remote PTO
when the jumper is connected from P1/J1:35 (Set) Resume Switch
to P1/J1:5 (AP sensor/switch sensor common).
Input Sensor Common#2
• The switch status of the cruise control set/resume
switch is "OFF" when the jumper is removed. -
• The switch status of the cruise control set/resume 00000 000 • 0 0 1

switch changes from "OFF" to resume switch 2300000 O 0000014
"ON" when the jumper is connected from s~O000 ~ 000024
P1/J1:44 (switch resume terminal) to J1/P1:5 (AP s90000 0 00032
sensor/switch sensor common). 470 0 0 0 0 0 0 040
sTO 0 0 0 0 o 0 0 0 0 048
Results:
7oQ 0 Q 0 0 , 0 0 Qr_O00 0 0 5a
• Yes - T h e input for the set switch and the input
\
for the resume switch of the ECM are functioning
correctly. The problem is in the switches of the
vehicle or the problem is in the wiring of the
vehicle. Input j13 (Remote PTO Resume) /
/
Repair: Inspect the wiring. Select one of the
following options: Input #2 (Remote PTO Set)
• Repair the wiring or replace the wiring.
STOR Crimp a Deutsch pin to both ends of the wire.
• No - T h e ECM is not reading the switch status C. Disconnect vehicle harness connector P1 from
change. the ECM.
Repair: Perform the following diagnostic D. Connect a breakout T to ECM connector J1 and
procedure: connect P1 to the breakout T.
1, Temporarily connect a test ECM. E. Connect the electronic service tool to the data
link connector.
ECM matches the "PTO Configuration" of the F. Turn the ignition key switch to the ON position.
suspect ECM.
336
G. Access the "Remote PTO Set Switch" and Results:

"Remote PTO Resume Switch" status on the
electronic service tool. • Yes - I n p u t 2 ("Remote PTO Set Switch") and
input 3 ("Remote PTO Resume Switch") of the
H. While the status of the "Remote PTO Set Switch" ECM are functioning correctly. The problem is in
is being observed on the electronic service tool, the switches of the vehicle or the problem is in
install the jumper into the breakout T in order the wiring of the vehicle.
to connect J1/P1:58 (Input 2) to J1/P1:3 (Input
sensor common 2). Also, while the switch status Repair: Inspect the wiring. Select one of the
is being observed on the electronic service tool following options:
remove the jumper from the breakout T in order
to disconnect J1/P1:58 (Input 2) from J1/P1:3 • Repair the wiring or replace the wiring.
(Input sensor common 2).
While the status of the "Remote PTO Resume
Switch" is being observed on the electronic Verify that the repair eliminates the problem.
service tool, install the jumper into the breakout
T in order to connect J1/P1:60 (Input 3) to STOP.
J1/P1:3 (Input sensor common 2). Also, while the
switch status is being observed on the electronic • No - T h e ECM is not reading the switch status
service tool remove the jumper from the breakout change.
T in order to disconnect J1/P1:60 (Input 3) from
J1/P1:3 (Input sensor common 2). Repair: Perform the following diagnostic
procedure:
The J1/1:58 Input 2 is the set switch for the PTO
and the J1/P1:60 Input 3 is the resume switch 1, Temporarily connect a test ECM.
for the PTO.
Refer to Illustration 156. ECM matches the "PTO Configuration" of the
suspect ECM
Expected Result:
3, Remove all jumpers and replace all connectors.
The switch status of the "Remote PTO Set Switch"
onthe electronic service tool behaves in the 4. Recheck the system for Active diagnostic
following manner: codes.
• The switch status of the "Remote PTO Set Switch" 5, Repeat the test step.
is "OFF" when the jumper is removed.
• The switch status of the "Remote PTO Set Switch" reconnect the suspect ECM.
changes from "OFF" to set switch "ON" when the
jumper is connected from J1/P1:58 (Input 2) to 7. If the problem returns with the suspect ECM,
J1/P1:3 (Input Sensor Common 2). replace the ECM.
The switch status of the "Remote PTO Resume 8. Verify that the repair eliminates the problem.
Switch" on the electronic service tool behaves in
the following manner: STOR
• The switch status of the "Remote PTO Resume

i01864922
Switch" is "OFF" when the jumper is removed.
• The switch status of the "Remote PTO Resume

PTO Switch ON Lamp Circuit
Switch" changes from "OFF" to resume switch - Test
"ON" when the jumper is connected from J1/P1:60
(Input 3) to J1/P1:3 (Input sensor common 2). SMCS Code: 7431-038

337
Use the following information in order to determine

if the PTO Switch On Lamp is operating incorrectly.
Terminal 30 (Output 1)
With software that is older than OCT99, J1:30

(Output 1) is dedicated for use as a PTO Switch
ON Lamp Output. If the "PTO Configuration" is
programmed to Cab switches, Remote Switches, or
Remote Throttle, the Output will turn the lamp ON
whenever the PTO Switch Circuit is turned ON.
With OCT99 and newer software, J1:30 (Output

1) can be used as an output for the PTO Switch
ON Lamp or as an output for the Low Coolant
Level Warning Lamp. The parameters should
be programmed to match the desired usage of
the terminal. If the "Engine Monitoring Lamps"
parameter is programmed to Warning Lamp, then
output 1 is used for the PTO Switch ON Lamp.
programmed to Option 1 and the "Coolant Level
Lamp" parameter is programmed to "4-Pin" or "2
wire Float Sensor", then output 1 is used for the low
coolant level warning.
Note: The "PTO Configuration" must be programmed

to Cab Switches, Remote Switches, or Remote
Throttle to utilize the PTO Switch ON Lamp. Option
1 is not available for the GM truck manufacturer.
Electrical Connection of Lamps
One terminal of the lamp must be connected to

battery voltage through the vehicle wiring. The
other terminal is connected to the ECM at terminal
J1/P1:30.
The ECM provides a path to ground in order to turn

on the lamp.
r-i FI
- - K998-BU ~--~Output 1
P! J1
PTO SWITCH ON LAMP
Circuit schematic for PTO Switch On Lamp
If terminal 30 is used for another function, a lamp

may be wired to a multiple pole PTO On/Off switch.
338
PTO ON/OFF P1 J1 ECM

(PTO OFF POSITION) PTO INTERLOCK 993-BR~-]-~INPUT
SENSOR COMMON #2
171 ~ \1 INPUT
K999-GN~_~ #I
PTO SWITCH ON LAMP

E
- 12
Illustration 158
900834964
Optional circuit for PTO Switch On Lamp
~0000000000000,~)
0000 o 00000~, I
Illi;o o oooo,,,
oooo;:,1
II l i 7 0 0 0 0 I,l~.JJ 0000401 OUTPUT ~11 (PTO SWITCH ON LAMP)
II 1~,~6oooo ~'~------"~o o o o o,,'el
[/~°° °° °° °b°°°°°6~/
ECM Side
1 2 3 4 5 6 ~8 9 10 I1 12 13~
OUTPUT ~1 (PTO SWITCH ON LAMP)
~858 51) 60 61 62 63 r-I 65 66 67 66 69 70~

II II
Harness Side
illustration 159
g00668646
Test Step 1. Inspect Electrical Connectors (3. Check the ECM connector (allen head screw) for
and Wiring the proper torque of 6.0 N.m (55 Ib in).
Ao Thoroughly inspect ECM connector J1/P1, the D. Check the harness and wiring for abrasion and
firewall bulkhead connector, or the PTO Switch pinch points from the battery to the ECM.
On Lamp. Refer to Troubleshooting, "Electrical
Connectors -Inspect" for details. Expected Result:
B. Perform a 45 N (10 Ib) pull test on each of the All connectors, pins and sockets should be
wires in the ECM Connector that are associated completely coupled and/or inserted and the harness
with the PTO Switch On Lamp. and wiring should be free of corrosion, abrasion
or pinch points.
339
Results:
• Not OK

STOR
Test Step 2. Check for Normal Operation

of the PTO Switch On Lamp
A. Use the following procedure for the output 1
(PTO Switch On Lamp).
Connect the electronic service tool to the data

link connector. Access the status screen that
displays the "PTO Configuration" and the PTO
On/Off Switch. The "PTO Configuration" must
indicate "Cab Switches", "Remote Switches", or
"Remote Throttle". The "PTO Configuration" is
not programmed to turn on the PTO Switch On
Lamp if the "PTO Configuration" parameter is
programmed to "OFF".
While the PTO Switch On Lamp and the status

of PTO On/Off Switch is being monitored on
the electronic service tool, turn the PTO On/Off
Switch to the ON position and the OFF position.
The PTO Switch On Lamp should turn on when
the PTO On/Off Switch is in the ON position. Also,
the PTO Switch On Lamp should turn off when
the PTO On/Off switch is in the OFF position.
Expected Result:
The lamp turns on and the lamp turns off per the
above description.
Results:
• Yes - T h e lamp appears to operating correctly
at this time. STOR
• No - Proceed to Test Step 3.

340
Test Step 3. Test the Circuit for the PTO

Switch On Lamp
UNSWlTCHED +BATTERY
13 Op? ON ~ 0 0 0 0 0 0 1
2~ o ~) (~o o ~ o o o o o ~4
f b,.o 0002
oo\cx III, I ,,900 2
o 00,o.040
57 0 0 • 0 0 ~ o • 0 0 0"0 48
7o 0 0 0 0 0 ~ " ~ L ~ 0 0 0 0 0 58
\%, !I / / . . f - \. ,j
ECM Side \ OUTPUT #1
-BATTERY (PTO SWITCH ON LAMP)
ECM connectorP1
A. Disconnect ECM connector J1/PI. Result 3 The lamp will stay on while the ECM
connector is disconnected.
Crimp a Deutsch pin to both ends of the wire. Results:
C. Insert the jumper into P1:30 output 1. Result 1 - T h e circuit for the PTO Switch On
Lamp is functioning properly. Proceed to Test
D. Connect the other end of the jumper wire to one Step 4.
of the following terminal connections:.
Result 2 - The lamp did not turn on. The vehicle's
• P1:63 -battery lamp circuit is not functioning properly. The lamp
is probably burned out or there is a problem in
• P1:65 -battery the wiring from the cab to either the ECM or the
+Battery connection. Repair the lamp circuit or
• P1/67-battery send the vehicle to the OEM dealer for repairs.
STOP.
• P1:69 -battery
• Result 3
F. While the lamp is being watched, insert the procedure:
Refer to Illustration 160. shorted to chassis ground. Repair the circuit or
Expected Result:
STOR
Result I The PTO Switch On Lamp turns on while
the jumper is connected to both sockets. Also, the Test Step 4. Use the Special Test "PTO
PTO Switch On Lamp turns off when the jumper is Switch On Lamp" onthe Electronic
removed from one of the sockets.
Result 2 The suspect lamp does not turn on while

the jumper is connected to both sockets.
341
Service Tool to Check the Operation of

the ECM
UNSWITCHED +BATTERY
\\ ",q L~
o o o o
o atc 0~___~0 0 0 0 0 14
131o o,@\ ([-~]X~O 0 0 0 24
00032
I,, oo c
I OOOC
17o 0 0 0/~ o o o o
/ / \ ,J
ECM Side ~ " J

OUTPUT
-BATTERY (PTO SWITCH O~N
1 LAMP)

A. Disconnect ECM connector J1/P1. • "Diagnostic Test"
B. Insert a breakout T between ECM connector J1 • "Special Test"

and ECM connector P1.
H. Activate the special test for the PTO Switch On
C. Connect one probe of the voltage test lamp to Lamp. Observe the voltage test lamp. The lamp
terminal 63 (-battery). Connect the other probe of should turn on when the test is active. Also, the
the voltage test lamp to terminal 48 (unswitched lamp should turn off when the test is inactive,
+battery) of the breakout T.
Note: Perform the same test procedure with
D. The test lamp should turn on. If the test lamp terminals P1:52, P1:53, and P1:55 unswitched +batt.
the wiring to the ECM is faulty. Continue with this Expected Result:
step if the lamp turns ON.
The test lamp turns on and the test lamp turns off
Note: Use the same procedure to check the per the above description.
following:
Results:
• P1:65 and P1:52
• Yes - T h e ECM is operating correctly. There is a
• P1:67 and P1:53 problem in the vehicle wiring or the lamp. STOR
• P1:69 and P1:55 • No
E. Leave the probe of the test lamp connected to Repair: Temporarily connect a test ECM. Ensure
terminal 48 (unswitched +battery). that the "PTO Configuration" of the test ECM
matches the "PTO Configuration" of the suspect
F. Connect the other probe of the test lamp to ECM. Check the ECM output for the PTO Switch
terminal 30 (Output 1) of the breakout T. On Lamp when the test ECM is installed. If the
problem is resolved with the test ECM, reconnect
Refer to Illustration 161. the suspect ECM. If the problem returns with
the suspect ECM, replace the ECM. Refer to
G. Connect the electronic service tool. Access the Troubleshooting, "Replacing the ECM".
following display screens in order:
STOP.
• "Diagnostics"
342
i01901604 The accelerator position sensor will produce a

duty cycle of 10 to 22 percent at low idle and 75
Remote PTO Accelerator to 90 percent when the accelerator pedal is fully
Position Sensor Circuit- Test depressed. The percent of duty cycle is translated
in the ECM into an accelerator pedal position of 3
SMCS Code: 1913-038 to 100 percent.
System Operation Description: The accelerator position sensor can be replaced

separately from the pedal assembly. An incorrectly
Use this procedure under the following situation: calibrated pedal assembly can not be adjusted.
The entire pedal assembly must be replaced.
Use this procedure if any of the following diagnostic
codes are indicated: If the vehicle is using the ECM dedicated PTO
functions, the accelerator position sensor will be
• 30-08 PTO Throttle Signal Invalid (29) ignored while the engine is in "PTO Mode" and the
"PTO Configuration" is programmed to the following
• 30-13 PTO Throttle Out Of Calibration (29) setting:
Also, use this procedure if the remote accelerator • "Remote Throttle"

position sensor is suspected of improper operation.
The ECM is in "PTO Mode" if the PTO On/Off Switch
Remote Accelerator Position Sensor is on. This can be checked through the status
screen on the electronic service tool.
A remote accelerator position sensor may be used
for PTO purposes. The remote accelerator position The ECM will not respond to the remote accelerator
sensor should be connected to J1/P1:68. Before position sensor when both of the following
the ECM will respond to the remote accelerator conditions are met:
position sensor, the ECM "PTO Configuration" must
be programmed to "Remote Throttle", and the "PTO • The PTO On/Off circuit is switched from the OFF
On/Off Switch" must be in the ON position. Also, position to the ON position.
Caterpillar offers the following recommendation:
• The ECM reads the remote accelerator position
• The remote accelerator position sensor must be sensor above low idle.
powered from the vehicle battery (+12 V).
This prevents the engine from experiencing
Therefore, the +12 V version of the accelerator unexpected acceleration or sudden acceleration
position sensor must be used for the remote when the PTO On/Off circuit is turned on. The
accelerator position sensor, and the +8 V version remote accelerator position sensor must return to
for the accelerator pedal position sensor in the cab. low idle before the ECM will respond. The ECM must
also see a transition from the OFF position to the ON
The ECM will not respond to the remote accelerator position in the PTO On/Off Switch in order to allow
position sensor if 253-02 Check Customer or System the other PTO speed control functions to operate. If
Parameters (56) is active under some conditions. the engine is started with the PTO On/Off Switch in
Refer to Troubleshooting, "ECM Memory - Test" if the ON position, the accelerator will respond. The
253-02 Check Customer or System Parameters (56) response will occur only if the accelerator pedal
is active. is first returned to the low idle position. The other
speed control functions will not respond.
The remote accelerator position sensor is used to
provide a throttle position signal to the 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 position sensor in the cab is

attached directly to the accelerator pedal assembly
and the sensor requires no adjustment.
343
REMOTE ACCELERATORPOSITION SENSOR WITH SET AND RESUME
CAB PTO SWITCH I ~ REMOTEPTO

PTO SET/RESUME ON LAMP _c~ ~ SWITCH ON LAMP
~R
(SET OFF POSITION)
ESUME OFF POSITION'
ECM
OFF PTO INTERLOCK
K998-BU--~ OUTPUT i1
K980-PK--V<I58<-fl INPUT ~2
--K982-YL--t<I60<-fl INPUT ~3
POSITION)
- INPUT SENSOR COMMON~2
G845-PU~ INPUT |8
ACCELERATOR POSITION SENSOR

+BATTERY~'--BK~B-<
INPUT SENSORCOMMON~2~RD---~<A<
ACCELERATOR POSITION~--WH~
J403 P403
REMOTE ACCELERATORPOSITION SENSOR WITHOUT SET AND RESUME
S W I T C H Ir---o~--p
~I REMOTEPTO
CABoNPTOLAMP(~:~j I SWITCH ON LAMP
PTO ON/OFF PTO INTERLOCK I ECM

--K998-BU--~[30~ OUTPUT ~1
K999-GN--~<I56< INPUT ~1
993-BR~J3< INPUT SENSOR COMMON~2
G845-PU--~_J._68.~ INPUT ~8
P1 J1
ACCELERATOR POSITION SENSOR
~1 +BATTERY~-BK-- B,~
INPUT SENSOR COMMON~2 ~RD-- A,~
ACCELERATOR POSITION~--W:: C<
J403 P403
Schematicfor remoteacceleratorpedal position sensor
344
/•,•o o o o o o o o e~o e ~
II I'i'sO 0 0 0 0 O0000t~
o[ /
IIIkoooo ~ oooo~,,I
II I ago 0 0 0 Ir/_'~ll 0 0 0 032
II I M O 0 0 IL°)II 00004'01
IIII II'I~70
7 oooo ~ o o- o o o o . ,'8'! INPUT 18 (PTO ACCELERATOR)
nn ~70o o q r o o o o o o o o o os;s/
1 2 5 4 5 G I 18 9 10 11 12 15~__~
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O O Z C C O 65
58 59 60 61 62 63
0 066 ~67O NI
68 69-70J / INPUT ~8 (PTO ACCELERATOR)
~_ II ~ 11
Harness Side

Test Step 1. Inspect Electrical Connectors 15. Check the harness and wiring for abrasion and
and Wiring pinch points from the remote accelerator position
sensor to the ECM.
link connector. Verify that the parameter for Expected Result:
the PTO Configuration is programmed to the
"Remote Throttle". All connectors, pins and sockets should be
B. Thoroughly inspect ECM vehicle harness and wiring should be free of corrosion, abrasion
connector J1/P1, the firewall bulkhead connector or pinch points.
and the connector for the remote accelerator
position sensor. Refer to Troubleshooting, Results:
"Electrical Connectors - Inspect" for details.
C. Perform a 45 N (10 Ib) pull test on each of the
wires in the ECM connector that are associated • Not OK
with the remote accelerator position sensor:
• J1/P1:68 procedure:
D. Check the ECM connector (Allen Head Screw)

345
Repair the connectors or wiring and/or replace Test Step 3. Check the Supply Voltage for
the connectors or wiring. Ensure that all of the the Remote Accelerator Position Sensor
connectors are completely coupled. A. Turn the ignition key switch to the ON position.
Verify that the repair eliminates the problem. B. Measure the voltage at terminal "A" (+12 V) with
reference to terminal "B" (sensor common) at
STOR J406. This connector is for the remote accelerator
position sensor.
Test Step 2. Check for Active Diagnostic
Codes Expected Result:
A. Connect the electronic service tool to the data The measured voltage is between 11.0 VDC and
link connector. 13.5 VDC.
B. Turn the ignition key switch to the ON position. Results:
C. Monitor the active diagnostic code screen on the • OK - T h e voltage is OK. Proceed to Test Step 4.
electronic service tool. Check and record active
diagnostic codes. • Not OK - The vehicle wiring or the battery is
causing the problem. Repair the wiring or the
Note: When the ECM automatically calibrates new battery. Replace the wiring or the battery. Perform
duty cycle values for the low idle throttle position the repair that is necessary. Verify that the repair
and the high idle throttle position the ECM assumes has fixed the problem. STOR
22 percent duty cycle at low idle and 75 percent
duty cycle at high idle. As a result, you may notice Test Step 4. Check the Duty Cycle of
that the PTO throttle position status reaches 100 the Remote Accelerator Pedal Position
percent well before the remote PTO accelerator Sensor
pedal is fully depressed. This is normal. After
some cycling of the accelerator pedal to the high A. Turn the ignition key switch to the ON position.
idle position, the ECM will adjust the calibration
automatically. The ECM will adjust the calibration B. Monitor the duty cycle of the PTO throttle sensor
automatically provided that the high idle stop on the electronic service tool. Access the
position is within the 75 to 90 percent duty cycle following display screen in order:
range, and the low idle is in the 10 to 22 percent
duty cycle range. During normal operation, you • "Service"
may notice that more movement of the remote PTO
accelerator pedal is required for the PTO throttle • "Calibrations"
position status to increase above 3 percent. You
may also observe that the status reaches the 100 • "Monitor Throttle Position Sensor"
percent value prior to the limit of the high idle
position. This is done in order to ensure that the Expected Result:
accelerator reaches these two critical points for
engine operation. The duty cycle is between 10 and 22 percent with
the accelerator pedal assembly in the low idle
Expected Result: position, and the duty cycle is between 75 and 90
percent with the accelerator pedal assembly in the
Result 1 30-08 or 30-13 are active. high idle position.
Result 2 There are no active diagnostic codes Results:

that are related to the accelerator position sensor
circuit at this time, but a problem is suspected with • OK - T h e remote accelerator position sensor is
operation of the remote PTO acelerator position operating correctly. Proceed to Test Step 5.
sensor circuit.
• Not OK - T h e remote accelerator position sensor
Results: circuit is not operating correctly. Proceed to Test
Step 6.

346
Test Step 5. Check the Status of the B. Remove the signal wire for the remote accelerator
Power Train Data Link on the Electronic position sensor (terminal "C") from J406. This is
Service Tool the vehicle harness side of the connector for the
accelerator position sensor.
A, Start the engine. While the status of the PTO
throttle position is being monitored on the C. Install a breakout T with 3 terminals at the
electronic service tool, depress the remote PTO connector J406/P406 for the remote accelerator
accelerator pedal and release the remote PTO position sensor.
accelerator pedal. The throttle position status
and the engine should respond to the change in D. Connect the multimeter probes to terminal "C"
the accelerator pedal position. (Accelerator Pedal Position) and terminal "B"
(Accelerator/Switch Sensor Common) of the
B. Go to the "System Troubleshooting Settings" breakout T.
section of the electronic service tool and turn off
the power train data link. E. While the duty cycle is being monitored on the
multimeter, depress the accelerator pedal and
C. While the status of the PTO throttle position is release the accelerator pedal.
being monitored on the electronic service tool,
depress the accelerator pedal and release the Expected Result:
accelerator pedal. Also depress the accelerator
pedal and release the accelerator pedal while The duty cycle is between 10 and 22 percent with
the engine response is being monitored. the accelerator pedal assembly in the low idle
position, and the duty cycle is between 75 and 90
Expected Result: percent with the accelerator pedal assembly in the
high idle position.
The status of the PTQ throttle position and the
engine should respond to the change in the Results:
accelerator pedal position.
• OK - Reinsert the wire (terminal "C") into the
Result 1 The PTO accelerator is functioning connector for the remote accelerator position
properly. sensor. The sensor is working correctly. Proceed
to Test Step 7.
Result 2 The throttle response is limited by a power
train data link message. • Not OK - Leave the PWM probe connected to the
breakout T. Insert wire C into the connector for the
Results: remote accelerator position sensor. The sensor or
the accelerator pedal assembly is faulty. Proceed
• Result 1 - T h e remote accelerator position sensor to Test Step 8.
is operating correctly. Continue troubleshooting
until the original condition is resolved. STOP. Test Step 7. Check the Duty Cycle of the
Remote Accelerator Position Sensor at
• Result 2 - If the engine responds with the power the ECM
train data link in the OFF position, but not with
the power train data link in the ON position, Note: Performing certain steps within this procedure
a component of the power train data link is requires the use of a multimeter that is capable of
causing the response problem of the remote measuring a PWM duty cycle.
accelerator position sensor. Send the truck to the
vehicle manufacturer in order to repair the faulty A. Turn the ignition key switch to the OFF position.
component of the power train data link. STOR
B. Remove the wire from P1:68 Remote Accelerator
Test Step 6. Check the Duty Cycle of the Position Sensor from ECM connector P1/J1.
Remote Accelerator Position Sensor at
the Sensor C. Connect the multimeter probes between the
removed wire and the ECM sensor common or
Note: Performing certain steps within this procedure ground.
requires the use of a multimeter that is capable of
measuring a PWM duty cycle. D. Turn the ignition key switch to the ON position.

347
E. Use the multimeter in order to display the duty When the sensor is removed from the accelerator
cycle output of the accelerator position sensor. pedal assembly the following diagnostic codes
While the duty cycle output of the remote may be generated:
accelerator position sensor is being monitored on
the multimeter, move the accelerator assembly • 30-13 PTO Throttle Out Of Calibration (29)
from the low idle position to the high idle position.
Record the results. The diagnostic code should disappear when
the sensor is properly assembled back into the
F. Turn the ignition key switch to the OFF position. accelerator pedal assembly.
G. Insert terminal 68 into the ECM vehicle connector

P1/J1 terminal 70.
Expected Result:
The duty cycle is between 10 and 22 percent with
position, and the duty cycle is between 75 and 90
high idle position.
Results:
• OK - A good signal from the remote accelerator
position sensor is reaching the ECM. Verify that
the ECM is receiving the proper battery voltage. If
the ECM is receiving the proper battery voltage,
temporarily connect a test ECM and verify that the
problem is resolved. If the problem disappears
with the test ECM, reconnect the suspect ECM.
If the problem returns with the suspect ECM,
replace the ECM STOR
• Not OK - There is a problem with signal wire

for the remote accelerator position sensor in the
vehicle wiring harness. Proceed to Test Step 9.
Test Step 8. Remove the Remote

Accelerator Position Sensor From the
B. Remove the remote accelerator position sensor

from the accelerator pedal assembly. Note
sensor orientation in the accelerator pedal
assembly, and the sensor pigtail routing prior to
sensor removal. Thoroughly inspect the pigtail
for signs of abrasion.
C. Connect the multimeter that is capable of

measuring a PWM duty cycle to terminal "C" of
the breakout T.
D. Turn the ignition key switch to the ON position.
E. Display the duty cycle output of the remote

accelerator position sensor while the sensor slot
is released. Use a screwdriver to advance the
sensor slot to the maximum position. Refer to
Illustration 164.
348
A Mote sensor to accelerator pedal assembly. Key must match up

with the sensor slot. Check the sensor housinQ for o flush fit to the
pedal assembly mountino surface (This ensures slot on sensor
has mated correctly with the pedal assembly key.)
B Ensure the sensor is oriented the some as it was prior to removal

to ensure sensor harness pigtail is routed correctly.
C Line up screw holes and install mounting screws.
NOTE: Procedure is identico, for the suspended Mounting screw holes

occeleretor pedal assembly.
(5)Accelerator Pedal Assembly
3 ~
Maul Accelerator Block Assembly
Mountin( screw holes
~or mounting surface 1
slot prior
screw ~ - "~
(6) Accelerator Block Assembly

(1) Mountingscrew holes (3) Sensorhousing (5) Accelerator pedal assembly
(2) Sensorslot (4) Mounting surface for sensor (6) Acceleratorblock assembly
Expected Result: • Not OK - T h e remote accelerator position sensor

is faulty. Check the accelerator pedal assembly
When the sensor is removed from the accelerator in order to ensure that the accelerator pedal
pedal assembly and the sensor slot is released, the assembly is not causing damage to the sensor.
duty cycle is 10 percent or less. When the sensor If the accelerator pedal assembly is causing
slot is moved to the maximum position, the duty damage to the sensor, refer to the OEM dealer
cycle increases to 90 percent or more. for correct replacement of the accelerator pedal
assembly. STaR
Results:
Test Step 9. Route the Supply Bypass
• OK - T h e remote accelerator position sensor is Wires to the Remote Accelerator Pedal
working correctly. Clear any diagnostic codes that Position Sensor
were caused by performing this test procedure.
Refer to the OEM dealer for correct replacement A. Turn the ignition key switch to the OFF position.
of the accelerator pedal assembly. STaR
349
B. Remove P1:66 remote accelerator position Operation of the retarder solenoids is inhibited
sensor from P1 ECM connector. during undesirable engine operating conditions.
C. Remove terminal "C" (Accelerator Pedal Position) All of the following conditions must be met in order
from the connector for the remote accelerator to ensure the proper retarder operation regardless of
position sensor. the settings of the customer specified parameters:
D. Route new wiring from the ECM to the remote • Engine speed is above 800 rpm.
accelerator position sensor.
• The "Accelerator Pedal Position" is less than 8
E. Turn the ignition key switch to the ON position. percent.
F. Check the duty cycle of the remote accelerator • The clutch pedal is released.
position sensor withthe electronic service tool
while the accelerator pedal assembly is being Additional factors may affect retarder operation. The
moved over the full range. additional factors are based on the programming
of certain customer specified parameters. The
Expected Result: following parameters may affect retarder operation:
The duty cycle is between 10 and 22 percent with • "Engine Retarder Mode"
position, and the duty cycle is between 75 and 90 • "Auto Retarder In Cruise"
high idle position. • "Auto Retarder In Cruise Increment"
Results: • "Engine Retarder Minimum Vehicle Speed"
• OK - T h e wiring from the ECM to the accelerator • "Engine Retarder Minimum Vehicle Speed Type"
position sensor appears faulty. Permanently install
new wiring. Verify that the repair eliminates the • "Engine Retarder Delay"
problem. STOR
Note: If the "PTO Configuration" is programmed
• Not OK - Double check the wiring, the ECM to Cab Switches, Remote Switches, or Remote
vehicle harness connector J1/P1 and the sensor Throttle, the engine retarder is disabled whenever
connector. If a problem still exists, restart the test the PTO On/Off circuit is on.
procedure. STOR
When the Cruise Control On/Off Switch is in the
ON position, the following conditions exist:
i01906648
Retarder (Compression Brake) "Engine Retarder Mode"

Solenoid Circuit- Test When the cruise control On/Off switch is on, this
parameter provides two special options that allow
SMCS Code: 1129-038 the engine retarder to be operated only after the
driver has depressed the service brake pedal. The
System Operation Description: two modes of operation that follow are customer
programmable:
The engine retarder solenoids are usually factory
installed at Caterpillar and the switches are installed • The "Coast" mode engages the engine retarder
by the vehicle OEM The ECM directly drives the when the driver depresses the service brake
retarder solenoids, eliminating OEM installed relays pedal. The retarder disengages when the driver
and circuit protection. The ECM reads the status of releases the service brake pedal.
the OEM installed engine retarder switches in order
to determine the following modes of operation: • The "Latch" mode engages the retarder when the
driver depresses the service brake pedal. The
• OFF retarder remains engaged until the control detects
a change in a control input. The following actions
• Low are examples of a change in a control input:
• Medium • The throttle is depressed.
• High • The clutch pedal is depressed.

350
• The engine speed drops below 800 rpm. This parameter determines the minimum vehicle
speed limit for the engine retarders to turn ON.
The third option for the engine retarder parameter is When this parameter is programmed to "0" the
"Manual". The Manual mode operates in the same retarder will operate at all vehicle speeds.
manner regardless of the position of the cruise
control On/Off switch. The driver is not required to "Engine Retarder Minimum VSL Type"
depress the service brake pedal in order to initiate
the engine retarder. This is required in the Latch The "Engine Retarder Minimum VSL Type" defines
mode and the Coast mode. the use of the "Engine Retarder Minimum Vehicle
Speed" parameter. The "Engine Retarder Minimum
Note: The Latch mode and the Coast mode are VSL Type" provides the following two options:
customer programmable options. The Latch mode
and the Coast mode determine engine retarder • Hard Limit
operation only when the cruise control switch is in
the ON position. The Latch mode and the Coast • Soft Limit
mode do not determine engine retarder operation
when the engine is active in cruise control. Latch If the "Engine Retarder Minimum VSL Type" is
mode and Coast mode require the initiation of the programmed to the Hard Limit, the engine retarder
service brake before acting. The action of the will turn off when the value that is programmed into
service brake disengages the cruise control. the "Engine Retarder Minimum Vehicle Speed" is
reached.
"Auto Retarder In Cruise"
If the "Engine Retarder Minimum VSL Type" is
This parameter allows the engine retarder to programmed to the Soft Limit, the engine retarder
activate while the engine is in cruise control in will remain in the ON position below the value that
order to maintain the cruise set speed. The "Auto is programmed in the "Engine Retarder Minimum
Retarder in Cruise" option still requires the engine Vehicle Speed". The engine retarder will remain
retarder switches to be in the ON position. The in the ON position until the parameters that would
"Auto Retarder in Cruise" option will only activate normally turn off the engine retarder are met. The
the engine retarder to the level of braking that retarder cannot be activated when the vehicle
is determined by the switch setting. The "Auto speed is below the "Engine Retarder Minimum
Retarder in Cruise" parameter is a vehicle speed Vehicle Speed".
above the cruise set speed. When the vehicle
speed that is above the cruise set speed is met, the This parameter requires the "Engine Retarder
ECM will send a signal in order to begin engaging Minimum Vehicle Speed" parameter to be
the engine retarder. programmed above 0 mph.
At this vehicle speed, the engine retarder will "Engine Retarder Delay"
activate at the low level. The Medium and High
braking levels will be activated at the programmed The "Engine Retarder Delay" parameter provides
"Auto Retarder in Cruise Increment". This assumes a programmable delay after all basic conditions
that the engine retarder switches are set at the that are required to turn on the retarder are met.
high level. The "Auto Retarder in Cruise" affects the Once the conditions are met, the ECM will delay
engine retarder solenoids that are driven directly the activation of the retarder by the programmed
from the ECM engine harness connector P2 terminal additional time. The programmable range is 0.0 to
9, terminal 10 and terminal 11. 3.0 seconds in 0.1 second increments.
"Auto Retarder In Cruise Increment" Other Control Systems
The "Auto Retarder in Cruise Increment" parameter Trucks that are equipped with SAE J1922 systems
determines the increment in kilometers per hour may also control the engine retarder. For ABS
(km/h) or miles per hour (mph) when the higher systems that do not use SAE J1922 with the engine
levels of engine retarder will activate. This feature retarder solenoids, a relay may be connected into
requires the "Auto Retarder in Cruise " parameter the retarder switch circuit in order to disable the
to be programmed above 0 mph. engine retarder or a relay may be connected into
the clutch switch circuit in order to disable the
"Engine Retarder Minimum Vehicle Speed" engine retarder.
351
Note: If the vehicle is equipped with an Anti-Lock

Brake System (ABS), the vehicle may have an
additional relay in the switch circuit for the engine
retarder switches or the clutch switch. This is
installed so the ABS system can turn off the
engine retarder, if necessary. The relay should have
normally closed contacts. The ABS system can not
turn on the engine retarder. The Caterpillar ECM
must still activate the retarder.
Note: If the "Transmission Style" parameter is

programmed to Eaton Top 2 , normal engine
retarder operation can be inhibited by the ECM.
Normal engine retarder operation can be inhibited
by the ECM when the driver is attempting to make a
shift in Top 2 mode in order to provide better control
of torque during the process of shifting.
"Retarder Brake Test"
The "Retarder Brake Test" should be used to

assist in troubleshooting problems in the circuit
for the engine retarder. The ECM will only detect
shorts in the circuit' for the engine retarder when
the test is active. "Current high" diagnostic codes
(short circuits) will be logged once the test has
been deactivated. The ECM will only detect opens
in the circuit for the engine retarder when the
test is not active. The test must be activated and
then deactivated before the ECM will detect an
open circuit. "Current low" diagnostic codes (open
circuits) will be active once the test has been
deactivated.
ENGINE ENGINE ENGINE

RETARDER RETARDER RETARDER
SOLENOID SOLENOID SOLENOID
CYLINDERS CYLINDERS CYLINDERS ECM
l& 2 5 & 6 3 & 4 J3OO P300 P2 J2
JTOO-BR--~-[~ RETARDER SOLENOID MED/HI
J701-GN---Klll RETARDER SOLENOID LOW/HI
J7D2-BK~I9 RETARDER SOLENOID COMMON
r! ..........! .......... H 7 9 5 - P K - ~ - ~ AP SENSOR/SWITCH SENSOR COMMON
l
E716-GY-K 123~ RETARDER SOLENOID LOW/HI SWITCH
E717-GN-~ I40< RETARDER SOLENOID MED/HI SWITCH
pl jl
S0 LE ~ I ~N~ N~E~F~R~[~I TCH
ENGINE RETARDER
SOLENOID SELECTOR
SWITCH
• . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
OEM RESPONSIBILITY
Schematic for engine retarder(compressionbrake)
352
f II II
/- 1 2 5 4 5A6 LJ 8 g 101L12_1,3~"
O000q~D-OCRD-O-O00~
"00000 00000"~;
- - RETARDER SOLENOID LOW/HI SWITCH
oooooo
2 ~ o o o o o~ooooo.iiii
240000 ~ 00005' 3,o o o o [ f ~ ] o o o c2411 II
) 0,000 (([))) 0000 r
RETARDER SOLENOID MED/HI SWITCH
I ~ o o o IK.(, ; )11 0 o %c~211 II
,o0"000 ~ 000047 ,Toooo ~ ooo"04011 II
,00000 O0000s7 I~7o o o o o o ~ o o o o ~'"11 II
O00OOOOO00OO0
~5~1 ~)9006162 63 n 65 66 67 6116970.j
II II J
Horness Side [CM Side
Vehicle Horness Connector P2
f II II ~"
f! 2 3 4 ,5 6 "~8 9LIO_ILI2_13~ RETARDER SOLENOID COMMON
O000000001Mk.O0 RETARDER SOLENOID LOW/HI
(,5o o..~.e'e o o o o o o o
,400000 OOYD~OO2~ /2~oo'oroo o o o o o
z,O000 ~ 00~, RETARDER SOLENOID MED/HI r~or6-~-do ~ ooo
OOOO (( f. ] )) 0 0 0 0 t p~oooo IKO~I oooc~2
,oOOOO ~
,800000
0000000000000
000047
OOOOOs7 5700000o 0000C401~
470000
70000000000000
~ 000C40
%51l5~16001 62 6~ n 6S 66 67 68 69 7 0 j
--. II H
Hotness Side ECM Side
Engine Horness Connector P2
g00645629
Illustration 166

MED/HI LOW/HI Retorder
Solenoid Solenoid Solenoid D. Check the harness and wiring for abrasion and
1 Common pinch points from the accelerator pedal position
sensor to the ECM.
Expected Result:

O0 0 0 0 and wiring should be free of corrosion, abrasion
1 2 3 4 5 or pinch points.
g00999340 Results:
Illustration 167
Test Step 1. C h e c k Electrical C o n n e c t o r s
and W i r m g • Not OK
A. Thoroughly inspect the J1/P1 and J2/P2 ECM Repair: Perform the following repair:
connectors, the injector connector for the valve
cover J300/P300 and the firewall bulkhead Repair the connectors or wiring and/or replace
connector. Refer to Troubleshooting, "Electrical the connectors or wiring. Ensure that all of the
Connectors - Inspect" for details. seals are properly in place and ensure that the
connectors are completely coupled
wires in the ECM connector that are associated Verify that the repair eliminates the problem,
with the connections for the engine retarder
solenoids and the engine retarder switch: STOR
353
Test Step 2. Check for Diagnostic Codes • P300:11 (MED/HI Retarder Solenoid)
A. Connect the Caterpillar Electronic Technician D. If the diagnostic code is related to the "LOW/HI"
(Cat ET) to the data link connector. circuit, place the engine retarder switch in the
Low position.
B, Place the engine retarder switch in the High
position. If the diagnostic code is related to the "MED/HI"
circuit, place the engine retarder switch in the
C. Turn the key switch to the ON position. Medium position.
D, Check for active diagnostic codes and logged If the diagnostic code is related to both circuits,
diagnostic codes that are related to the engine place the engine retarder switch in the High
retarder. Clear any logged diagnostic codes that position.
are related to the engine retarder.
E, Access the "Retarder Brake Test" in the "Special
Tests" under the "Diagnostics" menu. F. Access the "Retarder Brake Test" in the "Special
Tests" under the "Diagnostics" menu.
F, Start the test. Allow the test to be active for five
seconds. G. Start the test.
G. Check for active diagnostic codes that are H. Check for active diagnostic codes that are
related to the engine retarder. related to the engine retarder.
H. Stop the test. I. Stop the test.
I, Check for active diagnostic codes that are J. Check for active diagnostic codes that are
related to the engine retarder. related to the engine retarder.
There is an active "current low" diagnostic code A "current high" diagnostic code (short circuit)iis
(open circuit) or an active "current high" diagnostic active when the jumper wire is in place and the
code (short circuit). "Retarder Brake Test" is active.
Results: Note: A "current low" diagnostic code (open circuit)

will be active when the jumper wire is removed and
• Current Low (Open) -There is an open in the the test is not active.
circuit for the engine retarder. Proceed to Test
Step 3. Results:
• Current High (Short) - There is a short in the • OK - T h e harness between the ECM and the
circuit for the engine retarder. Proceed to Test valve cover base is OK. Proceed to Test Step 4.
Step 6.
• Not OK - A "current high" diagnostic code
• No Codes - There are no diagnostic codes that (short circuit) was not active. There is a problem
are related to the engine retarder. Proceed to Test between the ECM and the valve cover base.
Step 9. Proceed to Test Step 5.
Test Step 3. Create a Short Circuit at the Test Step 4. Create a Short Circuit at the
Valve Cover Engine Retarder Solenoid
A. Turn the key switch to the OFF position. A. Turn the key switch to the OFF position.
B, Disconnect the J300/P300 Injector connector on B, Remove the valve cover(s).

the valve cover base.
C. Disconnect the wires for the suspect solenoid.
C. Connect a jumper wire between the terminal Insert a jumper wire between the two wires for
for the suspect circuit and P300:7 (Retarder the suspect solenoid.
Solenoid Common).
• P300:9 (LOW/HI Retarder Solenoid)
354
E. Access the "Retarder Brake Test" in the "Special Verify that the repair eliminates the problem.
STOR
F. Start the test.
Test Step 5. Create a Short Circuit at the
G. Check for active diagnostic codes that are ECM
related to the engine retarder.
H. Stop the test.
I, Check for active diagnostic codes that are
related to the engine retarder. C. Connect a 140-2266 Cable (Seventy-Pin
Breakout) to the J2 ECM connector. Do not
Expected Result: connect the P2 ECM connector.
A "current high" diagnostic code (short circuit) is D. Connect a jumper wire between the terminal
active when the jumper wire is in place and the for the suspect circuit on the breakout T and
"Retarder Brake Test" is active. Terminal 9 (Retarder Solenoid Common).
Note: A "current low" diagnostic code (open circuit) • Terminal 11 (LOW/HI Retarder Solenoid)
will be active when the jumper wire is removed and
the test is not active. • Terminal 10 (MED/HI Retarder Solenoid)
Results: E. Turn the key switch to the ON position.
• OK -There may be a problem with the engine F. Access the "Retarder Brake Test" in the "Special
retarder solenoid. Tests" under the "Diagnostics" menu.
Repair: Temporarily connect a new engine G. Start the test.

retarder solenoid.
H. Check for active diagnostic codes that are
If the new solenoid fixes the problem, reconnect related to the engine retarder.
the suspect solenoid.
I. Stop the test.
solenoid. J. Check for active diagnostic codes that are
Expected Result:
STOR
A "current high" diagnostic code (short circuit) is
• Not OK - T h e r e is a problem in the harness active when the jumper wire is in place and the
under the valve cover. "Retarder Brake Test" is active.
Repair: Inspect the wiring between the valve Note: A "current low" diagnostic code (open circuit)
cover base and the engine retarder solenoids. will be active when the jumper wire is removed and
the test is not active.
Insert a jumper wire between the supply wire for
the suspect solenoid and chassis ground. Results:
Repeat this Test Step. • OK -There is a problem in the harness between
the ECM and the valve cover base.
If there is still a "current low" diagnostic code
(open circuit), the problem is the supply wire. Repair: Remove the breakout T and reconnect the
J1/P1 ECM connector,
If there is a "current high" diagnostic code (short
circuit), the problem is the common wire. Inspect the wiring between the ECM and the
valve cover base.
Repair the wiring or replace the wiring.
Disconnect the P300 connector.
355
Insert a jumper wire between the terminal on the Expected Result:

P300 connector for the suspect solenoid and
chassis ground. A "current low" diagnostic code (open circuit) is
active.
Repeat this Test Step.
Results:
If there is still a "current low" diagnostic code
(open circuit), the problem is the supply wire. • OK - T h e harness between the ECM and the
valve cover base is OK. Proceed to Test Step 7.
If there is a "current high" diagnostic code (short
circuit), the problem is the common wire. • Not OK - There is a problem between the valve
cover base and the ECM. Proceed to Test Step 8.
Test Step 7. Create an Open Circuit at the
Verify that the repair eliminates the problem. Retarder Solenoids
STOR A. Turn the key switch to the OFF position.
• Not OK - There may be a problem with the ECM. B. Remove the valve cover(s).
Repair: Temporarily connect a test ECM. C. Disconnect the wires from each engine retarder
solenoid. Ensure that the wires are not touching
If the test ECM fixes the problem, reconnect the any metal parts.
suspect ECM.
ECM. E. Access the "Retarder Brake Test" in the "Special
F. Start the test.
STOR
G. Check for active diagnostic codes that are
Test Step 6. Create an Open Circuit at the related to the engine retarder.
Valve Cover
H. Stop the test.
A. Disconnect the J300/P300 Injector connector on
the valve cover base. I. Check for active diagnostic codes that are
B. If the diagnostic code is related to the "LOW/HI"
circuit, place the engine retarder switch in the Expected Result:
Low position.
A "current low" diagnostic code (open circuit)is
If the diagnostic code is related to the "MED/HI" active.
circuit, place the engine retarder switch in the
Medium position. Results:
If the diagnostic code is related to both circuits, • OK -There may be a problem with the engine
place the engine retarder switch in the High retarder solenoid.
position.
Repair: Inspect the common wire for shorts.
C. Access the "Retarder Brake Test" in the "Special Repair any faulty wiring or replace any faulty
Tests" under the "Diagnostics" menu. wiring.
D. Start the test. Temporarily connect a new engine retarder

solenoid.
E. Check for active diagnostic codes that are
related to the engine retarder. If the new solenoid fixes the problem, reconnect
the suspect solenoid.
F: Stop the test.
G. Check for active diagnostic codes that are solenoid.
356
Verify that the repair eliminates the problem. If the test ECM fixes the problem, reconnect the
suspect ECM.
STOR
• Not OK - There is a problem in the harness ECM.
under the valve cover.
Repair: Inspect the wiring between the valve
cover base and the engine retarder solenoids. STOR
Repair the wiring or replace the wiring. Test Step 9. Check the Status of the
Engine Retarder Switch
STOR
B. Monitor the status for "Retarder Off/Low/Med/High
Test Step 8. Create an Open Circuit at the Switch" on Cat ET.
ECM
C. Operate the engine retarder switch in the ON
A. Turn the key switch to the OFF position. position and the OFF position. Also, operate the
engine retarder switch in the Low, Medium, and
B. Disconnect the J2/P2 ECM connector. High positions.
C. Turn the key switch to the ON position. Expected Result:

D, Access the "Retarder Brake Test" in the "Special The status for "Retarder Off/Low/Med/High Switch"
Tests" under the "Diagnostics" menu. correlates to the position of the engine retarder
switch.
E, Start the test.
Results:
F, Check for active diagnostic codes that are
related to the engine retarder. • OK - The engine retarder switch is operating
correctly. Proceed to Test Step 10.
G, Stop the test.
• Not OK - There is a problem in the circuit for the
H, Check for active diagnostic codes that are engine retarder switch. STOR
Test Step 10. Check the Operating
Expected Result: Parameters of the Engine Retarder
A "current low" diagnostic code (open circuit) is A. Turn the key switch to the ON position.
active.
B. Access the "Configuration" screen on Cat
Results: ET. Review the programming of the following
parameters:
• OK -There is a problem in the harness between
the ECM and the valve cover base. • "Engine Retarder Mode"
Repair: Inspect the wiring between the ECM and • "Engine Retarder Minimum VSL Type"
the valve cover base.
• "Engine Retarder Minimum Vehicle Speed"
• "Engine Retarder Delay"
C. Use the following information when the parameter
STOR for the "Engine Retarder Mode" is being
reviewed:
• Not OK - There may be a problem with the ECM.
Repair: Temporarily connect a test ECM.

357
a. If the parameter is programmed to Latch Refer to Troubleshooting, "Customer Specified

mode or Coast mode, the engine retarder will Parameters" for additional information on the
not turn on unless the following conditions are listed parameters.
met:
STOR
• The Cruise Control On/Off Switch is on.
• Not OK - T h e parameters are programmed
• The service brake pedal has been correctly. Proceed to Test Step 11.
depressed.
Test Step 11. Check the Accelerator Pedal
D. Use the following information when the parameter
for the "Engine Retarder Minimum VSL Type" is A. Turn the key switch to the ON position.
being reviewed:
B. Monitor the status for "Accelerator Pedal
a. This parameter has no effect on engine Position" on Cat ET while the accelerator pedal
retarder operation when the "Engine Retarder is fully released.
Minimum Vehicle Speed" is programmed to
0 mph. C. While the status is monitored, depress the
accelerator pedal.
b. When this parameter is programmed to the
Hard Limit and the vehicle speed drops below Expected Result:
the Engine Retarder Minimum Vehicle Speed,
the engine retarder turns off. The status for "Accelerator Pedal Position" is
less than 8% when the accelerator pedal is fully
C, When this parameter is programmed to released. The status changes as the accelerator
the Soft Limit and the vehicle speed drops is depressed.
below the Engine Retarder Minimum Vehicle
Speed, the engine retarder remains in the Results:
QN position.
• OK - T h e accelerator pedal is operating correctly.
E. Use the following information when the parameter Proceed to Test Step 12.
for the "Engine Retarder Minimum Vehicle
Speed" is being reviewed: • Not OK - The accelerator pedal position sensor
is not operating correctly.
a. When the programmed value is more than
0 mph, the engine retarder wilt not turn on Repair: Refer to Troubleshooting, "Accelerator
below the programmed value. Pedal (Throttle) Position Sensor Circuit - Test".
Note: The retarder will not turn on if the vehicle STOR

speed is already below the "Engine Retarder
Minimum Vehicle Speed". Test Step 12. Check the Clutch Switch
F, Use the following information when the parameter A. Turn the key switch to the ON position.
for the "Engine Retarder Delay" is being
reviewed: B, Monitor the status for "Clutch Pedal Position
Switch" while the clutch pedal is fully released.
a. This parameter provides a programmable
delay once the conditions are met in order to C. While the status is monitored, depress the clutch
turn the engine retarder. pedal.

The problem is due to the programming of any of The status for "Clutch Pedal Position Switch" is "Off"
the listed parameters. when the clutch pedal is fully released. The status
is "On" when the clutch pedal is depressed.
Results:
Note: If a clutch pedal is not installed, select "OK".
• OK
Results:
procedure: • OK - T h e clutch pedal position switch is
operating correctly. There may be a mechanical
Program parameters for desired operation. problem with the engine retarder.
358
Repair: Refer to Testing and Adjusting, • "ldle/PTO Bump rpm"

"Compression Brake".
• "ldle/PTO rpm Ramp Rate"
STOR
• Not OK - T h e clutch pedal position switch is not
operating correctly. The vehicle speed calibration can also affect
the cruise control, the idle set speed, and the
Repair: Refer to Troubleshooting, "Clutch Pedal PTO if the vehicle speed calibration is incorrectly
Position Switch Circuit - Test". programmed. Refer to Troubleshooting, "Customer
Specified Parameters".
STOR
Service Brake Pedal Position (Switch 1)
i01870469
The switch for the Service Brake Pedal Position
Service Brake Pedal Position (Switch 1) is normally closed when the respective
pedal is released. Depressing the brake pedal
(Switch 1) Circuit- Test should open the individual circuit. This switch is
OEM supplied. The Service Brake Pedal Position
SMCS Code: 1435-038-BRK (Switch 1) is typically a pressure switch.
System Operation Description: Kickout Switches

Use this procedure under the following situation: The service brake pedal position switches, the
neutral switch and the clutch switch are used
Use this procedure to determine if the Service in the cruise control mode, the PTO mode and
Brake Pedal Position (Switch 1)is preventing normal the Idle mode in order to discontinue the cruise
operation of cruise control, idle set speed, or PTO operation, the PTO operation, or the idle operation.
operation: The capability to override the idle shutdown timer is
determined by the "Allow Idle Shutdown Override"
The following switch circuits can also prevent the parameter setting. The "Allow Idle Shutdown
correct operation of the cruise control, idle set Override" is a customer parameter.
Usage of Transmission Style Switches
The "Transmission Style" parameter determines
• Service Brake Pedal Position (Switch 2) the switches that will be used. The following
switches can be used with being dependent on the
• Neutral Switch parameter setting:
• Cruise Control Set/Resume Switch • Clutch Pedal Position
• Cruise Control On/Off Switch • Neutral
• PTO On/Off Switch • Service Brake Pedal Position (Switch 1)
The switches are described in the respective circuit • Service Brake Pedal Position (Switch 2)
tests in Troubleshooting.
Refer to Table 154 for additional information.
All of the following customer programmable
and PTO operation:
• "Low Cruise Control Speed Set Limit"
• "High Cruise Control Speed Set Limit"
• "Cruise/Idle/PTO Switch Configuration"

359
Table 154
Setting For Switch Usage.
Transmission
Style Service Service
Clutch Neutral
Parameter Brake 1 Brake 2
Manual
X X
Option 1
Automatic
Option 1 X
Automatic
Option 2
X X
Automatic
X X X
Option 3
Automatic
Option 4 X X
Eaton Top 2 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 Clutch Pedal Position Switch
connects to the ECM through Connector P1:22.
The Neutral Switch connects to the ECM through
Connector P1:62.
SET/RESUME
(SET OFF POSITION)
ECM
CRUISE CONTROL ON/OFF I I C978-BR~ SET
(CRUlSE OFF POSlTION) C979-0R-KI44~ RESUME
C975-WI-H-<I59~ CRUISE CONTROL ON/OFF SWITCH
SERVICE BRAKE PEDAL POSITION [ C992-PU-KI45~ SERVICE BRAKE PEDAL POSITION SWITCH
0977-BU-~122 ~ CLUTCH PEDAL POSITION SWITCH
H795-PK--~_J_~ AP SENSOR/SWITCH SENSOR COMMON
EDAL RELEASED POSITION) P1 Jt L
CLUTCH PEDAL POSITION
(PEDAL RELEASEDPOSITION)

Schematic for cruise control switch,service brake pedal position(switch 1) and clutch pedal positionswitch
Test Step 1. Check the Status for the c. Access the status for the "Service Brake Pedal
" S e r v i c e Brake Pedal Position Switch # 1 " Position Switch #1" on the electronic service tool.
A. Connect the electronic service tool to the data D. While the status for the "Service Brake Pedal
link connector. Position Switch #1" is monitored, depress the
brake and release the brake.
360
Expected Result:
The status for the "Service Brake Pedal Position
Switch #1" is "Off" when the brake is released. The
status for the "Service Brake Pedal Position Switch
#1" is "On" when the brake is depressed.
Results:
• OK - T h e service brake pedal position (Switch 1)
is working correctly. STOP.
• Not OK - T h e service brake pedal position

(Switch 1) is not working correctly. Proceed to
Test Step 2.
Test Step 2. Determine the Configuration

of the Switch
A. Determine if the wiring for the service brake
pedal position (Switch 1) is wired directly to the
ECM or through the J1939 data link.
B. Verify that the "Service Brake Pedal Position

Switch #1" parameter is programmed to reflect
the proper wiring.
Expected Result:
The service brake pedal position (Switch 1) is wired
Results:
• OK - T h e service brake pedal position (Switch 1)
is wired directly to the ECM.
Repair: Verify that the "Service Brake Pedal

Position Switch #1" parameter is programmed to
"J1/P1:45".
• Not OK - T h e service brake pedal position

(Switch 1) is wired through the J1939 data link.
Repair: Verify that the "Service Brake Pedal

Position Switch #1" parameter is programmed
to "J1939 - Body Controller", "J1939 - Cab
Controller", or "J 1939 - Instrument Cluster".

Circuit - Test".
STOR
361

And Wir,ng

13OOOOOOO0~OO
230 O O O O o O O O O O14
3tO O O O ~ O O O 024
390 O O,O ~-O--J~l O O OO,]2
470 0 ~ 0 0 0 040
570 0 0 0 0 o 0 0 0 0 048
700 0 0 O 0 0 0 0 0 0 0 0 0 5 8
1 2 3 4 5,A6 ' ' 8--9_10_11-12_13 ~ '

A-] O 0 0 0 f O 0 0 0 0 0 0 0
LII1400000 ~ 000002~
~] AP SENSOR/SWITCH SENSOR COMMON
-I~40000 /F~'~"X 0 0 0 0 3 ~
poooo (( r.. ) >) o o . D o F
: ooo SERVICE BRAKE PEDAL POSITION SWITCH
"soSOSoooSSOOoO
\',. ,~esgs0s 626s ~ 6s66~768697o / -~
tt tt
Harness Side
A. Thoroughly inspect the J1/P1 ECM connector, Results:

for the following switches in the connectors: • OK - Proceed to Test Step 4.
• J1/P1:5 (AP Sensor/Switch Sensor Common) • Not OK
• J1/P1:45 (Service Brake Pedal Position (Switch Repair: Perform the following repair:
1))
Refer to Troubleshooting, "Electrical Connectors the connectors or wiring. Ensure that all of the
- Inspect" for details. seals are properly in place and ensure that the
wires in the ECM connector that are associated Verify that the repair eliminates the problem.
with the switches.
STOR
C. Check the ECM connector (allen head screw) for the E C M
A. Turn the key switch to the OFF position,
pinch points from the sensor to the ECM. B. Fabricate a jumper wire 100 mm (4 inch) long.
Expected Result:
C. Connect a 140-2266 Cable (Seventy-Pin
All connectors, pins, and sockets should be Breakout) between the J1 and P1 ECM
completely coupled and/or inserted and the harness connectors.
or pinch points.
362
D, Install the jumper into terminal 45 (Service Brake D. Turn the key switch to the ON position.
Pedal Position Switch) of the breakout T. Connect
the other end of the jumper to terminal 5 (AP E. Access the status for the "Service Brake Pedal
Sensor/Switch Sensor Common) of the breakout Position Switch #1"
T.
F. While the status for the "Service Brake Pedal
E. Turn the key switch to the ON position. Position Switch #1" is monitored, connect the
wires for the service brake pedal position (Switch
F. Access the status for the "Service Brake Pedal 1) and disconnect the wires for the service brake
Position Switch #1". pedal position (Switch 1).
G. While the status for the "Service Brake Pedal Expected Result:
Position Switch #1" is monitored, remove the
jumper from terminal 5 and insert the jumper into The status for the "Service Brake Pedal Position
terminal 5 (AP Sensor/Switch Sensor Common). Switch #1" is "Off" when the wires are disconnected.
The status for the "Service Brake Pedal Position
Expected Result: Switch #1" is "On" when the wires are connected.
The status for the "Service Brake Pedal Position Results:

Switch #1" is "Off" when the jumper wire is removed.
The status for the "Service Brake Pedal Position • OK
Switch #1" is "On" when the jumper wire is installed.
Repair: Replace the faulty switch.
Results:
STOR
the J1 and P1 ECM connectors. • Not OK - There is a problem in the harness
Proceed to Test Step 5. Step 6.
• Not OK - The ECM is not functioning properly. Test Step 6. Insert a Jumper at the
Bulkhead Connector
1. Temporarily connect a test ECM.
2. Remove the breakout T and reconnect the J1 Crimp a Deutsch pin to each end of the wire.
C. Locate the terminal for the "Service Brake Pedal
3. If the problem is resolved with the test ECM, Position (Switch 1)" and the "AP Sensor/Switch
reconnect the suspect ECM Sensor Common" on the engine side of the
bulkhead connector.
4, If the problem returns with the suspect ECM,
replace the ECM. D. Insert the jumper wire between the two terminals
in the engine side of the bulkhead connector.
El Turn the key switch to the ON position.
STOR
F. Access the status for the "Service Brake Pedal
Test Step 5. Insert a Jumper at the Position Switch #1".
G. While the status for the "Service Brake Pedal
A. Turn the key switch to the OFF position. Position Switch #1" is monitored, remove the
jumper from one of the terminals and insert the
B, Find the switch for the Service Brake Pedal jumper wire into the terminal.
Position (Switch 1) in the vehicle.
C, Disconnect the wires from the switch terminals.

363
Expected Result: • "Allow Idle Shutdown Override"
The status for the "Service Brake Pedal Position Refer to Troubleshooting, "Service Brake Pedal
Switch #1" is "Off" when the jumper wire is removed. Position (Switch 1) Circuit - Test" for more details on
The status for the "Service Brake Pedal Position the operation of the brake pedal position switches.
Switch #1" is "On" when the jumper wire is installed.
Table 155
Results: Switch Usage.
Setting For
• OK - T h e problem is in the vehicle wiring Style
between the bulkhead connector and the switch. Brake Brake Clutch Neutral
Parameter 1 2
Repair: Inspect the vehicle wiring and repair the Manual X
vehicle wiring, as required. If the problem still X
Option 1
exists with the wiring, send the vehicle to the
OEM dea~er. Automatic X
Option 1
STOR Automatic X X
Option 2
• Not OK - T h e problem is in the vehicle wiring Automatic X
between the bulkhead connector and the ECM. X X
Option 3
Repair: Inspect the vehicle wiring and repair the Automatic
X X
vehicle wiring, as required. If the problem still Option 4
exists with the wiring, send the vehicle to the Eaton Top 2 X X
OEM dealer.
STOR
i01626422
Service Brake Pedal Position

(Switch 2) Circuit- Test
Use this procedure to determine if the "Service

Brake Pedal Position (Switch 2)" is preventing
normal operation of the cruise control, the idle set
speed or the PTO.
"Service Brake Pedal Position (Switch 2)"
The "Service Brake Pedal Position (Switch 2)" is

required when the "Transmission Style" parameter
is programmed to Automatic Option 2 or Automatic
Option 3. This switch has an identical function as
"Service Brake Pedal Position (Switch 1)". This
switch is used only when a redundant system is
required. Unlike the "Service Brake Pedal Position
(Switch 1)", this switch connects to + Battery. This
provides a fully redundant system. A logged fault
will be present if the status of the two brake switches
do not agree. This switch is used to exit cruise
control, Cab Switch PTO mode or idle. The switch
may also be used to override the idle shutdown
timer during the last 90 seconds. This capability is
determined by the following customer parameter:
364
SERVICE BRAKE ~2 PEDAL POSITION ECM

~(PEDAL RELEASED POSITION) r
L9OO-PU~ INPUT J15

,p', al
Illustration 170
g00646450
Schematic for service brake pedal position (switch 2)

and Wiring
~500000000000001
230 0 0 0 0 o 0 O O 0 014
310 0 0 0 ( ~ ' ~ 0 0 O 024
590000 L ~ ) 000032
470 0 0 0 0 0 0 04(
570 O O O 0 o 0 O 0 O 04e
700 O O O O O ~ D O O O O O5~ /
// INPUT 13-SERVICE BRAKE PEDAL POSITION (SWITCH 2)

f fl I1
/fl 2 34 5 6 n 8 91o.,215-'-.,\
ooooo ooooo-iI]
~ O00OO00000OOO]-
-~-ks~uu f,~-x\ 00005,1-
P OOOO (( r..1 )) OOOO~
r:;8oO8oOo
_ O00000q_O00OO0 - INPUT 13-SERVICE BRAKE PEDAL POSITION (SWITCH 2)
\ /
Harness Side
g00704926
Illustration171
A. Thoroughly inspect ECM vehicle harness B. Check the harness and wiring for abrasion and
connector J1/P1 and the firewall bulkhead pinch points from the sensor to the ECM
connector.
Expected Result:
Refer to Troubleshooting, " Electrical Connectors
- Inspect" for details. All connectors, pins, and sockets should be
B. Perform a 45 N (10 Ib) pull test on each of the and wiring should be free of corrosion, abrasion,
wires in the ECM connector that are associated or pinch points.
with the switches.
Results:
the proper torque of 6.0 N.m (55 Ib in). • Not OK
365

STOP.
Test Step 2. Check the Switch Status on

ET
Table 156
Table for Status of the Service Brake Pedal Position (Switch 2)
Switch Position or Pedal Position Switch Status Circuit
The Service Brake is Depressed. ON Shorted
The Service Brake is Released. OFF Open
A, Access the status screen on the Caterpillar

Electronic Technician (ET).
C. Start the engine or ensure that the air system

is charged if the vehicle is equipped with air
brakes.
D. Depress the Service Brake while the status of

both brake switches is being observed on ET.
E. Release the service brake while the status of

both brake switches is being observed on ET.
Note: If the Service Brake Pedal Position (Switch

2) status indicates "Not Installed", check the
programming of the "Transmission Style" parameter.
The "Transmission Style" must be programmed
to Automatic Option 2 or Automatic Option 3 if a
second switch is used.
Expected Result:

table 156
Results:
• OK - T h e switch is operating normally.

procedure:
Troubleshooting, "Service Brake Pedal Position

(Switch 1) Circuit - Test".
STOR

366
Test Step 3. Check the Switch Circuit of

the E C M
Table 157
Table for Status of the Service Brake Pedal Position (Switch 2)
Terminal 64 is Open. OFF Open
Terminal 64 is connected to + Battery. ON Shorted
A. Turn the ignition key switch to the OFF position. 4. Repeat the Test Step.
B. Fabricate a jumper wire 100 mm (4 inch) long. 5. If the problem is resolved with the test ECM,
Crimp a Deutsch pin to both ends of the wire. reconnect the suspect ECM.
C. Disconnect vehicle harness connector P1 from 6. If the problem returns with the suspect ECM,
the ECM. replace the ECM.
D. Connect a 70-Termial Breakout T to ECM 7. Verify that the repair eliminates the problem.
connector J1 and connect P1 to the breakout T.
STOP.
E. Install the jumper wire into terminal 52
(unswitched +Battery) of the breakout T. Connect
the other end of the jumper wire to (terminal 64)
which is the Service Brake Pedal Position (Switch
2) of the breakout T.
G, Connect ET to the cab data link connector.
H. Access the status screen on ET.
I, While the status of the Service Brake Pedal

Position (Switch 2) is being monitored on the
status screen, slowly remove the jumper from
terminal 52 and slowly insert the jumper from
terminal 52.
Expected Result:
table 157
Results:
• OK - T h e ECM is functioning properly. Proceed
to Test Step 4.

1, Temporarily connect a test ECM.
2, Remove all jumpers and replace all connectors.
8, Recheck the system for active diagnostic

codes.
367

Table 158
Table for Input Status of the Service Brake Pedal Position (Switch 2)
Switch wires are disconnected. OFF Open
Switch wires are connected. ON Shorted
A, Turn the ignition key switch to the OFF position.
B, Ensure that ECM vehicle harness connector

J1/P1 is connected.
C, Find the switch in the vehicle.
D, Disconnect the wires from the switch terminals.
F, Connect ET to the cab data link connector.
G, Access the status screen on ET.
H, While the switch status is being monitored on

the status screen slowly connect the suspect
switch wires and slowly disconnect the suspect
switch wires.
Expected Result:
Refer to table 158.
Results:
• OK
Replace the faulty switch. Verify that the repair

eliminates the problem.
STOR
• Not OK -There is a problem in the harness

Step 5.

Bulkhead Connector
Table 159
Table for Input Status of the Service Brake Pedal Position (Switch 2)
Switch wires are disconnected. OFF Open
Switch wires are connected. ON Shorted
A, Turn the ignition key switch to the OFF position.

368
B. Fabricate a jumper wire 100 mm (4 inch) long. Use this procedure to determine if the Starting Aid
Crimp a Deutsch pin to both ends of the wires. Output circuit is operating properly.
C. Find the switch terminal in the engine side of the The following background information is related
bulkhead connector for the vehicle harness. Also, to this procedure:
find a convenient location for + Battery voltage.
The "Starting Aid Output" can be programmed to
D. Insert the jumper wire between the two terminals J1/P1:10, J1/P1:12, or J1/P1:13.
in the engine side of the bulkhead connector.
The "Starting Aid Output" will function on the
E. Turn the ignition key switch to the ON position. following corresponding output that is selected:
F. Connect ET to the cab data link connector. • ECM Connector J1/P1 terminal 10
G. Access the status screen on ET. • ECM Connector J1/P1 terminal 12
H. While the switch status is being monitored • ECM Connector J1/P1 terminal 13
on the status screen alternately remove the
jumper wire from the + Battery connection, and This "Starting Aid Output" is used to connect to a
alternately install the jumper wire at the + Battery relay and/or a solenoid in order to control a starting
connection. aid system. Typical starting aid systems inject ether
into the inlet manifold in order to aid starting of the
Expected Result: engine during cold weather operation. The output
can be automatically controlled by the ECM, or an
Refer to table 159. additional switch can be added to the system. This
switch allows the operator to disable the system
Results: if the operator desires. The On/Off switch for the
starting aid can be programmed to use J1/P1:6,
• OK - T h e problem is in the vehicle wiring J1/P1:7, J1/P1:46, or J1/P1:47. The reading of the
between the bulkhead connector and the switch. coolant temperature sensor is used to determine
if conditions require the use of the starting aid.
Repair: Perform the following repair: If a fault condition exists with the circuit for the
coolant temperature sensor, the reading for the
Inspect the vehicle wiring and repair the vehicle inlet manifold temperature sensor will be used. The
wiring, as required. If the problem still exists with "Starting Aid Output" will be enabled for a maximum
the wiring, send the vehicle to the OEM dealer. of 30 seconds while the engine is cranking and
the temperature reading is below 0 °C (32 °F).
STOR The "Starting Aid Output" will be disabled if the
engine starts. The "Starting Aid Output" will also be
• Not OK - The problem is in the vehicle wiring disabled if a condition that prevents fuel injection
between the bulkhead connector and the ECM Occurs.
Inspect the vehicle wiring and repair the vehicle

STOR
i01626360
Starting Aid Output Circuit-

Test
SMCS Code: 1456-038

369
ECM
STARTING AID
ENABLE SWITCH m
GB41-GN 7 ~ 4 7 7~ * INPUT ~4
(OPTIONAL) GB42-GY * INPUT J5
0,.o. *INPUT |6
L
m G844-PK *INPUT ~7
E991-GY * OUTPUT J3
E718-PK J~. I10~ * OUTPUT ~2
G836-WH * OUTPUT ~4
STARTING AID P1 j1
SOLENOID VALVE
-_~_-
NOTE: STARTING AID OUTPUT PARAMETER MUST BE PROGRAMMED TO THE OUTPUT SELECTION.
OUTPUT 2, 3, OR 4 MAY BE USED.
NOTE: STARTING AID ON/OFF SWITCH PARAMETER MUST BE PROGRAMMEDTO INPUT
SELECTION. INPUT 4, 5, 6, OR 7 MAY BE USED.

Starting Aid Output Circuit
Output |2
~3 ~o-6-0 o 0 0 o 0 1
Output J3
Output J4
IIIIs,° ° ° ° ff.-.-hl oo_0o
4t111
II I1,3~°°° Ik u )1 °°°~3~1 II
II I1470 0 0 0 k . ~ , ; 0 0 o u,~Otl II
iiIl.OOOOO o ooooo,81111
_oooo
ECM SIDE VEHICLE HARNESS CONNECTOR Pt
t 2 3 4 5 6 u 8 9 10~!~ ! 2 1 x ~ , OUTPUT 12
O00000000ero ~ I
,, 0000
=1240000 ~
>PEI<
00003~I
OUTPUT 14
OUTPUT 13
0000 (( I] ] ))360000 El
d,0oooo ooo0-1
1114sO0000 00000571
O000OO0000000 j
~ . 5 8 59 60 61 62 63 n 65 66 67 68 69 7 0 J
II II J
HARNESS SIDE

Terminal locationsfor the ECM
Test Step 1. Check the Electrical B. Perform a 45 N (10 Ib) pull test on terminal 10,
Connectors and the Wiring terminal 12, or terminal 13 in the ECM connector.
A. Thoroughly inspect the ECM Vehicle Harness C. Check the ECM connector (allen head screw) for
Connector J1/P1, and the firewall bulkhead the proper torque of 6.0 N.m (55 Ib in).
Connectors - Inspect" for details. D. Check the harness and the wiring for abrasion
and pinch points from the relays to the ECM.
370
Expected Result: B. Access the "Starting Aid Output Special Test"

on ET. The "Starting Aid Output Special Test" will
All connectors, pins, and sockets are completely enable the "Starting Aid Output" when the test
coupled and/or inserted, and the harness and is active.
points. Disconnect the starting aid canister in order to
prevent accidental discharge.
Results:
C. Begin the "Starting Aid Output Special Test" and
• OK - Proceed to Test Step 2. listen for the solenoid or the relay to "click". You
may need to be near the engine in order to hear
• Not OK - Repair the wiring or replace the wiring, the "click".
the connectors, if necessary. Ensure that all of Expected Result:
of the connectors are connected properly. Verify The solenoid or the relay activates when the special
that the repair eliminates the problem. STOR test is enabled.
Test Step 2, Ensure Correct Parameter Results:

Programming
A. Connect the Caterpillar Electronic Technician operating correctly. Ensure that the ether canister
(ET) to the cab data link connector. is not empty. STOR
B. Turn the ignition key switch to the ON position. • Not OK - Proceed to Test Step 4.
C. Access the Customer Specified Parameter Test Step 4. Check the ECM on ET
Screen in order to make sure that the ECM is
programmed to use the starting aid output. A. Connect ET to the cab data link connector.
D. Ensure that the starting aid circuit is connected B. Turn the ignition key switch to the OFF position.
to the programmed output.
Expected Result: JI/P1.
The circuit is connected to the correct ECM terminal D. Install a 70 Terminal breakout T between
that is selected for the "Starting Aid Output". connectors J1 and P1.
Results: E. If the "Starting Aid Output" is programmed to

J1/P1:10, connect a voltage test lamp to terminal
• OK - Proceed to Test Step 3. 10 (Output 2) and terminal 65 (-Battery) of the
breakout T.
• Not OK - Update the customer specified
parameter in order to match the correct output R If the "Starting Aid Output" is programmed to
terminal. Proceed to Test Step 3. J1/P1:12, connect a voltage test lamp to terminal
12 (Output 3) and terminal 65 (-Battery) of the
Test Step 3. Check the Relay on ET breakout T.
A. Turn the ignition key switch to the ON position. G. If the "Starting Aid Output" is programmed to
J1/P1:13, connect a voltage test lamp to terminal
13 (Output 4) and terminal 65 (-Battery) of the
breakout T.
Personal injury or death can result from not fol- H. Turn the ignition key switch to the ON position.
lowing the proper procedures.
i. Access the "Starting Aid Output Special Test"
To avoid the possibility of injury or death, follow on ET.
the established procedure.
J, Cycle the corresponding "Starting Aid Output
Special Test" to the ON position and to the OFF
position and watch the voltage test lamp.
371
K. Stop the "Starting Aid Output Special Test". A starting aid feature that is controlled by the ECM
is available with NOV99 and newer software.
Note: A multimeter can not be used in place of the
voltage test lamp when the ECM outputs are being The starting aid system does not require a switch
tested. for automatic operation. A switch can be installed in
order to allow the operator to override the automatic
Note: The "Starting Aid Output Special Test" will starting aid. If a switch is installed and the "starting
only remain active for one second in order to aid On/Off switch" parameter is programmed to the
prevent accidental discharge. The test lamp will corresponding switch input, the switch will control
turn off when the "Starting Aid Output Special Test" the starting aid system. The starting aid system
is disabled. will automatically enable the starting aid output
when the switch is in the ON position. However,
Expected Result: the conditions must require the use of a starting
aid. When the switch is in the OFF position, the
The voltage test Lamp will turn ON when the starting aid system will not function. If the "Starting
"Starting Aid Output Special Test" is active. The Aid On/Off Switch" parameter is programmed to
voltage test lamp will turn off when the "Starting Aid "None" (default), this feature is not used. The
Output Special Test" is disabled. "Starting Aid On/Off Switch" parameter should be
programmed to one of the inputs (J1/P1:7, J1/P1:47,
Results: J1/P1:6, J1/P1:46). Also, the switch circuit should
be connected to the same input option.
• OK - T h e ECM is OK. The problem is in the
vehicle wiring. Inspect the vehicle wiring and then Note: The wiring for your particular application may
repair the vehicle wiring. Otherwise, send the be slightly different. The sensor common circuits are
vehicle to the OEM dealer for repair. Verify that used interchangeably by the OEM of the vehicle.
the original condition is resolved. STOR The following circuits are common within the ECM:
• Not OK - Temporarily connect a test ECM. Use • The "Input Sensor Common 1" is terminal 18.
the "Starting Aid Output Special Test" on ET to
check the ECM. If the problem is resolved with • The "Input Sensor Common 2" is terminal 3.
the test ECM, install the suspect ECM. If the
problem returns with the suspect ECM, replace • The "AP Sensor/Switch Sensor Common" is
the ECM. Verify that the repair eliminates the terminal 5.
problem. STOR
i01627841
Starting Aid Switch Circuit-

Test
SMCS Code: 7332-038

starting aid switch is operating correctly.

to this procedure:
The ECM can use various inputs in a number

programming. Certain features are available on
"Starting Aid On/Off Switch"

372
ECM
STARTING AID G841-GN~ INPUT |4

ON/OFF SWITCH G842-GY-~I47~ INPUT #5
7~o(SHOWN IN OFF POSITION) C84~-0R-1-<16~INPUT |6
• G844-Pqfi145, INPUT J7
[-- H795-PK-~_J_~ AP SENSOR/SWITCH SENSOR COMMON
P1 J1
NOTE:INPUT ~4,15.16 OR 17 MAY BE USED. THE STARTING AID ON/OfF SWITCH

Illustration 174
g00682699
Schematic for the Starting Aid Switch
INPUT 4
ooooo ooo,
oooo o ~@__q~~ INPUT 6
o o o [ / - ~ x / o-6~o2~T~.
o o.gm_Lt_k_mkL~
o -o- o o3il II INPUT 7
II I'.,--. ~ o o o o,0tl II
INPUT 5
INPUT 6
~~4 1 2 3 II 4 5 6 ~ -j. 8 9 10II 11 12 13~'~
-'~
oooe@eDooooo
oo©(F~oooo@s INPUT 4
~24oooo /~\ 000031
i
~] O O O O (( ( . . } ) ) 3 6 O O O O p ' E INPUT 5
d400000~ OOQ@,7
1114800000 000C~57 INPUT 7
0000000000000
\ ~ . . 585960 61 62 63 rq 6566 676869 7 O j
~-- II II J
HARNESS SIDE
g00682618
Illustration 175
Test Step 1. Check the Electrical C. Check the ECM connector (allen head screw) for
Connectors and the Wiring the proper torque of 6.0 N.m (55 Ib in).
Ao Thoroughly inspect the ECM vehicle harness D. Check the harness and the wiring for abrasion
connector J1/P1, the connectors, and the firewall and pinch points from the battery to the ECM
bulkhead connectors. Refer to Troubleshooting, Then, check from the ignition key switch to the
"Electrical Connectors - Inspect" for details. ECM.
B. Perform a 45 N (10 Ib) pull test on each of the Refer to Illustration 175 for terminal locations
wires in the ECM connector that are associated for the ECM,
with the circuit for the starting aid switch.
373
Expected Result:
points.
Results:
• Not OK - Repair the wiring and connectors or

the repair eliminates the problem. STOP.
Test Step 2. Check the "Starting Aid

On/Off Switch' Status on ET
D. View the "Starting Aid On/Off Switch" status on

ET.
E. If the "Starting Aid On/Off Switch" status indicates

"Not Installed", then the "Starting Aid On/Off
Switch" parameter has not been programmed.
Expected Result:
The status screen should indicate ON if the switch
is turned on. The status screen should indicate OFF
if the switch is off.
Results:
resolved. STOR
• Not OK - The ECM is not reading the "Switch

Status" change. Proceed to Test Step 3.
374
Test Step 3, Check the Switch Circuit for

the E C M
Input #6
!
o o o oo
AP Sensor~Switch Sensor Common
I 230 0 0 0 000014
Input i~4
310 0 0 0 I"____~] 0 0 0 024
390 O O O ~~O- 000032 Input |5
478 9 0 0 000040
~
Input #7
570 OOOO 000048
100 0 0 0 0 0 0 0 0 0 0 0 0 5 8
g00682624
Illustration 176
Connector for the Breakout T
A. Turn the ignition key switch to the OFF position. 1. Temporarily connect a test ECM. Only connect
ECM harness JI/P1.
B, Install a 70 terminal breakout T to the ECM
vehicle harness connector J1/P1. 2. Recheck for an +5 V diagnostic code when
the engine harness is disconnected.
Crimp a Deutsch pin to both ends of the wire. 3. If the problem is resolved with the test ECM,
D. Insert the jumper wire into the input terminal for
the starting aid switch of the breakout T. Connect 4. If the problem returns with the suspect ECM,
the other end of the jumper wire to terminal 5 in replace the ECM.
the breakout T. Terminal 5 is AP Sensor/Switch
Common. STOR
Note: Refer to the programmed selection of Test Step 4. Insert a Jumper Wire at the
the "starting aid On/Off switch" parameter. This Switch
reference will display the appropriate input.
E, Connect ET to the cab data link connector.
B, Reconnect the ECM vehicle harness connector
F. Turn the ignition key switch to the ON position. JI/P1.
G. Alternately remove the jumper wire and then C, Fabricate a jumper wire 100 mm (4 inch) long.
insert the jumper wire from terminal 5. At the Crimp a Deutsch pin to both ends of the wire.
same time, monitor the status screen on ET.
D. Insert the jumper wire between the two switch
Expected Result: terminals of the starting aid switch.
The switch status changes to "ON" with the jumper E. Turn the ignition key switch to the ON position.
when the jumper wire is removed. R Alternately remove the jumper wire and then
insert the jumper wire at the switch terminals. At
Results: the same time, watch the status screen on ET.
• OK - T h e ECM is functioning properly at this Expected Result:

• Not OK - The ECM is not functioning properly. wire in place. The switch status changes to "OFF"
when the jumper wire is removed.
procedure:
375
Results: i01870995
• OK Tachometer Circuit - Test

Repair: Perform the following diagnostic SMCS Code: 7462-038
procedure:
Replace the switch.
If the vehicle tachometer is driven by the ECM the
Verify that the repair eliminates the problem. vehicle tachometer will be connected to the ECM
through connector J1/P1:38 and/or J1/P1:39. Some
STOR tachometers require only one of the ECM tachometer
signal lines to operate while other tachometers may
• Not OK - There is a problem in the wire harness require both of the ECM tachometer signal lines to
between the starting aid switch and the ECM. operate.
Test Step 5. Insert a Jumper Wire at the to this procedure:
Bulkhead Connector
The tachometer circuit consists of the tachometer
A. Turn the ignition key switch to the OFF position. that is connected to the ECM through connector
J1/P1 and associated wiring. The ECM engine
B. Fabricate a jumper wire 100 mm (4 inch) long. speed signal is provided by the primary engine
Crimp a Deutsch pin to both ends of the wire. speed/timing sensor. The ECM converts the signal
from the primary engine speed/timing sensor into
C. Locate the socket for the starting aid switch engine rpm in pulses per revolution before the ECM
that is suspect in the engine side of the ECM sends a signal to the tachometer. The selection of
bulkhead connector. the pulses per revolution for the tachometer is done
through the "Tachometer Calibration" parameter.
D. Insert the wire jumper pin between the switch
socket and the sensor common connection. The ECM tachometer signal is programmable
Install the jumper wire on the engine side of the from 12.0 to 500.0 pulses per revolution in 0.1
ECM bulkhead connector. increments. The tachometer must be calibrated
identically to this value for proper operation.
The most likely source of a tachometer circuit
F. Alternately connect and then disconnect the problem is the vehicle wiring. The second most
jumper wire. At the same time, monitor the status likely source of a tachometer circuit problem is
screen on ET. the tachometer and the least likely source of a
tachometer circuit problem is the ECM.
Expected Result:
Note: A tachometer may also be driven by the SAE
The switch status changes from "ON" with the J1587 data link or the J1939 data link. If the engine
jumper wire in place. The switch status changes to ECM communicates with the electronic service tool
"OFF" when the jumper wire is removed. and the instrument cluster uses the signal from a
data link, the problem is in one of two locations.
Results: Either the problem is in the wiring from the ECM to
the dash, or the problem is in the dash.
between the bulkhead connector and the switch. Note: Do not disturb the secondary engine
Inspect the vehicle wiring and then repair the speed/timing sensor and the primary engine
vehicle wiring. Otherwise, send the vehicle to speed/timing sensor in order to troubleshoot a
the OEM dealer for repair. Verify that the original tachometer circuit problem. If there is a problem
condition is resolved. STOP. that is associated with the sensors, refer to
Troubleshooting, "Engine Speed/Timing Sensor
• Not OK - The problem is in the vehicle wiring Circuit - Test". Any problem that is associated with
between the bulkhead connector and the ECM. the secondary engine speed/timing sensor and the
Inspect the vehicle wiring and then repair the primary engine speed/timing sensor will be apparent
vehicle wiring. Otherwise, send the vehicle to because of engine operation with a diagnostic code
the OEM dealer for repair. Verify that the original that is present. There are no diagnostic codes that
condition is resolved. STOR are associated with the tachometer circuit.
376
TACHOMETER ECM
- - -- 450-YL ~TACHOMETER POSITIVE

X ~ 451-BR TACHOMETER NEGATIVE
P1 J1

Schematic No. 1 for tachometer
TACHOMETER
ECM
450-YL TACHOMETER POSITIVE
- 451-BR TACHOMETER NEGATIVE
TO STARTER P! J1
CASE GROUND

Schematic No. 2 for tachometer
Test Step 1. Use an Electronic Service • Result 2 - The engine rpm is not indicated or the
Tool to Check the ECM Tachometer engine rpm is erratic. Proceed to Test Step 2.
Signal
• Result 3 - T h e engine rpm is not within 50 rpm
A. Connect the electronic service tool at the data of 1500 rpm. Proceed to Test Step 6.
link connector.
Test Step 2. Determine the Type of
B. Turn the key switch to the ON position. Connection
C. Access the "Tachometer Circuit Test". Access A. Determine if the wiring for the tachometer is
the following display screens in order: wired directly to the ECM or through the J1939
or J1587 data link.
• "Diagnostics"
Expected Result:
The tachometer is wired directly to the ECM.
• "Special Test"
Results:
D. While the clash tachometer is being monitored,
begin the test. • OK - The tachometer is wired directly to the
Expected Result:
• J1939 data link - T h e tachometer is wired through
RESULT 1 The dash tachometer indicates the J1939 data link.
approximately 1500 + 150 rpm and the dash
tachometer is stable. Repair: Refer to Troubleshooting, "Powertrain
Data Link Circuit - Test".
RESULT 2 The tachometer does not indicate an
engine rpm or the tachometer is erratic. STOR
RESULT 3 The tachometer rpm is stable but the • J1587 data link - T h e tachometer is wired through
tachometer rpm is not within 50 rpm of 1500 rpm. the J1587 data link.
Results: Repair: Refer to Troubleshooting, "ATA (SAE

J1587 / J1708) Data Link Circuit - Test".
• Result 1 - T h e ECM and the tachometer are OK.
STOP. STOR
377

and Wiring
1300000000000001
z3ooooo o 0000014
310 0.,0 0 ~ 0 0 0 024
TACHOMETER POSITIVE
39~J1~0 0 ~ O x ~ J 0 0 0 O32
TACHOMETER NEGATIVE
470"0 0 0 0 0 0 O4C
57OOOOO o 0 000 048
10OOOOOOOOOOOOO5~
~--. ~
1 2 3 4 5 6 r7 8 9 10 11 1213~
OOOOOOOOOOOOO
1400000 ~ 000002~
-I:24O 0 0 O /'-~-~"x 000_-0_31 TACHOMETER POSITIVE
oooo (( 0 )) TACHOMETER NEGATIVE
~1400000 ~ 000047
1114800000 0000057
u-I O 0 0 O O 0 0 O O 0 0 O O
~__ 58 59 60 61 62 63 r7 65 6667 68 69 70_//
II II J
Harness Side
A, Thoroughly inspect the J1/P1 ECM connector, the Results:

firewall bulkhead connector, and the terminals
for the tachometer in the connectors. Refer • OK - Proceed to Test Step 4.
to Troubleshooting, "Electrical Connectors -
Inspect" for details, • Not OK
B, Perform a 45 N (10 Ib) pull test on each of the Repair: Perform the following repair:
with the terminals for the tachometer: 1. Repair the connectors or wiring and/or replace
• P1:38 seals are properly in place and ensure that the
• P1:39
STOP.
the proper torque of 6.0 N-m (55 Ib in). Test Step 4. Check the ECM Connection
to the Tachometer
B. Check the harness and wiring for abrasion and
pinch points from the battery to the ECM. A. Inspect the J1/P1 ECM connector. Verify that the
connections are present at P1:39 Tachometer-
Expected Result: and/or P1:38 Tachometer+.
All connectors, pins and sockets should be Note: Some of the tachometers require only one
completely coupled and/or inserted and the harness signal line to be connected. Either of the ECM
and wiring should be free of corrosion, abrasion terminals can be used for this type of tachometer.
or pinch points. The other wire should be left disconnected. If both
wires are connected, and one indicates an open
circuit, repair this line.
378
Expected Result:
Wires are connected to the ECM terminals for the

tachometer, P1:39 (Tachometer-) and/or PI: 38
(Tachometer+).
Results:
• OK - T h e ECM is providing the signal for the

tachometer. Proceed to Test Step 5.
• Not OK - The ECM is not connected in order to

supply the signal to the tachometer.
Repair: Send the vehicle to the OEM dealer in

order to repair the tachometer circuit.
STOR
Test Step 5. C h e c k the E C M T a c h o m e t e r

Signal
r(l~ooooooooooooo~ /
112~0 0 0 0 0 o 0 0 0 00t41
TACHOMETER POSITIVE
TACHOMETER NEGATIVE
i II-OO o o ~ -~ ~ ~ o,0 I
/llSTOOOOO o ooooo~8 I
\~70o o o o o o o o o o o o o58j
g00649125
Illustration 180
ECM BreakoutT-connector
Note: Performing certain steps within this procedure • "Diagnostics"

requires the use of a multimeter that is capable of
measuring a PWM Duty Cycle. • "Diagnostic Tests"
A. Disconnect the J1/P1 ECM connector. • "Special Test"
B. Connect a 140-2266 Cable (Seventy-Pin F. Attach one of the multimeter leads to the jumper
Breakout) between the J1 and P1 ECM connector wire from P1:38.
G. Attach the other multimeter lead to the jumper

C. Fabricate two jumper wires 100 mm (4 inch) long. wire from P1:39.
Crimp a Deutsch Pin to one end of each wire.
H. While the "Tachometer Circuit Test" is being run,
D. Insert one of the jumper wires into P1:39 observe the reading on the multimeter.
(Tachometer-) of the breakout T and insert the
other jumper wire into P1:38 (Tachometer+) of Expected Result:
the breakout T.
The multimeter indicates a duty cycle from 30
Refer to Illustration 180. to 70 percent from each of the terminals for the
tachometer while the engine is running.
E. Access the "Tachometer Circuit Test". Access
the following display screens in order:
379
Results: 2. Verify that the repair eliminates the problem.
• OK - The ECM tachometer output is OK. STOR
Repair: Remove the breakout T and reconnect the • Not OK - The tachometer is not correctly
J1/P1 ECM connector. calibrated.
Proceed to Test Step 7. Repair: Perform the following repair:
• Not OK - The duty cycle is out of the range. 1. Calibrate the tachometer in order to match
the ECM.
a. If the tachometer calibration is known and
1. Temporarily connect a test ECM. the tachometer calibration is within 12.0 to
500.0 pulses per revolution, change the
2. Remove all jumpers and replace all connectors. Customer Programmable Parameter of the
ECM "Tachometer Calibration" in order to
3. Recheck the system for active diagnostic match the tachometer.
codes.
4. Repeat the test step.
STOR
reconnect the suspect ECM. Test Step 7. Check the ECM Connection
to the Tachometer
6. If the problem returns with the suspect ECM,
replace the ECM. A. Find the tachometer signal connections to the
tachometer.
B. Disconnect the wires from the ECM to the
STOP. tachometer at the ECM connector and at the
tachometer.
Test Step 6. Inspect the Tachometer
Calibration Refer to Illustration 180.
A. Determine the tachometer engine speed C. Check for continuity through the wires to the
calibration setting in pulses per revolution. You ECM connector P1:39 (Tachometer-) and P1:38
may be required to contact the OEM dealer or (Tachometer+).
you may be required to send the vehicle to the
OEM dealer for this information. Note: Some of the tachometers require only one
signal line to be connected. Either of the ECM
B, Connect the electronic service tool to the data terminals can be used for this type of tachometer.
link connector. The other wire should be left disconnected. If both
wires are connected, and one indicates an open
C. Check the "Tachometer Calibration" parameter circuit, repair this line.
on the "Configuration" screen.
Expected Result:
Expected Result:
The wires from the ECM to the tachometer are
The "Tachometer Calibration" matches the ECM undamaged.
tachometer calibration.
Results:
Results:
• OK - The wiring is OK. Proceed to Test Step 8.
• OK - T h e tachometer is correctly calibrated.
• Not OK - The wiring is damaged.
1. If the tachometer is correctly calibrated but
the tachometer does not work, replace the
tachometer or send the tachometer to the OEM
dealer for repair.
380
Either repair the wiring or send the vehicle to the The ECM can use various inputs in a number
OEM dealer. Verify that the repair eliminates the of ways. The inputs depend on the parameter
problem. programming. Certain features are available on
STOR switch must match the actual switch installation in
the Tachometer Torque Limit Switch
A. Connect the tachometer lines to the ECM and The torque limit switch provides a way to temporarily
the tachometer. protect equipment from damage that is caused
by applying too much torque. Torque limiting is
B, Check the positive battery connections and the typically used during PTO operation. Torque limiting
negative battery connections to the tachometer. can also be used when the PTO On/Off switch is
Include the fuses and the circuit protection. in the OFF position.
Expected Result: In order to use torque limiting, a "Torque Limit" must

be programmed. The "Torque Limit" parameter is
The tachometer is receiving the correct battery located under the "Dedicated PTO Parameters".
supply voltage. The default setting is 3400 N.m (2500 Ib ft). The
"Torque Limit Switch" input selection must also be
Results: programmed. If the "Torque Limit Switch" parameter
is programmed to "None" (default), this feature is
• OK - T h e battery supply voltage is OK. not used. If the "Torque Limit Switch" is programmed
to J1/P1:7, then the feature is available and the
Repair: Perform the following repair: switch circuit should be connected to terminal 7 of
the J1/P1 ECM vehicle harness connector.
If the tachometer is receiving the correct battery
supply voltage but the tachometer does not work, Note: The wiring for your particular application may
replace the tachometer or send the tachometer to be slightly different. The circuits for the sensor
the OEM dealer for repair. common are used interchangeably by the OEM
STOP. within the ECM:
• Not OK - The battery supply voltage is incorrect. • The "Input Sensor Common 1" is terminal 18.
Repair: Perform the following repair: • The "Input Sensor Common 2" is terminal 3.
1. Repair the wiring for the battery connection. • The "AP Sensor/Switch Sensor Common" is
terminal 5.
STOP.
i01625987
Torque Limit Switch Circuit-

Test
SMCS Code: 1435-038
torque limit switch is operating correctly.

to this procedure:
381
ECM
TORQUE LIMIT SWITCH
6841-6N-~INPUT ~4 (TORQUE LIMIT SWITCH)
L901-GY--~-<I18<-IINPUT SENSOR COMMON I1
P1 J!

Schematic for Torque Limit Switch

oo o oo .~ .r'~o o o 6 INPUT 4
OOO O o OOO OO1411
11113,0000 oooo,1
I}11;3~°°° I~ <) /I 00003:~/
111'47 oo kx-.Z/) 000o4011
Illl ,ooooo o ooooo,4l
~\\~700 O 0 0 0 0 0 0 0 0 0 587
ECM SIDE VEHICLE HARNESS CONNECTOR P1
~ 1 4 8I 2 3 II 4 5_6~8_9_10_11_12_13-'~
II ~" AP Sensor/Switch Sensor Common
OO00OQ.OO0000 ]NPUT 4
0000 >P~EI<q.XDC)C)O2~
--1240000 /'-~-'x 000031
Is 0 0 0 0 (( F..fl ) ) 3 6 0 0 0 0 r
d400000 ~ 000047
111,,800000 0000057
OOOOO00OO000O ,
~. 585960 61 62 63 H 6566 676869 70~/
II II J
HARNESS SIDE

Terminal Locationsfor ECM
Test Step 1. Check the Electrical D. Check the harness and the wiring for abrasion
Connectors and the Wiring and pinch points from the battery to the ECM.
A. Thoroughly inspect the ECM vehicle harness ECM.
bulkhead connectors. Refer to Troubleshooting, Refer to Illustration 182 for terminal locations
"Electrical Connectors - Inspect" for details. for the ECM.
B. Perform a 45 N (10 Ib) pull test on each of the Expected Result:

with the torque limit switch circuit. All connectors, pins, and sockets are completely
The wires are on the following terminals: wiring should be free of corrosion, abrasion, or
pinch points.
• terminal 7
Results:
• terminal 5
382
• Not OK - Repair the wiring and connectors or

the repair eliminates the problem. STOR

Torque Limit Switch on ET
C. Operate the switch in the ON position and the

OFF position.
D. View the "Torque Limit Switch" status on ET.
E, If the "Torque Limit Switch" status indicates

"Not Installed", then the "Torque Limit Switch"
parameter has not been programmed.
Expected Result:
The status screen should indicate "ON" if the switch

Results:

resolved. STOP.
• Not OK - The ECM is not reading the "Switch

Status" change. Proceed to Test Step 3.

the E C M
I I
~O0000000QO0
13( O0 AP Sensor/Switch Sensor Common
230
23( 0 0 0 O ----o__9__~0"~0
- '~- 0 0 014
~10000 l ~ 1
31 ( 00 0 024 ZNPUT 4
~
39( 0 0 0 0 O 0 032
447(
70 0 Q 0 Q 0 040
57(
5 700000 0 000 0 048
0 0 0 0 0 0 0 0 0 0 0 05~
' !9

A. Turn the ignition key switch to the OFF position. C, Fabricate a jumper wire 100 mm (4 inch) long.
B. Install a 70 terminal breakout T to the ECM
vehicle harness connector J1/P1.
383
D. Insert the jumper wire into terminal 7 of the F. Alternately remove the jumper wire and then
breakout T. Connect the other end of the jumper insert the jumper wire at the switch terminals. At
wire to terminal 5 in the breakout T. Terminal 5 the same time, watch the status screen on ET.
is AP Sensor/Switch Common.
Expected Result:
E. Connect ET to the cab data link connector.
F. Turn the ignition key switch to the ON position. wire in place. The switch status changes to "OFF"
when the jumper wire is removed.
G. Alternately remove the jumper wire and then
insert the jumper wire from terminal 5. At the Results:
same time, monitor the status screen on ET.
• OK
Expected Result:
The switch status changes to "ON" with the jumper procedure:
when the jumper wire is removed. Replace the torque limit switch.
• OK - T h e ECM is functioning properly at this STOR

Not OK - There is a problem in the wire harness
• Not OK - The ECM is not functioning properly. between the torque limit switch and the ECM.
1. Temporarily connect a test ECM. Bulkhead Connector
2, Remove all jumpers and replace all connectors. A, Turn the ignition key switch to the OFF position.
3, Recheck the system for active diagnostic B, Fabricate a jumper wire 100 mm (4 inch) long.
codes. Crimp a Deutsch pin to both ends of the wire.
4. Repeat the Test Step. C. Locate the torque limit switch socket in the
engine side of the ECM bulkhead connector.
reconnect the suspect ECM. D. Insert the wire jumper pin between the switch
socket and the sensor common connection.
6. If the problem returns with the suspect ECM, Install the jumper wire on the Engine side of the
replace the ECM. ECM bulkhead connector.
7, Verify that the repair eliminates the problem. E° Turn the ignition key switch to the ON position.
STOR R Alternately connect and then disconnect the

Test Step 4. Insert a Jumper Wire at the screen on ET.
Switch
Expected Result:
The switch status changes from "ON" with the
B, Reconnect the ECM vehicle harness connector jumper wire in place. The switch status changes to
JI/P1. "OFF" when the jumper wire is removed.
C. Fabricate a jumper wire 100 mm (4 inch) long. Results:

D. Insert the jumper wire between the two switch between the Bulkhead connector and the switch.
terminals of the torque limit switch. Inspect the vehicle wiring and then repair the
E, Turn the ignition key switch to the ON position. the OEM dealer for repair. Verify that the original
condition is resolved. STOP.
384

i01871027
Two Speed Axle Switch Circuit

- Test
SMCS Code: 7332-038-ZX
The "Two Speed Axle Switch" is suspected of

incorrect operation.
Two Speed Axle Switch

If a two-speed axle is used, the change in gear
ratios alters the calibration of the vehicle speed
signal. When the Two-Speed Axle Switch is in the
ON position, the ECM will automatically adjust
the vehicle speed calibration. This will ensure
that the ECM driven speedometer and the stored
information in the ECM correctly reflect the actual
vehicle speed. In order for this feature to function
properly, the "Low Speed Range Axle Ratio" and
"High Speed Range Axle Ratio" parameters must
be programmed. If the "Two Speed Axle Switch"
parameter is programmed to "None" (default),
this feature is not used. If the "Two Speed Axle
Switch" parameter is programmed to J1/P1:6, the
feature is available and the switch circuit should
be connected to terminal 6 of the J1/P1 ECM
connector. The switch can also be connected

be slightly different. The sensor common circuits are
used interchangeably by the OEM of the vehicle.
The following circuits are common within the ECM:
• The "AP Sensor/Switch Sensor Common" is

terminal 5.
385
2-SPEED AXLE SWITCH ECM

G843-OR~INPUT J6 (2-SPEEDAXLESWITCH)
L901-GY--~-qlS~INPUT SENSOR COMMON Jl
/
P1 J1
Schematic for Two Speed Axle Switch Circuit
INPUT 6
o o o o o o e*o%~ o o ot] AP SENSOR/SWITCH SENSOR COMMON
II 1123oo o o o o o o o.I
1111;3,oooo ~ oooo21
1111399_o o o o o o o3~'
111470 0 0 0 000040~
Illl,,ooooo o ooooo,
[\\~700QOQOQO00000058'
1 2 3 4 5.._6. u 8_9_10_11_12_13~'~ AP SENSOR/SWITCH SENSOR COMMON

O000-QDO00000 i~ INPUT 6
00©0 >PEI< 0 0 0 0 ~ 2 ~
d240000 / , ~ ~ OUUUs~F
Is 0 0 0 0 (( < ) ) ) 3 6 0 0 0 0 El
d400000 ~ 0000"~
111,800000 0000057111
OOO0000000000
\\.585960 61 62 63 n 6566 676869 7 0 J /
HARNESS SIDE

Test Step 1. Check the Status of the "Two Results:

Speed Axle Switch"
A. Connect the electronic service tool to the data troubleshooting if the original condition is not
link connector. resolved. STOP.
B. Turn the key switch to the ON position. • Not OK - The ECM is not reading the "Switch
Status" change. Proceed to Test Step 2,
C. Monitor the status for the "Two Speed Axle
Switch" while the switch is operated in the QN Test Step 2. Determine the Configuration
and OFF positions. of the Switch
D. If the "Two Speed Axle Switch" status indicates A. Determine if the wiring for the switch is wired
"Not Installed", then the "Two Speed Axle Switch" directly to the ECM or through the J1939 data
parameter has not been programmed. link.
Expected Result: B. Verify that the "Two-Speed Axle Switch"

parameter is programmed to reflect the proper
The status screen should indicate "QN" if the switch wiring.
386
Expected Result: • Not OK - Repair the wiring and connectors or

The switch is wired directly to the ECM. all of the seals are properly connected. Verify that
the repair eliminates the problem. STOP.
Results:
• OK - The switch is wired directly to the ECM.
Repair: Verify that the "Two-Speed Axle Switch"

parameter is programmed to "J1/P1:6".
• Not OK - The switch is wired through the J1939

data link.
Repair: Verify that the "Two-Speed Axle Switch"

parameter is programmed to "J1939 - Body
STOP.


with the two speed axle switch circuit:
• terminal 6
• terminal 5


Refer to Illustration 185 for terminal locations

for the ECM.
Expected Result:
wiring should be free of corrosion, abrasion, or
pinch points.
Results:
387

the ECM.
ooooooo.'o..OOOO,
230 0 0 O 0 0 0 0 014
INPUT 6
310 0 0 0 ~ 0 0 0 024
390000 ~ J 000032
47OOOO 00004c
.57000 00 O O O O OO41~
7o000000000 0000~8

A. Turn the key switch to the OFF position. 2. Remove the breakout T and reconnect the J1
B. Install a 140-2266 Cable (Seventy-Pin Breakout)
between the J1 and P1 ECM connector. 8. If the problem is resolved with the test ECM,
Crimp a Deutsch pin to each end of the wire. 4. If the problem returns with the suspect ECM,
replace the ECM.
B. Insert the jumper wire into terminal 6 of the
breakout T. Connect the other end of the jumper 5. Verify that the repair eliminates the problem.
wire to terminal 5 (AP Sensor/Switch Common)
of the breakout T. STOR
E. Connect the electronic service tool to the data Test Step 5. Insert a Jumper Wire at the
link connector. Switch
F. Turn the key switch to the ON position. A. Turn the key switch to the OFF position.
G. Alternately remove the jumper wire and then B. Fabricate a jumper wire 100 mm (4 inch) long.
insert the jumper wire from terminal 5. At the Crimp a Deutsch pin to both ends of the wire.
same time, monitor the status screen on the
electronic service tool. C. Locate the switch for the Two-Speed Axle.
Insert the jumper wire between the two switch
Expected Result: terminals.
The switch status changes to "ON" with the jumper D. Turn the key switch to the ON position.
when the jumper wire is removed. E, Alternately remove the jumper wire and then
insert the jumper wire at the switch terminals. At
Results: the same time, watch the status screen on the
• OK - The ECM is functioning properly at this time.
Expected Result:
the J1 and P1 ECM connectors. The switch status changes to "ON" with the jumper
Proceed to Test Step 5. when the jumper wire is removed.
• Not OK - The ECM is not functioning properly. Results:

Repair: Perform the following repair: • OK - Replace the switch. Verify that the repair
solves the problem. STOR
1. Temporarily connect a test ECM
388
• Not OK - There is a problem in the wire harness • There is an easily repeated diagnostic code that
between the switch for the two-speed axle and is associated with the vehicle speed circuit.
the ECM. Proceed to Test Step 6.
Refer to Troubleshooting, "Vehicle Speed Circuit -
Test Step 6. Insert a Jumper Wire at the Calibrate" if the vehicle speed is being calibrated
Bulkhead Connector in ppm (pulses per mile) or PPKM (pulses per
kilometer).
B. Fabricate a jumper wire 100 mm (4 inch) long. to this procedure:
The vehicle speed circuit consists of the vehicle
C. Locate the two speed axle switch socket in the speed source and associated wiring. The
engine side of the ECM bulkhead connector. vehicle speed source is installed by the vehicle
OEM. Usually, a sensor reads movement of the
D. Insert the wire jumper pin between the switch transmission output shaft from the teeth on a
socket and the sensor common connection. chopper wheel. The ECM converts the signal from
Install the jumper wire on the engine side of the the vehicle speed source into vehicle speed for the
ECM bulkhead connector. following functions:
E. Turn the key switch to the ON position. • Cruise Control
F. Alternately connect and then disconnect the • Idle Speed Control

screen on the electronic service tool. • Progressive Shift
Expected Result: • Driver Reward
The switch status changes from "ON" with the • Speedometer

jumper wire in place. The switch status changes to
"OFF" when the jumper wire is removed. • Battery Monitor Engine Speed Control
Results: • PTO Operation
• OK - T h e problem is in the vehicle wiring • Vehicle Speed Limiting

between the bulkhead connector and the switch.
Inspect the vehicle wiring and then repair the • Engine Retarding
the OEM dealer for repair. Verify that the original • Idle Shutdown
• Secure Idle Theft Deterrent
between the bulkhead connector and the ECM. • Trip Data
vehicle wiring. Otherwise, send the vehicle to • Maintenance Data
condition is resolved. STOR To begin troubleshooting a vehicle speed problem,
the following information must be determined:
i01871031 The problem is electrical or the problem is a
Vehicle Speed and calibration problem.
Speedometer Circuit- Test Electrical problems would be an erratic speed

signal or no speed signal. A calibration problem
SMCS Code: 7463-038 would be a stable ECM speed, but an inaccurate
ECM speed. Another calibration problem would be
System Operation Description: a stable speedometer speed, but an inaccurate
speedometer speed.
• There is an active diagnostic code.
389
If the problem is related to vehicle speed calibration, • The circuit is operating properly.
refer to Troubleshooting, "Vehicle Speed Circuit
- Calibration" for calibrating the vehicle speed • The speedometer is operating properly.
in PPKM (pulses per kilometer) or ppm (pulses
per mile). The ECM Speedometer output signal is Note: While the test is active, the odometer will
set to 18,600 PPKM (30,000 ppm) and the ECM increment mileage.
speedometer output signal cannot be changed. All
speedometers that are driven by the ECM output Magnetic Sensors
(J1/P1:36 & 37) must match the ECM (30,000 ppm)
in order to operate properly. A magnetic pickup will have only two wires if the
magnetic pickup is a single coil magnetic sensor.
The type of vehicle speed sensor that is installed on Also, a magnetic pickup will have four wires if the
the vehicle must be determined. magnetic pickup is a dual coil magnetic sensor. The
magnetic pickup sensor does not require a power
Both single coil magnetic sensors and dual coil connection or a ground connection.
magnetic sensors are commonly used. Caterpillar
recommends single coil magnetic sensors. Some of Vehicles with Electronic Vehicle Speed Sources
the vehicles may provide the vehicle speed through
the transmission ECM. For these vehicles, the vehicle speed signal is
provided by an electronic source. The signal is
You must determine if the vehicle speedometer is received over a single wire that is connected
driven from the ECM. to J1/P1:32 (Vehicle Speed In Positive). No
other connection should be made to this line. A
The ECM can drive the speedometer through the speedometer is an example of a connection that
connection to J1:36 (Speedometer Positive) and/or should not be made to this line. For this type of
J 1:37 (Speedometer Negative). signal, the J1/P1:33 (Vehicle Speed In Negative)
should not be connected to the ECM in order to
Note: The ECM may also drive the speedometer prevent introducing electrical noise into the circuit.
by a connection to the J1587 ATA data link or the
J1939 data link, if the instrument cluster is capable For vehicle speed problems on trucks that are
of interpreting the signal. equipped with either of these vehicle speed
sources, first inspect the wiring from the electronic
Vehicle Speed Circuit Wiring source to the engine ECM for open circuits or short
circuits.
The vehicle speed signal is connected to the ECM
at J1/P1:32 (Vehicle Speed In Positive) and J1/P1:33
(Vehicle Speed In Negative).
Speedometer Connection
If the speedometer is driven by the ECM output,

the speedometer is connected to the following
terminals:
• J1/P1:36 (Speedometer Positive)
• J1/P1:37 (Speedometer Negative)
Note: Some speedometers require only one of the

ECM signal lines to operate. Other speedometers
may require both of the ECM signal lines to operate.
Speedometer Special Test
If the vehicle speedometer is driven by ECM

output, the speedometer circuit can be checked
by using the electronic service tool. The "55 mph
VSP/Speedometer Test" will drive the speedometer
to approximately 55 mph under the following
conditions:
• The "55 mph VSP/Speedometer Test" is activated.

390
SPEEDOMETER
ECM
VEHICLE SPEED SENSOR
VEHICLE SPEED +
VEHICLE SPEED -
X~] X C974-PU
C973-GN q ~ 1 3 7 ~
osos-au -K132<
GSO9-GN--~J_~
SPEEDOMETER +
SPEEDOMETER -
VEHICLE SPEED IN +
VEHICLE SPEED 1N -
P1 J1
g00643046
Illustration 187
Schematic for a single coil speed sensor and an ECM driven speedometer
VEH[CLE SPEED+
VEHICLE SPEED-
I X--~ SPEEDOMETER
ECM
VEHICLE SPEED SENSOR C974-PU K I 36 SPEEDOMETER +

C973-GN K 374 SPEEDOMETER -
VEHICLE SPEED+ ~ - - G808-BU I< I 32 VEHICLE SPEED IN ÷
VEHICLE SPEED- ~~-p21> I X X Gsog-cN I< I ~ VEHICLE SPEED IN -
P1 J1
g00643048
Illustration 188
Schematic for a single coil speed sensor and a second single coil sensor for a speedometer
SPEEDOMETER ~ ~
ECM
J1587 DATA LINK+

J1587 DATA LINK-
VEHICLE SPEED - - G808-BU VEHICLE SPEED IN+
VEHICLE SPEED X X G8og-GN ~l,~,~ VEHICLE SPEED I N -
PI J1
g00643050
Illustration 189
Schematic for a single coil speed sensor and a data link driven speedometer
391
SPEEDOMETER~ - - ~ - -
ECM
ELECTRONZC VEHICLE SPEED SOURCE ~/~ ,, C974-PU SPEEDOMETER+

c973-CN - K ],~7 SPEEDOMETER-
VEHTCLE SPEED~I".I .,, GeOS-BU - K I s2'~ VEHICLE SPEED IN+
1- i-i I
~809-GN --KI3~ VEHICLE SPEED I N -

P1 J1

Schematic for an electronic vehicle speed source and an ECM driven speedometer
SPEEDOMETER
ECM
ELECTRO.ZC VEHZCLE SPEED SOURCE

_
SPEEDOMETER+
C973-GN SPEEDOMETER-
SPEEDOMETER G8OS-BU VEHICLE SPEED IN+
G809-GN VEHICLE SPEED I N -
VEHICLE SPEED~" I>1

Schematic for an electronic vehicle speed source and a speedometer
392
{~ooooooooooooo~
SPEEDOMETER NEGATIVE
SPEEDOMETER POSITIVE
I~,o o
I~,o o ~ ~ VEHICLE SPEED POSITIVE
VEHICLE SPEED NEGATIVE
1~70 O 0 O 0 o
ECM Side
f 1 2 3 4 5 6 u 8 9 10 11 12 1 3 ~
VEHICLE SPEED POSITIVE

SPEEDOMETER POSITIVE
<. il
Harness Side
g00643054
Illustration 192
Test Step 1. Determine the Type of Repair: Refer to Troubleshooting, "ATA (SAE
Connection J1587 / J1708) Data Link Circuit - Test".
A. Determine if the wiring for the circuit is wired STaR

directly to the ECM or through the J1939 or
J1587 data link. Test Step 2. Inspect Electrical Connectors
and Wiring
Bo Verify that the "Vehicle Speed Input" parameter
is programmed to reflect the proper wiring. A. Thoroughly inspect the J1/P1 ECM connector,
Expected Result: for vehicle speed (terminals 32 and 33) in the
The suspect input is wired directly to the ECM. Connectors - Inspect" for details.
Results: B. Perform a 45 N (10 Ib) pull test on each of the

• OK - The suspect input is wired directly to the with the vehicle speed sensor.
• J1939 data link - The suspect input is wired
through the J1939 data link. C. Check the ECM connector (allen head screw) for
Repair: Refer to Troubleshooting, "Powertrain
Data Link Circuit - Test". D. Check the harness and wiring for abrasion and
STOR
• J1587 data link -

393
Expected Result: Result 2 The status screen and speed is stable,

but incorrect.
completely coupled and/or inserted and the harness Result 3 The status screen agrees with the actual
and wiring should be free of corrosion, abrasion speed, but the ECM driven speedometer is incorrect
or pinch points. or inoperable.
Results: Result 4 The speed that is displayed on the status

screen is not present, unstable, or erratic.
Results:
• Not OK
Result 1 - There is not a vehicle speed problem
Repair: Perform the following repair: at this time. If a problem still exists, continue
troubleshooting until the condition is resolved.
Repair the connectors or wiring and/or replace STOR
seals are properly in place and ensure that the • Result 2 - Proceed with vehicle speed calibration
connectors are completely coupled. and adjustment.
Verify that the repair eliminates the problem. Repair: Perform the following diagnostic
procedure:
STOR
Troubleshooting, "Vehicle Speed Circuit -
Test Step 3. Determine the Type of Calibrate"
Vehicle Speed Problem
STOR
A. Perform a dynamometer test on the vehicle or
perform a road test on the vehicle. Compare the • Result 3 - Proceed to Test Step 4.
vehicle speed on the status screen on ET against
the speedometer. Also, compare the vehicle • Result 4 - Proceed to Test Step 5.
speed on the status screen against the actual
vehicle speed. The actual vehicle speed can
be measured on a dynamometer or the actual
vehicle speed can be measured by a stopwatch.
B. Monitor the vehicle speed status on the electronic

service tool while the vehicle is parked and the
engine is running.
C. Operate various electrical devices in the vehicle

while the vehicle speed is being monitored. In
order to operate the various electrical devices,
cycle the electrical devices to the ON position
and the OFF position.
D. Increase the engine rpm a few times and

decrease the engine rpm a few times.
Note: If the operation of a specific electrical

device is producing a vehicle speed problem, the
electrical device may be the source of an electrical
noise problem. An electrical noise problem is
also a possibility if increasing the engine rpm on
a stationary vehicle produces a vehicle speed
problem.
Expected Result:
Result 1 The speed that is displayed on the
status screen and the speed of the ECM driven
speedometer are stable and both speeds agree
with the actual speed.
394
Test Step 4. Use the Special Test to

Check the Speedometer
I 2 3 4 5 6 L~ 8 9 10 II 12 1~~
VEHICLE SPEED POSITIVE

114LJ~OL.x ) ~ ~ )~ )~ ~ ~I
SPEEDOMETER P O S I T I V E
~.~ 56 59 60 61 62 61 [~ 65 66 67 68 69 70 ./
Harness Side
g00723985
Illustration 193
A. Inspect the P1 ECM connector. Observe whether Results:

connections are present at either of the following
terminals: OK - T h e ECM is providing the signal for the
speedometer and the wiring and the speed are
• P1:36 (Speedometer Positive) OK. Send the vehicle to the OEM dealer for repair
of the speedometer. STOP.
• P1:37 (Speedometer Negative)
• Not OK - The ECM is not connected to the
If there is a connection to either of the speedometer.
speedometer terminals continue with the
procedure. Repair: Perform the following repair:
B, Connect the electronic service tool to the data If the ECM is not connected to the OEM
link connector. speedometer, send the vehicle to the OEM dealer
for repair of the speedometer.
C, Access the "55 mph VSP/Speedometer Test" by
accessing the following display screens in order: STOP.
• "Diagnostics" • Not OK - The speedometer does not show any

vehicle speed.
Repair: If OEM truck wiring diagrams are
• "Special Test menu" available, trace the wiring to the speedometer
and repair the speedometer, as required.
D. Activate the test and observe the speedometer.
STOR
Note: Some types of speedometers only require
one ECM signal line to be connected to the • Not OK - The vehicle speed is not within the
speedometer. Either of the ECM terminals can be proper range.
used for these speedometers.
Refer to Illustration 193. procedure:
Expected Result: Troubleshooting, "Vehicle Speed Circuit -

Calibrate"
The speedometer indicates 80 to 96 km/h (50 to
60 mph). STOR
395
Test Step 5. Determine the Type of Results:

Vehicle Speed Circuit
• OK - Reconnect the sensor to the vehicle
A. Inspect the vehicle wiring for the type of vehicle harness. Proceed to Test Step 7.
speed circuit that is being used.
• Not OK
Compare the vehicle speed circuit with the
detailed circuit schematics: Repair: Perform the following repair:
Schematic I Refer to Illustration 187. If the sensor is damaged, replace the damaged
sensor or send the vehicle to the OEM dealer for
Schematic 2 Refer to Illustration 188. repairs.
Schematic 3 Refer to Illustration 189. Verify that any repair eliminates the problem.
Schematic 4 Refer to Illustration 190. STOR
Schematic 5 Refer to Illustration 191. Test Step 7. Inspect the Passive Magnetic
Speed Sensor for Vehicle Speed.
Select the schematic that is similar to the circuit
that is being repaired. A. Remove the vehicle speed sensor from the
transmission and inspect the vehicle speed
Expected Result: sensor for steel shavings, debris, or damage.
The vehicle speed circuit is similar to Schematic Note: Shavings and debris on the sensor may
1, 2, or 3. occur unless the transmission fluid is drained and
replaced according to the maintenance schedule.
Results:
B. Wipe off the sensor until the sensor is clean.
• OK - Proceed to Test Step 6. Test the sensor according to the manufacturer's
instructions. The sensor is OEM supplied.
• Not OK -The vehicle speed circuit is similar to
Schematic 4 or 5. Proceed to Test Step 8. Note: If the gap between the vehicle speed sensor
and the chopper wheel is too small, the sensor
Test Step 6. Measure Vehicle Speed may be damaged. Also if the gap between the
Sensor Resistance at the Sensor vehicle speed sensor and the chopper wheel is too
small, the sensor may create a signal due to the
A. Disconnect the vehicle speed sensor from the vibration of the chopper wheel. This will cause a
vehicle harness. vehicle speed signal when the vehicle is parked. If
the vehicle is parked and a vehicle speed signal is
B. Thoroughly inspect the connector. Ensure that produced, back out the sensor from the wheel until
the connector terminals are free of corrosion the signal disappears. Use caution, backing out
and ensure that the connector terminals are fully the sensor too far may cause a loss of the vehicle
seated into the housing of the connector. Repair speed signal. Back out the sensor no more than
the connector terminals or replace the connector one turn to one and one quarter turns.
terminals, as required.
Expected Result:
C. Measure the resistance between the two
terminals of the sensor connector. The sensor The vehicle speed sensor is correctly installed and
resistance measurement should be 100 to 4500 undamaged.
Ohms.
Results:
D. Reverse the meter leads and measure the
resistance. Switching the probes should not • OK - Proceed to Test Step 8.
change the resistance measurement by more
than 10 Ohms. • Not OK
Expected Result: Repair: Perform the following repair:

The sensor resistance that is measured is between If the sensor is damaged, replace the damaged
100 and 4500 Ohms and the sensor resistance sensor or send the vehicle to the OEM dealer for
that is measured is within 10 Ohms with the meter repairs.
probes in either position.
396
Verify that any repair eliminates the problem.
STOR
Test Step 8. Test ECM Vehicle Speed

Inputs by Using the Speedometer Special
Test.
C oooooo
1123o o o o o o
JUMPER WIRE
113,o o o o o o-II II
JUMPER WIRE
115,oooo o o/ ooo,.ll II
g00643436
Illustration 194
Jumper wire locations for breakout T
A. Turn the key switch to the OFF position. Expected Result:
B. Fabricate two jumper wires 100 mm (4 inch) long. The electronic service tool indicates a constant
Crimp a Deutsch pin to each end of the wires. vehicle speed between 80 to 96 km/h (50 to 60 mph)
when the jumper wires from the speedometer circuit
C. Connect a 140-2266 Cable (Seventy-Pin are connected.
Breakout) between the J1 and P1 ECM
connectors. Results:
B. Install one jumper into the breakout T in order to OK - T h e ECM is operating correctly. The source
connect terminal 36 (Speedometer Positive) to of the problem is either the wiring or the source
terminal 32 (Vehicle Speed In Positive). Install of the problem is the vehicle speed sensor.
the other jumper into the breakout T in order to
connect terminal 37 (Speedometer Negative) to Repair: Perform the following repair:
terminal 33 (Vehicle Speed In Negative).
If the sensor is damaged, replace the damaged
Refer to Illustration 194. sensor or send the vehicle to the OEM dealer for
repairs.
Verify that any repair eliminates the problem.
F. Connect the electronic service tool to the data
link connector. STOR
G. Access the "55 mph VSP/Speedometer Test" by Not OK - Recheck the connections of the jumper
accessing the following display screens in order: wires. Leave the jumper wires installed in the
breakout T. Disconnect the breakout T. Proceed
• "Diagnostics" to Test Step 9.
• "Diagnostic Tests" Test Step 9. Test the ECM Vehicle Speed

Inputs When the Test ECM is Installed
• "Special Test menu"
A. Connect a test ECM and reconnect the breakout
H. Activate the test and observe the vehicle speed T.
on the vehicle speed status screen.
397
B. Install one jumper into the breakout T in order to A warning lamp is required if the "Engine Monitoring"
connect terminal 36 (Speedometer Positive) to feature is used. The warning lamp indicates an
terminal 32 (Vehicle Speed In Positive). Install active problem with one of the monitored conditions
the other jumper into the breakout T in order to such as high coolant temperature. A flashing
connect terminal 37 (Speedometer Negative) to warning lamp indicates that the engine is derating
terminal 33 (Vehicle Speed In Negative). power. The warning lamp will turn on for a minimum
of two seconds after the engine has started.
With OCT99 and newer software, a new parameter
C. Turn the key switch to the ON position. is available to provide the option of using a
single warning lamp or multiple warning lamps.
D. Access the "55 mph VSP/Speedometer Test" by The programmable "Engine Montoring Lamps"
accessing the following display screens in order: parameter provides the option of using a single
warning lamp for all monitored conditions, or
• "Diagnostics" discrete lamps for each monitored condition.
• "Diagnostic Tests" programmed to "Warning Lamp", then J1/P1:29 is
used for the connection of a single warning lamp.
• "Special Test menu" If the "Engine Monitoring Lamps" parameter is
programmed to "Option 1", then J1/P1:29 is used
E. Activate the test and observe the vehicle speed to connect a lamp for Low Oil Pressure Warning
on the vehicle speed status screen. and J1/P1:31 is used to connect a lamp for High
Coolant Temperature Warning. If an optional Coolant
Expected Result: Level Sensor is also installed then J1/P1:30 is used
to connect a Low Coolant Level Warning Lamp.
The electronic service tool indicates a constant The "Coolant Level Sensor" parameter must be
vehicle speed between 80 to 96 km/h (50 to 60 mph) programmed to "4-pin".
when the jumper wires from the speedometer circuit
are connected. If a Coolant Level Sensor is not installed or
the "Engine Monitoring Lamps" parameter is
Results: programmed to "Warning Lamp", then J1/P1:30 will
function as a PTO Switch On Lamp output. The
• OK parameter for the "Coolant Level Sensor" must be
programmed to "NO" if the sensor is not installed.
Operation of Engine Monitoring
Reconnect the suspect ECM. If the problem
returns with the suspect ECM, replace the ECM. When the ECM has detected an engine condition
that exceeds the acceptable limits, the warning
STOR lamp will turn on. The activation of the lamp depends
on the existing conditions and the programming of
• Not OK - Recheck the connectors. Continue the parameter for "Engine Monitoring". The lamp will
troubleshooting until original condition is resolved. activate in one of the following modes:
STOR
• The lamp not only turns on, but the lamp stays on.
i01624592
• The lamp will flash on and off.
Warning Lamp Circuit- Test If the lamp turns on continuously, the engine is in
SMCS Code: 7431-038 warning mode. If the lamp begins to flash, the ECM
has begun to derate engine speed, vehicle speed,
System Operation Description: or power.
Use this procedure under the following situation: If the parameter for engine monitoring is
programmed to "Warning", the lamp will not
A problem is suspected with the operation of the flash. The lamp only flashes when the engine is
warning lamp. programmed to "Derate" or "Shutdown".
The following background information is related If the Customer Parameter for Engine Monitoring is
to the following procedure: programmed to "Warning", "Derate", or "Shutdown"
the lamp will turn on when a warning condition
Warning Lamp Operation exists. The lamp will be turned on continuously
while a warning condition exists.
398
If the customer parameter for engine monitoring is

programmed to "Derate" or "Shutdown", the lamp
flashes whenever engine monitoring is derating
engine speed, vehicle speed, and power.
If the customer parameter for engine monitoring

is programmed to "Shutdown", the warning lamp
will continue flashing after the derate mode until
the engine is shut down. Refer to Troubleshooting,
"System Overview".
Output I (PTO Switch On Lamp)

Output 1 is used for the PTO Switch ON Lamp when
0CT99 or older software is used. However, the
"PTO configuration" must be programmed to "Cab
Switches", "Remote Switches", or "Remote Throttle".
The PTO Switch ON Lamp should turn on when the
circuit for the PTO On/Off Switch is turned on.
With OCT99 and newer software, "Output 1" can

be used as a PTO Switch On Lamp output or a
Low Coolant Level Warning Lamp output. The
customer parameters determine the desired usage.
programmed to "Option 1" and the "Coolant Level
Sensor" parameter is programmed to "4-pin", then
"Output 1" is used as a Low Coolant Level Warning
Lamp output. Otherwise, "Output 1" can be used as
a PTO Switch On Lamp output. With 0CT99 and
older Software, "Output 1" was the PTO Switch On
Lamp.
"Output 9"
With 0CT99 and newer Software, the "Output 9"
can be used for a High Coolant Temperature Lamp
output if the "Engine Monitoring Lamps" parameter
is programmed to "Option 1". If the "Engine
Monitoring Lamps" parameter is programmed to the
"Warning Lamp" option, then "Output 9" is not used.
Electrical Connection of Lamps

One terminal of each lamp must be connected to
battery voltage through the vehicle wiring. The other
terminal is connected to the ECM at the ECM vehicle
harness connector J1/P1 at the following terminals:
• J1/P1:29 (Warning Lamp or Low Oil Pressure

Lamp)
• J1/P1:30 (PTO Switch On Lamp or Low Coolant

Level Lamp)
• J1/P1:31 (High Coolant Temperature Lamp)
The ECM illuminates the lamp by providing a path

to ground.
399
WARNING LAMP or
LOW OIL PRESSURE LAMP
PTO SWITCH ON LAMP or ECM

LOW COOLANT LEVEL LAMP 659-PK ~ W A R N I N G LAMP
I K998-BU~<I30~ OUTPUT I1
HIGH COOLANT TEMP LAMP
I-- G 8 8 o - P K ~ OUTPUT19
P1 J1
[}0 O 0 O 0 0 0 0 0 0 0 0 0 ~ .
~0 0 0 © 0 O O O OOt~ WARNING LAMP or
~,~ Q fro ; 0 0 0 02, LOW OIL PRESSURE LAMP
~'~0 ~ O000s',
LOW COOLANT LEVEL LAMP
,~o cx,o o o o o,!0
,7OOOOO o 000004
'o000 O0 000000 00~
ECM Side
1 2 3 4 5 6 LJ 8 9 tO II 12 13~'~
COoocoocooo00
~:DOO >"'< C~QO.O,: LOW COOLANT LEVEL LAMP
4 31
WARNING LAMP or
'~ 58 59 60 61 62 63 F~ 65 66 67 68 69 7 0 j
II [I ..
Harness Side
Test Step 1. Inspect Electrical Connectors B. Perform a 45 N (10 Ib) pull test on each of the
and Wiring wires in the ECM connector that is associated
with the suspect terminal for the lamp.
connector J1/P1, the firewall bulkhead connector, Refer to Illustration 196.
and the suspect terminal for the lamp. Refer
to Illustration 196. Refer to Troubleshooting, C. Check the ECM connector (allen head screw) for
"Electrical Connectors - Inspect" for details. the proper torque of 6.0 N.m (55 Ib in).

pinch points from the battery to the ECM.
400
Expected Result: While the warning lamp is being observed, start

the engine. The warning lamp should turn on
All connectors, pins, and sockets should be for a minimum of two seconds after the engine
completely coupled and/or inserted and the harness starts. Then, the warning lamp should turn off.
and wiring should be free of corrosion abrasion, If the lamp remains on, immediately shut down
or pinch points. the engine.

• OK - Proceed to Test Step 2. The warning lamp turns on and the Warning Lamp
turns off per the above description.
• Not OK
Results:
replace the connectors or wiring. Ensure that all • OK - T h e lamp appears to operating correctly
of the seals are properly in place and ensure that at this time. STOP.
• Not OK - The lamp is not operating correctly.
STOR
Test Step 2. Check for Normal Operation procedure:
of the Warning Lamp(s)
Use ET to determine if an "Engine Monitoring"
A. Monitor the check engine lamp. Turn the ignition condition is causing the lamp to turn on. If an
key switch to the ON position, while the engine "Engine Monitoring" condition is not present,
is off. The lamp should turn on for five seconds. perform the following diagnostic procedure.
Then, the lamp should turn off.
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.
Note: The warning lamp will not turn on until the

engine is cranked.
B. Connect ET in order to verify that the "Engine

Monitoring" has been programmed to "Warning",
"Derate", or "Shutdown". If "Engine Monitoring"
is programmed to "Off", the warning lamp is not
used and the ECM will not turn on the lamp.
The "Engine Monitoring Lamps" parameter must

be programmed to "Option 1" in order for the
following lamps to function.
• Low Oil Pressure
• High Coolant Temperature
• Low Coolant Level Warning
The lamp for the low coolant level also requires

the "Coolant Level Sensor" parameter to be
programmed to the "4-pin" option.
401
Test Step 3. Test the Lamp Circuit
0000000000000~ HIGH COOLANT TEMP LAMP

II o ooooo,, WARNING LAMP or
i i 1390 O"~D-,O IKr.NI 00 00~2
II I ,,o o 5
II I, ,ooooo o .... -'8
UNSWITCHED +BATTERY
-BATTERY
ECM Side
Illustration 197
g00676787
Vehicle harness connector P1
A. Disconnect ECM vehicle harness connector Results:

J1/P1.
• Result 1 - T h e warning lamp circuit is functioning
B. Fabricate a jumper wire 100 mm (4 inch) long. properly. Proceed to Test Step 4.
Result 2 - The lamp did not turn on. The vehicle's
C. Insert the jumper into the terminal of the suspect lamp circuit is not functioning properly. The lamp
lamp of connector P1. The jumper can be is probably burned out or there is a problem in
inserted into the following terminals in order to the wiring from the cab to either the ECM or the
test the appropriate lamp circuit: +Battery connection. Repair the lamp circuit or
• P1:31 (High Coolant Temperature Lamp) STOR
• P1:29 (Warning Lamp or Low Oil Pressure • Result 3

Lamp)
• P1:30 (PTO Switch On Lamp or Low Coolant procedure:
Level Lamp)
D, Connect the other side of the jumper wire to shorted to chassis ground. Repair the circuit or
P1:65 (-Battery). send the vehicle to the OEM dealer for repairs.
E, Turn the ignition key switch to the ON position. STOR
F. While the lamp is being watched, insert the

Refer to Illustration 197,
Expected Result:
Result 1 The lamp turns on while the jumper is
connected to both sockets. Also, the warning lamp
turns off when the jumper is removed from one of
the sockets.
Result 2 The lamp does not turn on while the

jumper is connected to both sockets.
Result 3 The lamp will stay on while the ECM

vehicle harness connector is disconnected.
402
Test Step 4. Check ECM Operation of the

Warning Lamp
~ 0 O 0 O 0 0~0 0 0 0 0 0 0 ~ HIGH COOLANT TEMP LAMP

310
t~,30 0 0 0 0 O 0 0144 WARNING LAMP or
II I ;o° °° °o °i °,
UNSWITCHED +BATTERY
-BATTERY
ECM Side
A. Disconnect ECM vehicle harness connector • Not OK - Temporarily connect a test ECM. Ensure
J1/PI. that the "Engine Monitoring" of the test ECM
matches the "Engine Monitoring" of the suspect
B. Insert a 70-Terminal breakout T between the ECM. Check the ECM operation of the Lamp
ECM vehicle harness connectors J1 and P1. when the test ECM is installed. If the problem
is resolved with the test ECM, reconnect the
C. Connect a voltage test lamp probe to terminal 65 suspect ECM If the problem returns with the
(-Battery) and connect the other probe to terminal suspect ECM, replace the ECM. STOP.
52 (Unswitched +Battery) of the breakout T.
D. The test lamp should turn on. If the test lamp

the wiring to the ECM is faulty. Continue with this
step if the lamp turns on.
E. Leave the voltage test lamp probe connected to

terminal 52 (Unswitched +Battery).
F, Connect the other probe of the test lamp to the

suspect lamp terminal on the breakout T.
G. Watch the voltage test lamp. Start the engine.

The lamp should turn on for a minimum of two
seconds after the engine starts. Then, the lamp
should turn off. Immediately turn the engine off
if the lamp continues to stay in the ON position.
Connect ET in order to determine the cause of
the problem.
Expected Result:
The lamp turns on and the warning lamp turns off
per the above description.
Results:
• OK - T h e ECM is operating correctly. There is a
problem in the vehicle wiring or the lamp. Repair
the vehicle wiring or the lamp, as required. STOP.
CATERPILLAR
CALIBRATION PROCEDURES
TABLE OF CONTENTS
DESCRIPTION PAGE
ENGINE SPEED/TIMING SENSOR - CALIBRATE............................................................................................................... 403
INJECTOR CODE - CALIBRATE........................................................................................................................................ 405
VEHICLE SPEED CIRCUIT - CALIBRATE .......................................................................................................................... 406
403
Calibration Procedures
i01907628 Mq
Engine Speed/Timing Sensor-

Calibrate
SMCS Code: 1912-524

C~
Use this procedure if any of the following conditions g00660979

Illustration 199
exist:
Note: The Timing Calibration will not increase the
• The ECM has been replaced and the old ECM will
available engine power or the Timing Calibration
not communicate with the Caterpillar Electronic
will not decrease the available engine power.
Technician (Cat ET).
Do not expect an increase in power due to the
performance of the timing calibration.
• 22-13 Check Timing Sensor Calibration is active.
Replacement ECM
• Work has been done to the front gear group.
If a replacement ECM is required, the ECM
The primary engine speed/timing sensor provides
parameters and the timing calibration can
an engine speed signal (rpm) to the ECM. The be transferred from the suspect ECM to the
signal is created as the crankshaft gear rotates
replacement ECM. Timing calibration will NOT be
past the pickup of the primary engine speed/timing
necessary. This feature requires Cat ET and this
sensor. The secondary engine speed/timing sensor
feature is only possible if the existing ECM can
provides the timing signal to the ECM. The signal
communicate with Cat ET.
is created as the camshaft gear rotates past the
pickup of the secondary engine speed/timing Table 160
sensor. A unique pattern on the gear allows the
ECM to determine the crankshaft position. This Required Special Tools
unique pattern on the gear allows the ECM to Part Number Description
determine the top center position of the piston in
the No. 1 cylinder. If the signal is lost from one of 6V- 2197 MagneticTransducer
the sensors, a diagnostic code is generated. If the 7X- 1695 Cable
signal is lost from one of the sensors, the ECM will
use a special type of logic that will allow the engine 7X- 1 1 7 1 TransducerAdapter
to start on only one sensor and this special type of 9S-9082 Engine TurningTool
logic will allow the engine to run on only one sensor.
Timing calibration is accomplished by installing a Test Step 1. Install the 7X-1171

special magnetic transducer into the side of the Transducer Adapter
engine block. The magnetic transducer senses
a special slot on the crankshaft counterweight. A. Turn the key switch to the OFF position.
The magnetic transducer is connected to the
ECM through the P400 Speed/Timing Calibration B, Use the 9S-9082 Engine Turning Tool to put
Connector that is on the engine wiring harness. either the No. 1 piston or the No. 6 piston at
top center. Rotate the engine in the opposite
When the engine rpm is from 1000 to 1200 rpm, direction of the correct engine rotation by the
the ECM is placed in timing calibration mode with following amount:
Cat ET.
• 60 Degrees
C. Use the following procedure for a C-10 or C-12

engine:
404
a. Remove the timing calibration plug from Test Step 3. Start the Engine and
the right side of the cylinder block as the Allow the Coolant to Reach Operating
engine is viewed from the flywheel. The Temperature
timing calibration plug is located on the No. 4
cylinder rod pocket. A. Start the engine and run at low idle until the
engine has warmed up enough to exit cold
b. Install the 7X- 1171 Transducer Adapter into mode operation. The status screen on Cat ET
the hole for the plug. will display "COLD MODE" in the upper corner
when cold mode operation exists. The engine
D. Use the following procedure for a 3406E, C-15, will adjust idle rpm from cold mode idle to the
C-16 or C-18 Engine: programmed low idle rpm when cold mode
operation is complete.
a. Remove the timing calibration plug from the
left side of the cylinder block as the engine is B. Check for active diagnostic codes. Use the
viewed from the flywheel. procedures in this manual to troubleshoot and
repair any active diagnostic codes before
b. Install the 7X- 1171 Transducer Adapter into attempting a calibration check. The engine must
the hole for the plug. not have any diagnostic fault conditions that are
present during the timing calibration except the
Results: following condition:
• OK - Proceed to Test Step 2. • 22-13 Engine Speed Signal Calibration Not

Performed
Test Step 2. Install the 6V-2197 Magnetic
Transducer on the Engine C. After the engine has warmed up, set the engine
speed to 1100 rpm by the use of the cruise
NOTICE control switches or the accelerator pedal.
If the crankshaft is not in the correct position when the
6V- 2197 Magnetic Transducer is installed, the Mag- Note: The engine rpm must be steady within the
netic Transducer will be damaged when the engine is 1000 to 1200 rpm range in order to perform a timing
started. calibration.
Results:
A. Put a 2D-6392 O-Ring Seal on the end of the
magnetic transducer. • OK - Proceed to Test Step 4.
Note: A small amount of clean engine oil will allow Test Step 4. Connect Cat ET
the seal to slide onto the transducer more easily.
B. Push the magnetic transducer through the
adapter until the magnetic transducer comes B. After the engine has exited cold mode operation,
in contact with the outermost portion of the access the "Timing Calibration Screen" on Cat
crankshaft counterweight. Move the O-ring seal ET. Access the following display screens in order:
downward against the adapter.
• "Service"
C. Withdraw the magnetic transducer 1.0 mm
(0.04 inch) and hand tighten the nut on the • "Calibrations"
adapter sleeve in order to secure the magnetic
transducer in place. • "Timing Calibration"
D. Connect the 6V-2197 Magnetic Transducer to Note: To perform a timing calibration, the engine rpm
the 7X- 1695 Cable. must remain as steady as possible at approximately
1100 rpm. This can be performed by the use of
Results: the cruise control switches or a steady foot on the
accelerator pedal. Any changes to engine rpm
• OK - Proceed to Test Step 3. that are more than 100 rpm will slow down the
procedure. These changes will also reduce the
accuracy of the procedure.
405
C, Connect the 7X-1695 Cable for the 6V-2197 2. If all of the problems have been corrected but
Magnetic Transducer to the P400 Speed/Timing the timing can not be calibrated, check the
Calibration Connector. cable of the 6V-2197 Magnetic Transducer
and check the 6V-2197 Magnetic Transducer
D. Ensure that all of the connections are made in order to verify that the Magnetic Transducer
correctly. is not bent. If the 6V-2197 Magnetic
Transducer is not bent, restart this procedure.
Results:
STOR
Test Step 6. Disconnect the 6V-2197
Test Step 5. Calibrate the Speed/Timing agnetic Transducer Before Exiting the
Sensor "Monitor/Calibrate Timing" Screen
A. To calibrate the timing to the correct setting, A. Disconnect the 6V-2197 Magnetic Transducer
select "Continue" on Cat ET. Wait until Cat ET from the P400 Speed/Timing Calibration
indicates that the timing is "CALIBRATED". Connector.
Note: If Cat ET displays "CALIBRATION B. Exit the timing calibration screen on Cat ET.
UNSUCCESSFUL", the electronic injection timing
has not been set. Recheck the tool installation and Note: Exiting the timing calibration screen on Cat ET
tool operation and try again to calibrate electronic will drop the engine rpm to the programmed low idle
injection timing. If the crankshaft and camshaft if the cruise control switches were used to maintain
gears have been reassembled incorrectly, the engine rpm during calibration. This is normal.
engine will not calibrate.
Expected Result:
If the timing calibration has been successfully
completed, do not exit the timing calibration The magnetic transducer was disconnected before
screen on Cat ET until you have disconnected exiting the timing calibration screen on Cat ET.
the 7X- 1695 Cable for the 6V-2197 Magnetic
Transducer from the P400 Speed/Timing Results:
Calibration Connector.
OK - STOR
Expected Result:
Not OK - If the magnetic transducer is still
The timing calibration procedure was completed installed after exiting the timing calibration screen
successfully. on Cat ET, vehicle speed diagnostic codes may
be generated.
Results:
Repair: If vehicle speed diagnostic codes are
• OK - T h e timing calibration procedure was generated, the vehicle speed diagnostic codes
completed successfully. Proceed to Test Step 6. should be cleared.
• Not OK STOR
Repair: Perform the following procedure:

i01741189
1. Verify that the engine rpm was stable during Injector Code - Calibrate
the testing (+ 50 rpm). If the engine rpm
was unstable or the engine rpm could not SMCS Code: 1290-524
be controlled within + 50 rpm because of
mechanical factors or electrical factors, refer System Operation Description:
to Troubleshooting, "Engine Misfires, Runs
Rough or Is Unstable". If any of the following conditions have occurred, the
injector trim codes should be calibrated:
• Replacement of the ECM
• Replacement of any of the unit injectors
A special code is stamped on the top of each unit

injector. The injector trim code allows the ECM to
compensate for variances in manufacturing.
406
Note: Changing the injector trim codes will not Results:

increase the power that is available to the engine.
• OK - T h e hardware was successfully replaced.
Test Step 1. Record Injector Trim Codes Proceed to Test Step 3.
A. Record the injector trim code and the Test S t e p 3, Enter Injector Trim Codes
corresponding cylinder number for each unit into the E C M
injector that will be replaced.
A. Connect Cat ET to the service tool connector.
Table 161
Injector Trim Code B, Turn the keyswitch to the ON position.
Cylinder Old New C, Open the "Injector Codes Calibration" in
1 "Calibrations" under the "Service" menu on Cat
ET.
2
3 D. Enter the new injector trim code for each cylinder.
4 Results:
5
• OK - STOR
6
i01810925
Note: If the ECM is replaced, all injector trim codes
must be recorded. The injector trim codes can be
found in "Calibrations" under the "Service" menu on
Vehicle Speed Circuit-
the Caterpillar Electronic Technician (Cat ET). Calibrate
Expected Result: SMCS Code: 7463-524
All injector trim codes were obtained. System Operation Description:
Results: The ECM uses vehicle speed information for the

following features:
• OK - A l l injector trim codes were obtained.
Proceed to Test Step 2. • Cruise control
• Not OK - The injector trim codes were not • Fast idle control
obtained.
• Idle speed control
Repair: Remove the valve cover and record the
injector trim code and the corresponding cylinder • PTO operation
number for each unit injector.
• Vehicle speed limiting
• Speedometer
Test Step 2. Replace Hardware
• Progressive shift
A. Replace the suspect unit injectors and/or the
ECM. • Idle shutdown
B. Record the injector trim code and the • Operation of the air inlet heater
corresponding cylinder number for each unit
injector. • Secure idle theft deterrent
Expected Result: • Trip data
All hardware was successfully replaced and the • Maintenance data

new injector trim codes were recorded.
407
There are three different methods that can be used The variable for the tire revolution could be affected
to obtain the information for the ECM to use for by changing from bias ply tires to radial tires
calculating vehicle speed. The ECM can calculate and vice versa. Also, changing to radial tires that
vehicle speed by either of the following means: have a low profile could affect the variable for the
tire revolution. This result may change the actual
• The ECM monitors the signal from a vehicle speed vehicle speed which could result in performance
sensor in pulses per kilometer (mile). The vehicle complaints or complaints about fuel consumption. If
speed sensor is connected to the vehicle speed the tire configuration has been changed, determine
input circuit (terminals 32 and 33 of the ECM). the new variable for the tire revolution. Enter the
This is the "Vehicle Speed Calibration" option. new value in pulses per km (PPKM) or pulses per
mile (PPM). The preferred method is obtaining the
• The ECM receives a message over the J1939 data from the individual tire manufacturers for the
data link from the Transmission ECU that indicates specific tire that is being used.
revolutions per kilometer (mile) of the transmission
output shaft. This is the "Vehicle Speed Cal Note: The ECM speedometer signal is set to
(J1939-Trans)" option. 18,600 pulses per km (PPKM) or 30,000 pulses per
mile (PPM). This setting cannot be changed. All
• The ECM receives a message over the J1939 speedometers that are driven by the ECM output
data link from the Anti-lock Brake System (ABS) (J1/P1 terminal 36 and terminal 37) must match the
that contains information about the wheel speed. fixed output of the ECM for proper operation.
This is the "Vehicle Speed Cal (J1939-ABS)"
option. Test Step 1. Use the Electronic Service
Tool to Determine the Configuration for
Each of these methods require a specific calibration the Vehicle Speed Input to the ECM
number to be programmed into the ECM to
calculate vehicle speed. A. Connect the electronic service tool to the cab
data link connector.
For the "Vehicle Speed Calibration" option that uses
the vehicle speed sensor, the ECM must know the B. Access the "Configuration Parameter List". View
number of pulses that are produced by the vehicle the "Vehicle Speed Parameters". Determine if
speed sensor during each kilometer (mile) of travel the vehicle is configured to use the "Vehicle
by the vehicle. In order to find the number of pulses Speed Calibration" option,the "Vehicle Speed
that are produced by the sensor, multiply the tire Cal (J1939-Trans)" option, or the "Vehicle Speed
size by the axle ratio. Multiply the number that was Cal (J 1939-ABS)" option.
obtained in the previous calculation by the number
of teeth on the output shaft that is used by the Expected Result:
sensor to obtain the pulses.
RESULT 1 The ECM is configured for the "Vehicle
For the "Vehicle Speed Cal (J1939-Trans)" option, Speed Calibration" option.
the ECM must know the number of times that the
output shaft revolves per kilometer (mile) of travel RESULT 2 The ECM is configured to use the
by the vehicle. This can be calculated by one of the "Vehicle Speed Cal (J1939-Trans)" option.
following methods:
RESULT 3 The ECM is configured to use the
• Divide the pulses per kilometer (mile) of the "Vehicle Speed Cal (J1939-ABS)" option.
sensor on the transmission output shaft by the
number of teeth on the transmission output shaft. Results:
• Multiply the axle ratio by the number of revolutions • RESULT 1 - Proceed to Test Step 2.
per kilometer (mile) of the tire.
• RESULT 2 - Proceed to Test Step 3.
For the "Vehicle Speed Cal (J1939-ABS)" option, the
ECM must know a calibration number. The number • RESULT 3 - Proceed to Test Step 4.
is calculated by dividing the actual tire revolutions
per kilometer (mile) by the tire revolutions per Test Step 2. Calculating Pulses Per
kilometer (mile) that is programmed into the ABS. Kilometer " all the Variables
are Known{?de) When
The ECM calculates vehicle speed by converting the
vehicle speed signal to kilometers per hour (kin/h) A. Calculate pulses per kilometer (PPKM) or pulses
or miles per hour (mph). The conversion factor is per mile (PPM).
customer programmable and the conversion factor
is stored in pulses per km (PPKM) or pulses per PPKM= K X R a X N .
mile (PPM).
408
PPM = M X R a X N . Expected Result:

K - T h i s symbol represents the tire revolutions The value is within the valid range of the ECM.
per kilometer. This is a constant that is divided
by the tire static loaded radius. Results:
M - T h i s symbol represents the tire revolutions • Yes - Once the value is entered, verify that the
per mile. This is a constant that is divided by the ECM is accurately measuring vehicle speed.
tire static loaded radius. Proceed to Test Step 5.
Ra - T h i s symbol represents the rear axle ratio. • No - Recalculate the value and re-enter the
The rear axle ratio can typically be found on the correct value into the ECM STOP.
housing of the rear axle, or the rear axle ratio
can typically be found on the specification sheet Test Step 4. Calculate Tire Revolutions
for the vehicle. Per Kilometer(Mile) When all the
Variables are Known
N - T h i s symbol represents the number of
chopper teeth on the transmission drive shaft. A. The correct calibration number must be entered
The magnetic pickup sensor is mounted here. for the "Vehicle Speed Cal J1939-ABS" setting. If
The number of chopper teeth is usually 16. Some this value is unknown, the following calculation
transmissions have 11 tooth chopper wheels. can be used to obtain the correct setting.
B. Use the electronic service tool to enter pulses Divide the actual tire revolutions per kilometer
per km (PPKM) or pulses per mile (PPM) into (mile) by the tire revolutions per kilometer (mile)
the ECM. that is broadcast by theABS.
Expected Result: For example, the actual tire revolutions per

kilometer (mile) could equal 400 revolutions per
This value is within the valid range of the ECM. kilometer (mile). The tire revolutions per kilometer
(mile) that is broadcast by the ABS could equal
Results: 500 revolutions per kilometer (mile).
• OK - Once the value is entered, verify that the The formula would be 400 / 500 = 0.800.
ECM is accurately measuring vehicle speed.
Proceed to Test Step 5. Therefore, 0.800 would be the value that would
be entered into the ECM.
• Not OK - Recalculate the value and re-enter the
correct value into the ECM. STOR B. Use the electronic service tool to enter the
calculated value into the ECM.
Test Step 3. Calculate the Revolutions
Per Kilometer (Mile) of the Transmission Expected Result:
Output Shaft
This value is within the valid range of the ECM.
A. The correct revolutions per kilometer (mile) of
the transmission output shaft must be entered Results:
for the "Vehicle Speed Cal J1939-Trans" setting.
If this value is unknown, either of the following • OK - Once the value is entered, verify that the
calculations can be used to obtain the correct ECM is accurately measuring vehicle speed.
setting: Proceed to Test Step 5.
• Divide the pulses per kilometer (mile) of the • Not OK - Recalculate the value and re-enter the
sensor on the transmission output shaft by the correct value into the ECM. STOP.
number of teeth on the transmission output
shaft. Test Step 5. Inspect the Speedometer
Calibration.
• Multiply the axle ratio by the number of
revolutions per kilometer (mile) of the tire. Determine the speedometer's vehicle speed
calibration setting.
B. Use the electronic service tool to enter the
calculated value into the ECM.
409
Expected Result:
The speedometer must be calibrated to 18,600

pulses per kilometer (30,000 pulses per mile).
The ECM can only provide the signal that is listed

above.
Results:
• OK - T h e speedometer is correctly calibrated.

STOP.
• Not OK

procedure:
Reprogram the speedometer to the correct setting

for the pulses per kilometer (mile).
STOP.
410 INDEX CONTINUED ON NEXT PAGE
Index Section
Index
Numerics 0111-01 Low Coolant Level Warning (62) ........... 141
0111-02 Coolant Level signal invalid (12) ............ 142
0001-11 Cylinder #1 Injector current fault (72) .... 116 0111-03 Coolant Level voltage high (12) ............. 143
0002-11 Cylinder #2 Injector current fault (72) .... 116 0111-04 Coolant Level voltage low (12) .............. 143
0003-11 Cylinder #3 Injector current fault (73) .... 117 0111-11 Very Low Coolant Level (62) ................. 143
0004-11 Cylinder #4 Injector current fault (73) .... 117 0121-05 Low/High Retarder current low (14) ...... 144
0005-11 Cylinder #5 Injector current fault (74) .... 118 0121-06 Low/High Retarder current high (14) ..... 145
0006-11 Cylinder #6 Injector current fault (74) .... 118 0122-05 Med/High Retarder current low (14) ...... 145
0022-11 Primary to Secondary Engine Speed Signal 0122-06 Med/High Retarder current high (14) ..... 145
Calibration (42) .................................................. 118 0168-02 ECM Battery Power Intermittent (51) .... 146
0022-13 Engine Speed Signal Calibration Not 0171-03 Ambient Air Temperature voltage high.. 146
Performed (42) ................................................... 120 0171-04 Ambient Air Temperature voltage tow .... 146
0030-08 PTO Throttle signal invalid (29) ............. 120 0171-11 Ambient Air Temperature Data Lost ...... 147
0030-13 PTO Throttle out of calibration (29) ....... 120 0174-00 High Fuel Temperature Warning (65) .... 147
0041-03 8 Volt Supply voltage high (21) .............. 121 0174-03 Fuel Temperature voltage high (13) ...... 147
0041-04 8 Volt Supply voltage low (21) ............... 121 0174-04 Fuel Temperature voltage low (13) ........ 148
0043-02 Key Switch Fault (71) ............................. 121 0190-00 Engine Overspeed Warning (35) ........... 148
0052-11 Air Inlet Shutoff Shutdown (00) ............. 122 0190-12 Primary Engine Speed loss of signal
0054-05 Auxiliary Output #06 current low (66) .... 122 (34) .................................................................... 148
0054-06 Auxiliary Output #06 current high (66)... 123 0191-07 Transmission Not Responding (68) ....... 149
0055-05 Auxiliary Output #07 current low (67) .... 123 0224-11 Theft Deterrent Active (00) .................... 149
0055-06 Auxiliary Output #07 current high (67)... 123 0224-14 Theft Deterrent Active with Engine Cranking
0064-12 Secondary Engine Speed loss of signal (00) .................................................................... 149
(34) .................................................................... 124 0231-02 J1939 Data Incorrect (58) ...................... 150
0071-00 Idle Shutdown Override (01) ................. 124 0231-11 J1939 Data Link Fault (58) .................... 150
0071-01 Idle Shutdown (47) ................................ 125 0231-12 J1939 Device Not Responding .............. 151
0071-14 PTO Shutdown (47) ............................... 125 0232-03 5 Volt Supply voltage high (21) .............. 151
0084-00 Vehicle Overspeed Warning (41) ........... 125 0232-04 5 Volt Supply voltage low (21) ............... 151
0084-01 Vehicle Speed loss of signal (31) .......... 126 0246-11 Brake Pedal Switch #1 Fault .................. 152
0084-02 Vehicle Speed signal invalid (36) ........... 126 0247-11 Brake Pedal Switch #2 Fault .................. 152
0084-08 Vehicle Speed signal out of range (36).. 127 0249-11 J1922 Data Link Fault (58) .................... 152
0084-10 Vehicle Speed signal rate of change 0252-11 Engine Software Incorrect (59) .............. 153
(36) .................................................................... 127 0253-02 Check Customer or System Parameters
0084-14 Quick Stop Occurrence ......................... 127 (56) .................................................................... 153
0091-08 Throttle Position Invalid (32) .................. 128 0253-11 Check Transmission Customer Parameters
0091-13 Throttle Position out of calibration (32).. 128 (56) .................................................................... 154
0100-01 Low Oil Pressure Warning (46) ............. 129 5 Volt Engine Pressure Sensor Supply Circuit -
0100-03 Oil Pressure voltage high (24) ............... 132 Test .................................................................... 155
0100-04 Oil Pressure voltage low (24) ................ 132
0100-11 Very Low Oil Pressure (46) ................... 133
0102-00 Excessive Boost Pressure ..................... 136 A
0102-03 Boost Pressure voltage high (25) .......... 137
0102-04 Boost Pressure voltage low (25) ........... 137 Accelerator Pedal (Throttle) Position Sensor Circuit -
0105-00 High Intake Manifold Air Temperature Test .................................................................... 160
Warning (64) ...................................................... 137 Air Inlet Shutoff Circuit - Test ............................... 168
0105-03 Intake Manifold Air Temperature voltage ATA (SAE J1587 / J1708) Data Link Circuit -
high (38) ............................................................. 138 Test .................................................................... 174
0105-04 Intake Manifold Air Temperature voltage low Auxiliary Brake Circuit - Test ................................ 180
(38) .................................................................... 138
0105-11 Very High Intake Manifold Air Temperature
(64) .................................................................... 139 C
0108-03 Barometric Pressure voltage high (26).. 139
0108-04 Barometric Pressure voltage low (26) ... 139 Calibration Procedures ........................................ 403
0110-00 High Coolant Temperature Warning Can Not Reach Top Engine RPM .......................... 83
(61) .................................................................... 140 Probable Causes ............................................... 83
0110-03 Coolant Temperature voltage high (27).. 140 Recommended Actions .................................... .. 83
0110-04 Coolant Temperature voltage low (27)... 141
0110-11 Very High Coolant Temperature (61) ..... 141
INDEX CONTINUED ON NEXT PAGE 411
Index Section
Can Not Reach Vehicle Speed Limit ..................... 84 ECM Date/Time Stamped Information ................... 39
Probable C a u s e s ............................................... 84 Adjustment of ECM Date/Time Clock ................ 39
R e c o m m e n d e d Actions ...................................... 84 E C M Diagnostic Clock ....................................... 40
Check Engine Lamp Circuit - Test ....................... 185 O c c u r r e n c e of Time Stamped Information ......... 39
Check Engine Lamp or Warning Lamp Is Proper Use of ECM Date/Time Stamped
Malfunctioning ...................................................... 86 Information ....................................................... 40
Probable C a u s e s ............................................... 86 ECM M e m o r y - Test ............................................. 238
R e c o m m e n d e d Actions ...................................... 86 ECM S n a p s h o t ...................................................... 40
Clutch Pedal Position Switch Circuit - Test .......... 190 Quick Stop Snapshot ......................................... 41
Coolant Level Sensor Circuit - Test ..................... 195 S n a p s h o t Information T h a t Is Triggered By A
Cooling Fan Circuit and N C High Pressure Switch Diagnostic Code ............................................... 41
Circuit - Test ....................................................... 205 Snapshot Information T h a t Is Triggered
Cooling Fan Is A l w a y s ON ..................................... 87 Externally ......................................................... 41
Probable C a u s e s ............................................... 87 Storage of S n a p s h o t s In T h e ECM ................... 42
R e c o m m e n d e d Actions ...................................... 87 Use Of S n a p s h o t ................................................ 40
Cruise Control Switch Circuit - Test ..................... 219 ECM Will Not Accept Factory Passwords .............. 93
Cruise Control, Idle, or PTO Can Not Be Set ........ 89 Probable C a u s e s ............................................... 93
Probable C a u s e s ............................................... 89 R e c o m m e n d e d Actions ...................................... 93
R e c o m m e n d e d Actions ...................................... 89 Electrical C o n n e c t o r s - Inspect ............................ 240
C u s t o m e r Passwords ............................................. 39 Electronic Service Tool Will Not C o m m u n i c a t e with
C u s t o m e r Specified Parameters ............................ 45 ECM ..................................................................... 94
"Cruise Control Parameters". ............................. 49 Probable C a u s e s ............................................... 94
C u s t o m e r Parameter Lockout ............................ 45 R e c o m m e n d e d Actions ...................................... 94
"Dash Display A c c e s s Parameters". .................. 64 Electronic Service Tools ........................................ 23
Data Link Parameters ........................................ 71 Optional Service Tools ....................................... 25
"Dedicated PTO Parameters". ............................ 53 Required Service Tools ...................................... 24
"Driver Reward". ................................................. 65 Electronic Troubleshooting ...................................... 5
"ECM Identification Parameters". ....................... 47 Engine Cranks but Will Not Start ........................... 95
"Engine Monitoring Parameters". ....................... 62 Probable C a u s e s ............................................... 95
"Engine/Gear Parameters" ................................. 56 R e c o m m e n d e d Actions ...................................... 95
"Idle Parameters". .............................................. 52 Engine Misfires, Runs Rough or Is Unstable ......... 98
Injector C o d e s .................................................... 71 Probable C a u s e s ............................................... 98
"Input Selections". .............................................. 66 R e c o m m e n d e d Actions ...................................... 98
" M a i n t e n a n c e Parameters". ................................ 63 Engine Pressure Sensor O p e n or Short Circuit -
"Output Selections". ........................................... 70 Test .................................................................... 247
"Security Access Parameters". .......................... 47 Engine Retarder (Compression Brake) Will Not Turn
"Selected Engine Rating". .................................. 46 ON ....................................................................... 99
"Timer Parameters". ........................................... 60 Probable C a u s e s ............................................... 99
"Trip Parameters". .............................................. 63 R e c o m m e n d e d Actions ...................................... 99
"Vehicle Activity Report". .................................... 65 Engine R u n n i n g Output Circuit - Test .................. 254
"Vehicle Speed Parameters". ............................. 47 Engine S h u t d o w n Output Circuit - Test ................ 257
C u s t o m e r Specified Parameters Table .................. 72 Engine S p e e d / T i m i n g Sensor - Calibrate ............ 403
Customer Specified Parameters Worksheet .......... 78 Engine S p e e d / T i m i n g Sensor Circuit - Test ......... 260
Injector C o d e s .................................................... 81 Engine Temperature Sensor O p e n or Short Circuit -
Lifetime Totals Worksheet .................................. 81 Test .................................................................... 267
Engine Vibration .................................................. 100
Probable C a u s e s ............................................. 100
D R e c o m m e n d e d Actions .................................... 101
Engine Will Not Crank ......................................... 102
Diagnostic C o d e s ................................................ 115 Probable C a u s e s ............................................. 102
Diagnostic Enable Switch Circuit - Test ............... 227 R e c o m m e n d e d Actions .................................... 102
Diagnostic Functional Tests ................................. 155 Engine Wiring Harness Diagram ........................... 34
Driver Q u e s t i o n n a i r e .............................................. 91 Excessive Black Smoke ....................................... 103
Driver Q u e s t i o n n a i r e Response ............................ 92 Probable C a u s e s ............................................. 103
R e c o m m e n d e d Actions .................................... 103
Excessive Fuel C o n s u m p t i o n .............................. 104
E Probable C a u s e s ............................................. 104
Eaton Top 2 Transmission Circuit - Test .............. 231 Excessive White Smoke ...................................... 105
Probable C a u s e s ............................................. 105
412 INDEX CONTINUED ON NEXT PAGE
Index Section
F PTO Engine RPM Set Speed (Input A and Input B)

Circuit - Test ....................................................... 319
Factory Passwords ................................................ 42 PTO S h u t d o w n T i m e r - Test ................................ 324
Factory Passwords Worksheet .............................. 42 PTO Switch Circuit - Test ..................................... 326
Fan Override Switch Circuit - Test ....................... 273 PTO Switch ON Lamp Circuit - Test .................... 336
Flash Programming ............................................... 43
"WinFlash" Error M e s s a g e s ............................... 44
R
G Remote PTO Accelerator Position Sensor Circuit -

Test .................................................................... 342
Glossary ................................................................ 16 Replacing the ECM ................................................ 25
Replacing the E C M with the Use of the ECM
Replacement Feature ....................................... 25
Replacing the ECM without the Use of the ECM
Replacement Feature ....................................... 26
Idle S h u t d o w n T i m e r - Test .................................. 278 Retarder (Compression Brake) Solenoid Circuit -
Ignition Key Switch Circuit and Battery S u p p l y Circuit Test .................................................................... 349
- Test .................................................................. 281
Ignore Brake/Clutch Switch Circuit - Test ............ 287
Important Safety Information ................................... 2 S
Injector Code - Calibrate ...................................... 405
Injector Solenoid Circuit - Test ............................. 291 Sensors and Electrical Connectors ....................... 27
Intermittent Cruise Control, Idle, or PTO Kickout.. 106 3406E Engine .................................................... 31
Probable C a u s e s ............................................. 106 C-10 and C-12 Engines ..................................... 29
R e c o m m e n d e d Actions .................................... 107 C-15, C-16 and C-18 Engines ............................ 33
Intermittent Engine S h u t d o w n ............................. 108 Service Brake Pedal Position (Switch 1) C i r c u i t -
Probable C a u s e s ............................................. 108 Test .................................................................... 358
R e c o m m e n d e d Actions .................................... 108 Service Brake Pedal Position (Switch 2) Circuit -
Intermittent Low Power or Power Cutout ............. 109 Test .................................................................... 363
Probable C a u s e s ............................................. 109 Service Information Report ................................... 44
R e c o m m e n d e d Actions .................................... 109 R e c o m m e n d a t i o n s ............................................. 44
Starting Aid Output Circuit - Test ......................... 368
Starting Aid Switch Circuit - Test ......................... 371
L System Configuration Parameters ......................... 82
"Engine Serial Number" ..................................... 82
Low Power/Poor or No Response to Throttle ...... 111 "Full Load Setting". ............................................. 82
Probable C a u s e s ............................................. 111 "Full Torque Setting". .......................................... 82
R e c o m m e n d e d Actions .................................... 111 Personality M o d u l e Code ................................... 82
"Personality M o d u l e Release Date". .................. 82
System O v e r v i e w ..................................................... 5
M ECM Lifetime Totals ........................................... 11
Effect Of Diagnostic C o d e s On Engine
Multi-Torque - Test ............................................... 303 Performance ..................................................... 10
Engine Monitoring ................................................ 6
Engine S n a p s h o t Data ....................................... 10
N Other E C M Functions Of Performance .............. 10
Passwords .......................................................... 15
Neutral Switch Circuit - Test ................................ 304 Programmable Parameters ................................ 15
No Diagnostic Code Detected (55) ...................... 116 Self-Diagnostics ................................................. 10
System Operation ................................................ 5
Trip Data That Is Stored In T h e ECM ................. 11
P
Poor Acceleration or Response ........................... 113 T

Probable C a u s e s ............................................. 113
R e c o m m e n d e d Actions .................................... 113 Table of Contents ..................................................... 3
Powertrain Data Link Circuit - Test ...................... 311 Tachometer Circuit - Test ..................................... 375
Programming Parameters ...................................... 38 Test E C M Mode ..................................................... 38
Programming a N e w ECM ................................. 38 Torque Limit Switch Circuit - Test ........................ 380
Troubleshooting Section .......................................... 5
413
Index Section
Troubleshooting with a Diagnostic Code ............. 115

Troubleshooting without a Diagnostic Code .......... 83
Two Speed Axle Switch Circuit - Test .................. 384
Vehicle Speed and S p e e d o m e t e r Circuit - Test ... 388

Vehicle Speed Circuit - Calibrate ......................... 406
Vehicle Wiring H a r n e s s Diagram ........................... 36
Warning Lamp Circuit - Test ................................ 397

RENR2238-06
April 2003
CATERPILLAR °
3406E, C-1 O, C-12, C-15, C-16 and C-18

On-highway Engines
WIAI-Up (Engine)
CPD1-Up (Engine)
1MMI-Up (Engine)
CJP1-Up (Engine)
MDP1-Up (Engine)
MEP1-Up (Engine)
2KS1-Up (Engine)
2WS1-Up (Engine)
3CS1-Up (Engine)
6NZ1-Up (Engine)
7CZ1-Up (Engine)

3406E, C-10, C-12, C-15, C-16 AND C-18 TRUCK ENGINE Troubleshooting

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3406E, C-10, C-12, C-15, C-16 AND C-18 TRUCK ENGINE Troubleshooting

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CATERPILLAR

3406E, C-10, C-12, C-15, C-16 AND C-18 TRUCK ENGINE

PROGRAMMING PARAMETERS ......................................................................................................................................... 38

CUSTOMER SPECIFIED PARAMETERS .............................................................................................................................. 45

SYSTEM CONFIGURATION PARAMETERS ......................................................................................................................... 82

TROUBLESHOOTING WITHOUT A DI AGNOSTIC CODE ..................................................................................................... 83

TROUBLESHOOTING WITH A DIAGNOSTIC CODE........................................................................................................... 115

DIAGNOSTIC FUNCTIONAL TESTS .................................................................................................................................. 155

CALIBRATION PROCEDURES .......................................................................................................................................... 403

ALPHABETICAL INDEX ..................................................................................................................................................... 410

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Troubleshooting Section The desired engine speed is typically determined

• The position of the accelerator pedal

i01914266 • The desired engine rpm in PTO control

Electronic Controls At start-up, the ECM determines the top center

Many of the customer parameters provide additional

For example, if DERATE mode was selected, the DERATE Operation

WARNING Operation • High Coolant Temperature

If the problem is due to one of the following • Available power

The SHUTDOWN mode will shut down the engine

• Oil pressure becomes Very Low Oil Pressure.

• Coolant level becomes Very Low Coolant Level.

o. -75g" 160 ho (119kW)

Illustration 7 g00732031 Illustration 9 g00628192

3 Graph of Very low oil pressure start-up or restart

Other ECM Functions Of Engine Snapshot Data

When diagnostic codes occur, the diagnostic

If the driver does not indicate a problem with

In this situation, the system has no faults except

• Driving Time Three histograms are available. One histogram

• Overall Fuel Economy Cat ET calculates the percentage of time that is

• PTQ Fuel • Cat ET which may require Customer Passwords

• Percent PTO Time • Caterpillar Fleet Information Software (FIS)

• Average Load Factor • CAT ID which requires Customer Parameters

• Maximum Engine Speed • Cat ET

• Start Time • Caterpillar Fleet Information Software (FIS)

• End Time • CAT ID

Fleet Trip Data

Refer to the example of a Custom Data program, as

"Fuel Burned when Fuel Temperature is between

AND 4 AND WHEN 5 The Custom Data programs are protected by

Fuel Correction Factor

• Fuel Rate Maintenance Indicator Data

The CAT ID will also display engine diagnostic

Driver Reward Feature Programmable Parameters

• Custom Data Some of the parameters may affect engine operation

• Current Totals Refer to Troubleshooting, "Customer Specified

SMCS Code: 1900 Analog Sensors - Analog sensors produce a DC

Aftermarket Device - An aftermarket device is a Auxiliary Pressure Sensor - This sensor is an

Sensor - T h e sensor is a device that is used

OFF /Ill/ TIME

Standard SAE Diagnostic Communications Data

Top Center - This refers to the crankshaft position

Torque Limit - T h i s is a programmable parameter

Required Service Tools • Flash programming

Table 1 • Set parameters

• Engine rating history

• Driver and fleet trip segments

• ECM date/time clock

Cat ET can also be used to perform the following