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SENR5574-04 Diagnostic Code Listing Cooling Fan Always ON

January 1999 Flash Troubleshooting Check the following on an Electronic Service Tool:
Code Description Code Guide Procedure 1. Cooling Fan Type Customer Parameter must be
1-11 Cylinder 1 Fault 72 PC-33 programmed to "On-Off" or "Three Speed Fan".
2-11 Cylinder 2 Fault 72 PC-33 If programmed to "None" the fan may always be ON.
3-11 Cylinder 3 Fault 73 PC-33 2. For AUG96 and later Personality Modules,
Engine Sensor Open or Short Circuit Test 4-11
5-11
Cylinder 4 Fault
Cylinder 5 Fault
73
74
PC-33
PC-33
Multi-Function Output #4 Customer Parameter
must be programmed to "Cooling Fan".
Connect Electronic Service Tool to Cab Data Link 6-11 Cylinder 6 Fault 74 PC-33 If both of the above are correctly programmed, inspect
and check for ACTIVE Engine Sensor Open or 22-13 Check Timing Sensor Calibration 42 PC-32 ECM Connector J1/P1 for wire connected to pin-28. If no
Short Circuit Code. If the code is not ACTIVE and 26-05 Multi-Function Output #1 Open Circuit 69 PB-25 wire is present at pin-28 then the ECM is not used to
the Engine is not running properly, refer to 26-06 Multi-Function Output #1 Short Circuit 69 PB-25 control the Cooling Fan System. The problem is in the
Troubleshooting Without A Diagnostic Code. 30-08 Invalid PTO Throttle Signal 29 PB-12 OEM Vehicle System.
30-13 PTO Throttle Sensor Calibration 29 PB-12
ACTIVE 40-05 Multi-Function Output #2 Open Circuit 66 PB-25 ECM is used to control the
Open or Short Cooling Fan System
40-06 Mulit-Function Output #2 Short Circuit 66 PB-25
Circuit Code NOT 41-03 8 Volt Supply Above Normal 21 PB-12
Turn ignition key ON, engine OFF. Access the Cooling
Check Electrical Connectors and Wiring. OK 41-04 8 Volt Supply Below Normal 21 PB-12
Fan Driver Special Test on an Electronic Service Tool.
Refer to PB-10 51-05 Multi-Function Output #3 Open Circuit 67 PB-25
Make the test Active and Not Active while listening for the
51-06 Multi-Function Output #3 Short Circuit 67 PB-25
ACTIVE Short ACTIVE Open 71-00 Idle Shutdown Override 01 PB-21
solenoid and/or relay to click as test status changes.
Circuit Code Circuit Code 71-01 Idle Shutdown Occurrence 47 PB-21
Is clicking detected?
71-14 PTO Shutdown Occurrence 47 PB-21 NO
With the ignition key OFF, disconnect the Measure the Sensor Supply Voltage with NOT
84-00 Vehicle Overspeed Warning 41 PC-36 YES Refer to PB-18
Sensor Connector with the ACTIVE Short a Voltmeter. Reading should be within OK Refer 84-01 Loss of Vehicle Speed Signal 31 PB-14
to
Circuit Code. Does the Short Circuit the range of 4.5 VDC to 5.5 VDC. PC-34 84-02 Invalid Vehicle Speed Signal 36 PB-14 Check A/C Fan status parameter on
Code remain Active? 84-08 Vehicle Speed Out of Range 36 PB-14 Electronic Service Tool.
OK 84-10 Vehicle Speed Rate of Change 36 PB-14 1. If A/C Fan status indicates "DISABLED" then the
84-14 Quick Stop Occurrence 00 PB-36
Code Changes Short Circuit ECM does not use and A/C High Pressure Switch to
91-08 Invalid Throttle Signal 32 PB-12
To Open Circuit Install a short circuit between pin-C and control the Cooling Fan System.
Code Remains 91-13 Throttle Sensor Calibration 28 PB-12
pin-B of the sensor harness connector 2. If parameter indicates "OFF" at any time and the fan
100-01 Low Oil Pressure Warning 46 PC-36
and check for an ACTIVE Short Circuit 100-03 Oil Pressure Sensor Open Circuit 24 PC-35 is still ON then the A/C High Pressure circuit is not

3176B, C-10, C-12, & 3406E


If a Short Circuit code was Active before Diagnostic Code. Does the Open
the sensor was disconnected, but an 100-04 Oil Pressure Sensor Short Circuit 24 PC-35 the reason the Fan is ON.
Circuit Code remain Active? 100-11 Very Low Oil Pressure 46 PC-36
Open Circuit code became Active after the 3. If parameter indicates "ACTIVE DIAG", "ON", or
102-00 Boost Pressure Reading Stuck High 25 PC-35

On-highway Engine
sensor was disconnected then thoroughly "COUNTING" the fan is ON because of the A/C High
Open Circuit Code Short Circuit Code 102-03 Boost Pressure Sensor Open Circuit 25 PC-35
Pressure circuit.
inspect the connector for moisture.
Active with Jumper Active with Jumper 102-04 Boost Pressure Sensor Short Circuit 25 PC-35
Inspect the seals and connect the sensor. 102-13 Boost Pressure Sensor Calibration 42 PC-37

Electrical System
If the code reappears, the sensor or pigtail "ACTIVE DIAG",
If a Short Circuit Code appears, 105-00 High Intake Manifold Temp Warning 64 PC-36 "ON"Or "COUNTING"
harness is the problem. Temporarily "OFF" at any time
temporarily connect the suspect sensor. 105-03 Intake Manifold Temp Sensor Open Circuit 38 PC-35 or "DISABLED" Refer to PB-18
replace the sensor (connect sensor to 105-04 Intake Manifold Temp Sensor Short Circuit 38 PC-35
harness but do not install into engine) and If the Open Circuit code returns Active,
105-11 Very High Intake Manifold Temp 64 PC-36
ensure the code is no longer Active. If the replace the sensor and verify the Check for logged or active diagnostic codes as follows:
diagnostic code does not return. 108-03 Atmospheric Pr Sensor Open Circuit 26 PC-35
code disappears with a new sensor, 108-04 Atmospheric Pr Sensor Short Circuit 26 PC-35 1. 110-00 High Coolant Temp Warning
replace the old sensor. STOP. 5EK1-UP 110-00 High Coolant Temperature Warning 61 PC-36 2. 110-03 Coolant Temp Sensor Open
110-03 Coolant Temp Sensor Open Circuit 27 PC-35 3. 110-04 Coolant Temp Sensor Shorted
9CK1-UP 110-04 Coolant Temp Sensor Short Circuit 27 PC-35 4. 110-11 Very High Coolant Temp
Disconnect the ECM Connector J2/P2 and check for Active 110-11 Very High Coolant Temperature 61 PC-36
1YN1-UP 5. 105-00 High Manifold Temp Warning
Diagnostic Codes. The Open Circuit Diagnostic Code 111-01 Low Coolant Level Warning 62 PC-36
111-02 Coolant Level Sensor Fault 12 PB-17 6. 105-11 Very High Manifold Temp
should be Active without the harness connected. Install a 2PN1-UP 111-11 Very Low Coolant Level 62 PC-36 For codes 110-03 and 110-04 refer to procedure
jumper between the Sensor signal pin and pin-30 (Sensor
121-05 Retarder Solenoid Lo/Hi Open Circuit 14 PB-20 PC-35. For codes 105-00, 105-11, 110-00 and 110-11
Common). A Short Circuit Code should be Active with the 6TS1-UP 121-06 Retarder Solenoid Lo/Hi Short Circuit 14 PB-20 refer to procedure PC-36.
jumper in place.
122-05 Retarder Solenoid Med/Hi Open Circuit 14 PB-20
OK NOT 122-06 Retarder Solenoid Med/Hi Short Circuit 14 PB-20 No Listed Codes
OK 168-02 Low or Intermittent Battery 51 PB-11
171-03 Outside Air Temp Sensor Open Circuit 00 PC-35 The following conditions will turn Fan ON if engine
If the Open Circuit Diagnostic Code is not active without 171-04 Outside Air Temp Sensor Short Circuit 00 PC-35 speed < 2250 rpm:
the harness connected, or the Short Circuit Diagnostic 171-11 No Ambient Air Temperature Data 00 PB-21 1. Engine not running.
Code does not appear with the short circuit in place, 174-00 High Fuel Temp Warning 65 PC-36 2. During engine cranking.
temporarily install another ECM. Repeat this test step. If 174-03 Fuel Temp Sensor Open Circuit 13 PC-35
the problem is resolved with the new ECM, verify the 3. Coolant sensor temp > 205°F (96°C).
174-04 Fuel Temp Sensor Short Circuit 13 PC-35
problem returns with the old ECM. If the new ECM works 4. Coolant temp sensor diagnostic active.
190-00 Engine Overspeed Warning 35 PC-36
and the one on the engine did not, replace the ECM. STOP. 190-02 Loss of Engine RPM Signal 34 PC-31 5. Intake manifold air temp > 189°F (87°C).
228-03 A/C High Pressure Sw Open Circuit 19 PB-18 6. Intake manifold air temp > 162°F (72°C) with boost
Install Sensor Bypass Wiring. Disconnect J2/P2 231-11 J1939 Data Link Fault 58 PB-24 pressure > 10 psi (70 kPa).
NOT and remove the sensor signal wire from P2. Install 232-03 5 Volt Supply Above Normal 21 PC-34 7. Retarder solenoid ON in high mode > 10 seconds.
OK OK 232-04 5 Volt Supply Below Normal 21 PC-34
a 125-3662 3-Pin Engine Sensor Harness Bypass, Repair or 8. A/C high pressure switch open or ECM counting.
Restart Test 244-02 Event Recorder Data Lost 02 PB-11
or make a bypass and route the bypass wire Replace Harness 9. A/C high pressure switch diagnostic active.
249-11 J1922 Data Link Fault 58 PB-24
directly from the ECM Connector P2 to the Sensor. 252-11 Incorrect Engine Software 59 PC-30
10. PTO On/Off switch in ON position.
253-02 Check Customer or System Parameters 56 PC-30 If no listed condition exists then check for an open
253-11 Check Transmission Customer Parameters 56 PC-30 circuit in the solenoid or ECM fan relay circuit. If
254-12 ECM Fault 53 PC-30 problem can not be found refer to procedure PB-18.

© 1999 Caterpillar Printed in U.S.A.


All Rights Reserved

SENR5574-04
6 Page, JVD
3176B, C-10, C-12, & 3406E Engine Harness Wiring Diagram
P2 J2
J5 P5
D789-WH 12 D789-WH 5 INJECTOR COMMON 1 & 2
D790-OR 10 D790-OR 17 INJECTOR COMMON 3 & 4
D791-YL 8 D791-YL 27 INJECTOR COMMON 5 & 6
A706-GY 6 A706-GY 34 INJECTOR 6
A705-BU 5 A705-BU 28 INJECTOR 5
A704-GN 4 A704-GN 22 INJECTOR 4
A703-BR 3 A703-BR 18 INJECTOR 3
A702-PU 2 A702-PU 12 INJECTOR 2
A701-GY 1 A701-GY 6 INJECTOR 1
D786-BR 11 D786-BR 13 RETARDER SOLENOID MED/HI
D787-GN 9 D787-GN 19 RETARDER SOLENOID LO/HI
ENGINE ENGINE ENGINE D788-BK D788-BK 7 RETARDER SOLENOID COMMON
7
CYL CYL CYL CYL CYL CYL RETR RETR RETR D784-BU 40 VEHICLE SPEED OUT+ (NOTE A)
NO.1 NO.2 NO.3 NO.4 NO.5 NO.6 SOL CYL SOL CYL SOL CYL
1 D810-PU 39 TDC PROBE+/VEH SP IN+ (NOTE A)
1&2 5&6 3&4 2 D811-YL 4 TDC PROBE-/VEH SP IN- (NOTE A)
J24 P24 D785-GN 10 VEHICLE SPEED OUT - (NOTE A)
16
35
11
32
26
38
996-GN 1 +V ENG SP/TMG
998-BR 29 ENG SP/TMG COMMON
999-WH 37 ENG SP/TMG
A746-PK 23 BOOST PRESSURE
+V ENG SP/TMG OR A 996-GN A747-GY 20 ATM PRESSURE
SPEED/TIMING ENG SP/TMG COMMON BK B 998-BR 994-GY 8 OIL PRESSURE
SENSOR ENG SP/TMG WH C 999-WH 15
P9 J9 995-BU 14 COOLANT TEMP
C967-BU 2 INTAKE MANF AIR TEMP
A751-YL 3 FUEL TEMP
993-BR 30 SENSOR COMMON
997-OR 36 +5V
GN C A746-PK 21
BOOST PRESS.
BOOST PRESSURE YL B 993-BR 31
SENSOR COMMON
SENSOR OR A 997-OR 25
+5V
9 OUTSIDE AIR TEMP ECM GND STRAP
P3 J3 24
33 TO ECM
VOLTAGE SUPPLY WIRES ECM MOUNTING
BOLT
ATM PRESSURE GN C A747-GY COMMON WIRES
ATM PRESSURE SENSOR COMMON YL B 993-BR
SENSOR +5V OR A 997-OR INPUT SIGNAL WIRES
P22 J22
OUTPUT SIGNALS WIRES

OIL PRESSURE GN C 994-GY


OIL PRESSURE SENSOR COMMON YL B 993-BR
SENSOR +5V OR A 997-OR
P17 J17
1 2 3 4 5 6

6 5 4 3 2 1

7 12 12 11 10 9 8 7

COOLANT TEMP WH C 995-BU 13 18 18 17 16 15 14 13


COOLANT TEMP SENSOR COMMON BK B 993-BR 19 22 22 21 20 19
SENSOR +5V OR A 997-OR 23 28 28 27 26 25 24 23
J10 P10 29 34 34 33 32 31 30 29

40 39 38 37 36 35

35 36 37 38 39 40

Harness Side Engine Harness ECM Side


INTAKE MANF INTAKE MANF AIR TEMP WH C C967-BU ECM Connector
AIR TEMP SENSOR COMMON BK B 993-BR
SENSOR +5V OR A 997-OR
J21 P21

A B B A
FUEL TEMP WH C A751-YL
FUEL TEMP SENSOR COMMON BK B 993-BR
SENSOR +5V OR A 997-OR
J23 P23 Jack Plug C
C

3176B, C-10, C-12, & 3406E OEM Vehicle Harness Wiring Diagram
C +BAT. VOLTAGE SUPPLY WIRES
E -BAT.
D799-GN
ECM CKT BKR

D CHECK ENGINE LAMP COMMON WIRES


CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS F
B793-YL A ATA+
659-PK INPUT SIGNAL WIRES
N/O B792-BU B ATA- WARNING LAMP
RELAY DASH DATA LINK OUTPUT SIGNALS WIRES
C973-GN
SIGNAL-
OFF C SPEEDOMETER
15

B ON SIGNAL+ C974-PU
ST S
C987-RD

R 450-YL 1 2 3 4 5 6
SIGNAL+
TACHOMETER 6 5 4 3 2 1
SIGNAL- 451-BR
KEY SWITCH 7 12 12 11 10 9 8 7
SENR5574-04

13 18 18 17 16 15 14 13
PASSIVE 19 22 22 21 20 19
MAGNETIC D784-BU
23 28 28 27 26 25 24 23
VEHICLE SPEED D785-GN
S G SENSOR 29 34 34 33 32 31 30 29

40 39 38 37 36 35
BAT MTR
6 Page, Color 2, JVD

35 36 37 38 39 40
ALTERNATOR CRUISE ON/OFF
STARTER Harness Side OEM Vehicle Harness ECM Side
MOTOR C993-BR C975-WH ECM Connector
GND (12V)

SERVICE BRAKE N/C


C993-BR C992-PU A B B A
(PEDAL RELEASED POSITION)

- 12V + - 12V + - 12V +


Jack Plug C
CLUTCH N/C C
BATTERY 3 BATTERY 2 BATTERY 1
C993-BR C977-BU
(PEDAL RELEASED POSITION)

P1 J1 ECM
SET/RESUME
D799-GN 22 CHECK ENGINE LAMP
C993-BR C978-BR 659-PK 27 WARNING LAMP
C979-OR C973-GN 10 SPEEDOMETER-
E715-RD

C974-PU 16 SPEEDOMETER+ ECM GND STRAP


450-YL 17 TACHOMETER+
LO 451-BR 11 TACHOMETER-
E716-GY TO ECM
MED
C993-BR D784-BU 18 VEHICLE SPEED IN+ MOUNTING
HI
D785-GN 12 VEHICLE SPEED IN- BOLT
ENGINE RETARDER LO C975-WH 20 CRUISE CONT ON/OFF SW
SOLENOID MED
E717-GN C992-PU 14 SERVICE BRAKE SW
ON/OFF SW HI
C977-BU 24 CLUTCH SW
C978-BR 25 SET
ENGINE RETARDER
C979-OR 15 RESUME
SOLENOID SELECTOR SW
E716-GY 19 RETARDER SOLENOID LO/HI SW
E717-GN 13 RETARDER SOLENOID MED/HI SW
B792-BU 1 ATA DATA LINK- (J1587)
B793-YL 7 ATA DATA LINK+ (J1587)
C987-RD 6 +BATTERY
A/C HIGH PRESS. SW E715-RD 4 UNSWITCHED +BATTERY
N/C D745-YL 28 MULTI-FUNCTION OUTPUT #4 (NOTE B)
E718-PK 40 MULTI-FUNCTION OUTPUT #2
E971-GN E971-GN 38 A/C HIGH PRESSURE SW
TO J1939 DATA LINK CONNECTOR A249-BK 26 J1939 DATA LINK SHIELD (NOTE K)
TO J1939 DATA LINK CONNECTOR K990-GN 39 J1939 DATA LINK- (NOTE K)
TO J1939 DATA LINK CONNECTOR K900-YL 33 J1939 DATA LINK+ (NOTE K)
+5V C C997-OR C997-OR 36 +5V
COOL LEVEL NORMAL D C983-WH C983-WH 2 COOLANT LEVEL NORMAL
COOLANT LEVEL SENSOR C984-YL C984-YL 23 COOLANT LEVEL LOW
COOL LEVEL LOW A
SENSOR COMMON B C993-BR TO J1922 DATA LINK CONNECTOR E721-PK 9 J1922 DATA LINK+
TO J1922 DATA LINK CONNECTOR E720-WH 3 J1922 DATA LINK-
C988-BK C988-BK 5 -BATTERY
E991-GY 34 MULTI-FUNCTION OUTPUT #3
C985-BU 35 +8V
J11 P11 C986-BR 37 THROTTLE POSITION
ENG GND STUD C993-BR 29 SENSOR COMMON
+8 V RD A C985-BU
K999-GN 8 MULTI-FUNCTION INPUT #1
THROTTLE POSITION WH C C986-BR
K980-PK 32 MULTI-FUNCTION INPUT #2
SENSOR COMMON BK B C993-BR
K982-YL 31 MULTI-FUNCTION INPUT #3
ENGINE L901-GY 30 MULTI-FUNCTION SENSOR COMMON
THROTTLE POSITION
CYL HEAD K998-BU 21 MULTI-FUNCTION OUTPUT #1
SENSOR
OEM
COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED INSTALLED
Does not crank,
refer to PA-18
Either the vehicle wiring or another
device on the vehicle is causing
ATA DATA LINK+
ATA DATA LINK-
+ BATTERY

the communication problem.


- BATTERY
+BATTERY
- BATTERY

Service
Cables

Repair
Repair

Tool

OK
OK

Electronic Service Tool Will Not


Communicate with the ECM
the ECM. Install a Caterpillar 129-2018

completely different set of Service Tool


Harness Bypass. Connect the Bypass
directly to the Electronic Service Tool

Disconnect ECM Connector P1 from

ECM, but use the same Service Tool


to PC-30

Connect Another Service Tool to the


Harness and ECM as shown below.
ATA DATA LINK -

Communicate
ECM and Service Tool
Refer

Connect the Service Tool Using a


Cable Shown Below
Dashed in Area is

NOT
Harness Bypass Diagram
ATA DATA LINK +

G
C

Cables as in the previous step.


B
A

OK
F
or 139-4166 Cable
Cable P/N 8T5275

communicate with the Service Tool.


Engine Starts, but ECM does not
J
Service Tool "T"
Caterpillar

Try to Start the Engine.


ensure the Personality Module Chip is
Service Tool P/N 129-2018
Caterpillar Harness Bypass

If ECM Serial Number ends in "CA",


completely snapped into the ECM

No Communications

No Communications
Cables.
P1 J1
- 12V +

No Communications
5
6
7
1
- BATTERY
+BATTERY
ATA DATA LINK + (J1587)
ATA DATA LINK - (J1587)

socket.
ECM
-
12V

not start
Does
+
PC-30

Connect Electronic Service Tool to Cab Data Link,


PC-31

PC-33

PC-30

PB-11
Refer

ECM does not communicate


Refer

Refer

Refer

Refer

NOT
NOT

NOT

NOT

NOT

OK connections with the ignition key switch


OK

OK

OK

OK
to

to

to

to

to

Engine Cranks, But Will Not Start


Connector P1/J1 pin-6 +Battery to pin-5
-Battery should be 11.0 - 13.5 Volts DC.
recently replaced/updated, connect and

Ensure after-market engine protection


Ensure the Fuel Injector Connector (J5/P5)
Service Tool while cranking the engine.
the CAT ID will indicate Theft Deterrent

ensure the Personality Module Chip is


mechanical problems or extreme cold.

cranking - if no smoke is present there

If the Truck is equipped with a CAT ID,


Turn the ignition key ON, engine OFF,

Attempt to access Truck Functions.


devices (not installed by Caterpillar)
are not active, preventing the ECM
Observe engine rpm from Electronic

If ECM Serial Number ends in "CA",


check for an active 252-11 Incorrect
ensure Theft Deterrent is not Active.

turn ignition key ON, engine OFF.


is fully connected and free of corrosion.
If the Personality Module has been
may be a fuel supply or fuel quality
problem. Check fuel pressure, fuel

completely snapped into the ECM

ON. Battery voltage at the ECM


Check for combustion problems,

Check ECM power and ground


Monitor the exhaust stack while

from receiving battery power.


priming, and fuel filters.

Engine Software.

socket.
Active.

OK
OK

OK
OK

OK
OK

OK
OK

ECM Communicates