Académique Documents
Professionnel Documents
Culture Documents
March 2006
Troubleshooting
C11, C13 and C15 On-highway Engines
KCA1-Up (Engine)
KCB1-Up (Engine)
JAM1-Up (Engine)
BXS1-Up (Engine)
i01658146
SENR9698-09
3
Table of Contents
Table of Contents
Troubleshooting Section
Electronic Troubleshooting
System Overview .................................................... 6
Electronic Service Tools ........................................ 13
Replacing the ECM ............................................... 15
Sensors and Electrical Connectors ....................... 17
Programming Parameters
Programming Parameters .....................................
Dyno Mode ...........................................................
Test ECM Mode ....................................................
Customer Passwords ............................................
ECM Date/Time Stamped Information ..................
ECM Snapshot ......................................................
Factory Passwords ...............................................
Factory Passwords Worksheet .............................
Flash Programming ..............................................
Service Information Report ...................................
23
23
23
24
24
25
26
27
27
28
30
31
37
40
44
44
47
47
48
51
51
52
56
57
58
58
59
59
61
63
63
4
Table of Contents
SENR9698-09
SENR9698-09
Index Section
Index ................................................................... 413
5
Table of Contents
6
Troubleshooting Section
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Troubleshooting Section
Electronic Troubleshooting
i02182977
System Overview
SMCS Code: 1900
System Operation
These truck engines were designed for electronic
control. A solenoid on each injector controls the
amount of fuel that is delivered by the injector. An
Engine Control Module (ECM) sends a signal to each
injector solenoid in order to provide complete control
of the fuel injection.
Electronic Controls
RPM
Other characteristics
Fuel Injection
Engine Governor
Horsepower
Torque curves
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7
Troubleshooting Section
Engine Monitoring
Caterpillar provides a factory installed engine
monitoring system. The Caterpillar engine monitoring
system monitors engine oil pressure, coolant
temperature, intake manifold air temperature, and
coolant level (optional device). Optional devices are
OEM installed.
The oil pressure, intake manifold air temperature,
and coolant temperature sensors are standard on all
engines. The vehicle OEM installs the coolant level
sensor and the associated harness. The coolant level
sensor is the only optional component of Caterpillar
engine monitoring. Coolant level is selected through
a customer programmable parameter.
Illustration 1
(1)
(2)
(3)
(4)
g00628178
TC reference
Speed-timing signal
Electrical current to injector solenoid
Injection pressure curve
8
Troubleshooting Section
SENR9698-09
Self-Diagnostics
The electronic system has the ability to diagnose
problems. When a problem is detected, a diagnostic
code is generated and the check engine/diagnostic
lamp may be turned ON. In most cases, the code is
also stored in permanent memory or logged in the
ECM.
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9
Troubleshooting Section
10
Troubleshooting Section
SENR9698-09
Total Distance
Trip Data
Total Time
Driving Time
Distance
Idle Time
Fuel
Overall Fuel Economy
Driving Fuel Economy
Idle Fuel
Percent Idle Time
PTO Time
PTO Fuel
Percent PTO Time
Average Load Factor
Average Vehicle Speed
Average Driving Speed
Maximum Vehicle Speed
Maximum Engine Speed
Start Time
End Time
Start Odometer
End Odometer
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11
Troubleshooting Section
Illustration 2
g00628194
Basic Program
Engine Hours
Distance Traveled
Fuel Burned
Occurrences
Refer to the following list for information regarding
the options that are available for variable 2 and
variable 5.
Variables 3, 4, 6, and 7 define the minimum range
and the maximum range of variables 2 and 5.
Engine Speed
Vehicle Speed
Fuel Rate
Load Factor
Coolant Temperature
Oil Pressure
Fuel Temperature
Intake Manifold Air Temperature
Cruise
PTO
Engine Retarder
Throttle Position
Brake
12
Troubleshooting Section
PM1
PM2
Cooling system clean/flush
The ECM uses the previous point of maintenance in
order to calculate the timing of the next scheduled
maintenance work.
The maintenance indicator mode is programmable
to hours or distance. The PM 1 Interval parameter
is programmable to the Off, Automatic Distance,
Automatic Hours, Manual Distance, or Manual
Hours setting.
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Messenger
The Caterpillar Messenger Driver Information Display
is available to provide engine operating information
to the driver. The driver trip segment, the fleet trip
segment, and the maintenance indicator data can be
viewed. However, the fleet trip histograms and the
custom data cannot be viewed from the display.
Messenger provides the ability to enter an ID code
for a driver in order to divide the fleet trip segment
for two drivers. If the driver enters the information
regarding the state of travel, the fleet trip segment
can be tagged by the state of travel.
Messenger can be used in order to tag portions of
the fleet trip segment into two ID codes. Messenger
can also be used in order to tag portions of the fleet
trip segment into the state of travel. The ID code and
the information regarding the state of travel cannot
be viewed from the display. Only the Caterpillar Fleet
Information Software (FIS) can view this information.
The ability to reset any of these parameters is
dependent on customer parameters in the ECM.
Messenger will also display engine operating
parameters such as engine rpm, coolant
temperature, boost pressure and many other
parameters.
Messenger will also display engine diagnostic codes.
Messenger will also display a brief text description
of the diagnostic codes.
An available feature on Messenger is the theft
deterrent. The theft deterrent allows the driver to input
a password prior to shutdown. The theft deterrent will
prevent the engine from restarting until the password
is successfully entered. Messenger must have the
version of software that is capable of supporting this
feature.
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13
Troubleshooting Section
Custom data
Histograms
Current totals
Custom data
Economy model
Maintenance information
14
Troubleshooting Section
SENR9698-09
Table 1
Data logging
Part Number
N/A
Description
4 mm Allen Wrench
Snapshot recorder
The following components are required to use Cat
ET to service the engine.
6V-2197
Transducer
7X-1171
Transducer Adapter
7X-1695
Cable As
1U-5804
1U-5805
151-6320
167-9225
140-2266
Cable(70-Pin Breakout)
JERD2124
9U-7330
or
146-4080
Digital Multimeter
JERD2125
190-8900
Table 2
Digital Multimeter(RS-232)
or
JERD2129
Parameters
Diagnostic codes
Engine rating history
Driver and fleet trip segments
Histograms
Custom data
ECM date/time clock
Maintenance intervals
Cat ET can also be used to perform the following
functions:
Diagnostic tests
Sensor calibrations
Flash programming
Set parameters
171-4400(1)
Communication Adapter II Gp
237-7547(2)
Adapter Cable As
(1)
(2)
Description
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15
Troubleshooting Section
Part Number
Illustration 3
(1)
(2)
(3)
(4)
g00647144
Note: Items (2), (3), and (4) are part of the 171-4400
Communication Adapter II Gp.
Description
7X-6370
8T-8726
5P-7277
Voltage Tester
9U-5103
Socket(Slotted)
7X-1710
Multimeter Probe
1U-5718
Vacuum Pump
1U-8757
Tube(Fluid Sampling)
169-7372
9S-9082
198-4240
or
1U-5470
6V-9130
Temperature Adapter
124-5643
125-3662
157-4829
Cable Adapter
7X-1403
Adapter Cable As
7X-1686
Cable Adapter
139-4166
208-0059
i02126668
16
Troubleshooting Section
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SENR9698-09
17
Troubleshooting Section
18
Troubleshooting Section
Illustration 4
Diagram of components
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g01051473
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19
Troubleshooting Section
Illustration 5
Sensor locations (left side view)
g01098502
20
Troubleshooting Section
Illustration 6
SENR9698-09
g01004205
Illustration 7
Sensor locations (right side view)
g01004206
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21
Troubleshooting Section
C15 Engine
Illustration 8
Sensor locations (left side view)
g01098568
22
Troubleshooting Section
Illustration 9
Sensor locations (right side view)
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g01014707
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23
Troubleshooting Section
Programming Parameters
i02305999
Programming Parameters
i02345343
Dyno Mode
SMCS Code: 1901
Dyno mode is a feature in the software that helps
ensure that a dyno run is accurate. Dyno mode
should be used whenever a dyno run is performed on
the engine. Dyno mode disables certain strategies
that could cause the dyno run to be invalid. For
example, the cooling fan may be disabled. The
following features are disabled by dyno mode:
Idle shutdown
Control of the cooling fan
Fuel temperature power correction
Certain derates
24
Troubleshooting Section
SENR9698-09
Customer Passwords
SMCS Code: 0785
Customer passwords may be used to protect
customer parameters from being changed. The
passwords are programmed into the Electronic
Control Module (ECM) with the Caterpillar Electronic
Technician (ET). One password may be programmed
or both passwords may be programmed. If
customer passwords are not programmed, customer
parameters may be changed by anyone.
To obtain customer passwords, contact the owner of
the engine. If the owner has forgotten the customer
passwords, customer passwords may be read by
using Cat ET. Factory passwords are required in
order to read customer passwords.
Use the following procedure in order to read customer
passwords with Cat ET:
1. Select the Information menu. Then select
Passwords.
2. When the Factory Password screen appears,
record the information that is listed on the Factory
Passwords Worksheet. Refer to programming
parameters Troubleshooting, Factory Passwords
Worksheet for additional information.
SENR9698-09
Diagnostic Clock
Do not confuse the ECM Date/Time Clock with the
diagnostic clock. The diagnostic clock starts at zero
when battery power and the key switch input are first
applied to the ECM. Then, the diagnostic clock will
increment while the key switch and battery power are
applied to the ECM. The diagnostic clock is used to
time stamp diagnostic codes and event codes.
Logged diagnostic codes and logged event codes
display the diagnostic clock hour of the first
occurrence and the last occurrence and the total
number of occurrences.
Total Time
The Total Time is the total cumulative time of engine
operation. The Total Time can be obtained from the
Current Totals menu of Cat ET.
25
Troubleshooting Section
i02305595
ECM Snapshot
SMCS Code: 0785
The Engine Control Module (ECM) can record a
snapshot of certain engine parameters and certain
vehicle parameters. The snapshot records the
parameters for a period of 13 seconds that surround
an event. The following events trigger snapshots:
26
Troubleshooting Section
SENR9698-09
Clutch Switch
Vehicle Speed
Cruise Status
Brake Switch
Illustration 10
g00627693
Engine RPM
Throttle Position
Engine rpm
Range of vehicle speeds
Range of coolant temperatures
Use the snapshot data in order to determine the
operating conditions that were present during the
event. Attempt to duplicate the conditions in order
to get the code to recur.
Replacement of electronic components should
not be based on snapshot data alone. If too much
emphasis is put on snapshot data, the result could
be a misdiagnosed root cause. Also when snapshot
data that is triggered by a diagnostic code is being
viewed, the ECM sets a sensor value with an active
diagnostic code to a default value when the code
is active. This is the reason that the sensor value
suddenly jumps to a specific value at the trigger point
and the sensor value remains at the specific value for
the rest of the snapshot frames.
i02306413
Factory Passwords
SMCS Code: 0785
Factory passwords are required in order to perform
the following functions in the Caterpillar Electronic
Technician (ET):
Change the system configuration parameters.
When the Engine Control Module (ECM) is replaced,
the system configuration parameters must be
programmed into the new ECM. A new ECM will allow
these parameters to be programmed once without
factory passwords. After the initial programming,
factory passwords are required to program the
parameters.
SENR9698-09
27
Troubleshooting Section
Table 4
Telephone Number
Information From the Engine Information Plate
Engine Serial Number
Full Load Setting
Full Torque Setting
Information From the Vehicle Odometer
Engines Miles (km)
Information From the Factory Password Entry
Screen on the Caterpillar Electronic Technician (ET)
Electronic Service Tool
Serial Number
Engine Serial Number
ECM Serial Number
Total Tattletale
Reason Code
From Interlock(1)
To Interlock(1)
Factory Passwords
Factory Password (No. 1)
Factory Password (No. 2)
(1)
i02419726
Flash Programming
SMCS Code: 1901-591
Flash Programming This is a method of
programming or updating the flash file in an engines
Electronic Control Module (ECM).
Caterpillar Electronic Technician (ET) is used to flash
program a file into the memory of the engines ECM.
28
Troubleshooting Section
If you do not have the flash file, use the Flash File
Search tool on the Service Technician Workbench
(STW) to obtain the flash file for your engine.
Alternatively, use the Service Software Files feature
on SIS Web to obtain the flash file for your engine.
You must have the engine serial number in order to
search for the flash file. After locating the correct
flash file, download the flash file to your PC. Write
down the name of the flash file for future reference.
SENR9698-09
i02278907
Recommendations
Customers Complaint
Obtain as much information from the customer
as possible. Investigate any written information
that is available and document any information
that is gathered from the customer. The following
information is of particular importance:
Be as specific as possible.
Cause of Failure
Comments on the cause of failure should include
the number of diagnostic codes that were logged.
Comments should also indicate if the code was an
active code. Indicate the source of the problem. Also
indicate the method that was used to discover the
problem. Examples of the methods that were used to
discover the problem could be one of the following
methods:
Be as specific as possible.
Repair Procedure
Comments on the repair procedure should include
the following types of information:
SENR9698-09
Be as specific as possible.
29
Troubleshooting Section
30
Troubleshooting Section
SENR9698-09
Customer Specified
Parameters
Customer Specified
Parameters
SMCS Code: 1901
Customer specified parameters allow the vehicle
owner to influence the operating technique of a driver.
Some parameters may affect engine operation in a
way that would not be expected by an inadequately
trained driver. These parameters may lead to power
or performance complaints even though the engines
performance is within the engines specification.
Customer parameters may be changed repeatedly
as a customers operation changes or as new drivers
are assigned to a truck. Customer passwords are
required to change these parameters. The customer
password must be programmed into the Engine
Control Module (ECM).
Time of change
Operator during change
The following customer parameters are available for
lockout:
Multi-Torque Ratio
Vehicle Speed Calibration
Vehicle Speed Cal (J1939 - Trans)
Vehicle Speed Cal (J1939 - ABS)
Vehicle Speed Limit
VSL Protection
Soft Vehicle Speed Limit
Two Speed Axle - Low Speed Range Axle Ratio
Minimum
Maximum
Default
Transmission Style
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31
Troubleshooting Section
Customer Specified
Parameters Table
SMCS Code: 1901
Table 5
Default
17 Digits
Available characters are dependent
on the service tools.
all zeroes
No
Yes
No
Not Programmed
Not Programmed
0 to 6.550
Not Programmed
TEL rpm
No
Yes
No
1.00 to 19.99
1.00
1.0 to 9.99
1.00
(continued)
32
Troubleshooting Section
SENR9698-09
(Table 5, contd)
Default
Coast
Latch
Manual
Manual
Hard Limit
Soft Limit
Hard Limit
0 km/h (0 mph)
0 to 16 km/h (0 to 10 mph)
0 km/h (0 mph)
0 to 8 km/h (0 to 5 mph)
3 km/h (2 mph)
Set/Accel-Res/Decel
Set/Decel-Res/Accel
Set/Accel-Res/Decel
No
Yes
Yes
Disabled
Enabled
Disabled
2 to 24 km/h (1 to 15 mph)
2 km/h (1 mph)
2120 rpm
5 to 1000 rpm/sec
50 rpm/sec
5 to 500 rpm
20 rpm
Cab Switches
Off
Remote Switches
Remote Throttle
Off
2120 rpm
No
Yes
No
Low Idle
TEL
PTO TEL
TEL
2 km/h (1 mph)
3 to 1440 minutes
(continued)
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33
Troubleshooting Section
(Table 5, contd)
Default
Continuous
Normal
Normal
TEL rpm
5 to 48 km/h (3 to 30 mph)
5 km/h (3 mph)
TEL rpm
8 to 80 km/h (5 to 50 mph)
8 km/h (5 mph)
TEL rpm
600 rpm
Automatic Option 1
Automatic Option 2
Automatic Option 3
Automatic Option 4
Eaton Top 2
Manual Option 1
Manual Option 1
No
Yes
No
0.000 to 3.750
0.000
0.000 to 3.750
0.000
0.000 to 3.750
0.000
Full Range
Min/Max
Min/Max with Speed Control
Full Range
3 to 1440 minutes
0 minutes
2120 rpm
Yes
49 C (120 F)
49 C (120 F)
1 to 600 seconds
0 seconds
No
Yes
No
0.0 seconds
0 to 25.5 volts
0.0 volts
Derate
Shutdown
Warning
Warning
Governor Type
Timer Parameters
Idle Shutdown Time (0 = Off)
Idle Shutdown Timer Maximum RPM
Allow Idle Shutdown Override
(continued)
34
Troubleshooting Section
SENR9698-09
(Table 5, contd)
Default
Option 1
Warning Lamp
Warning Lamp
No
Disabled
Enabled
Disabled
Automatic Distance
Automatic Hours
Manual Distance
Manual Hours
Off
Off
19 to 57 L (20 to 60 qt)
63.5 to 63.5 %
0 %
No
Yes
No
Dash-PM 1 Reset
No
Yes
No
No
Yes
No
Dash-State Selection
No
Yes
Yes
Auto-Enable
No
Yes
No
Four Characters
0000
0 to 1440 minutes
0 minutes
Disabled
Enabled
Enabled
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35
Troubleshooting Section
(Table 5, contd)
Default
J1/P1:46
J1/P1:47
J1/P1:6
J1/P1:7
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None
None
None
J1939
J1/P1:62
None
J1/P1:47
None
None
J1/P1:7
None
None
J1/P1:46
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None
None
J1/P1:56
J1939 - Cab Controller
J1939 - Body Controller
J1939 - Instrument Cluster
J1/P1:56
J1/P1:58
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None
J1/P1:58
J1/P1:60
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None
J1/P1:60
J1/P1:46
J1/P1:58
J1/P1:6
J1/P1:60
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None
None
J1/P1:46
J1/P1:58
J1/P1:6
J1/P1:60
None
None
J1/P1:46
J1/P1:47
J1/P1:6
J1/P1:7
None
None
Diagnostic Enable
(continued)
36
Troubleshooting Section
SENR9698-09
(Table 5, contd)
Default
J1/P1:6
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None
None
J1/P1:59
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
J1/P1:59
J1/P1:35 & 44
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
J1/P1:35 & 44
None
J1/P1:22
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
J1/P1:22
J1/P1:23 & 40
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
J1/P1:23 & 40
J1/P1:45
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
J1/P1:45
J1/P1:66
J1/P1:66
J1/P1:32 & 33
J1939 ABS
J1939 Trans
J1/P1:32 & 33
J1/P1:10
J1/P1:12
J1/P1:13
None
None
J1/P1:10
J1/P1:12
J1/P1:13
None
None
Auxiliary Brake
J1/P1:12
None
None
J1/P1:10
J1/P1:12
J1/P1:13
None
None
J2/P2:13
None
None
Output Selections
Engine Running Output
(continued)
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37
Troubleshooting Section
(Table 5, contd)
Default
None
On/Off PWM
On/Off DC
Three-Speed Fan PWM
Three-Speed Fan DC
Variable Speed Fan Option S
None
J1/P1:19
None
None
8 Digits
Available characters are dependent
on the service tools.
Not Programmed
J1939
None
J1939
i02504411
Customer Specified
Parameters Worksheet
SMCS Code: 1901
Table 6
Table 8
38
Troubleshooting Section
Table 9
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Table 12
PTO Configuration
Table 10
Idle Parameters
Idle Vehicle Speed Limit
Idle RPM Limit
Idle/PTO RPM Ramp Rate
Idle/PTO Bump RPM
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39
Troubleshooting Section
Table 13
Table 16
Engine/Gear Parameters
Lower Gears Engine rpm
Limit
Engine Coolant
Temperature Derate
Enable Status
Table 17
Maintenance Parameters
Maintenance Indicator
Mode
PM 1 Interval
Engine Oil Capacity
Table 18
Trip Parameters
Fuel Correction Factor
Governor Type
Dash - PM 1 Reset
Dash - Fleet Trip Reset
Table 14
Timer Parameters
Idle Shutdown Time (0 =
Off)
Idle Shutdown Timer
Maximum RPM
Allow Idle Shutdown
Override
Minimum Idle Shutdown
Outside Temp
Maximum Idle Shutdown
Outside Temp
A/C Switch Fan On-Time
(0 = Off)
Table 15
Driver Reward
Smart Idle Parameters
40
Troubleshooting Section
Table 21
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Table 23
Input Selections
Customer Passwords
Customer Password #1
Transmission Neutral
Switch
Customer Password #2
Table 24
Diagnostic Enable
PTO On/Off Switch
Remote PTO Set Switch
Remote PTO Resume
Switch
PTO Engine RPM Set
Speed Input A
PTO Engine RPM Set
Speed Input B
Total Distance
Total Fuel
Cruise Control
Set/Resume/Accel/Decel
Switch
Output Selections
Engine Running Output
Engine Shutdown Output
Auxiliary Brake
Starting Aid Output
Air Inlet Shutoff Relay
Control
Fan Control Type
PTO Active Output
i02183201
Minimum
Maximum
Default
204 km/h
(127 mph)
204 km/h
(127 mph)
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41
Troubleshooting Section
Table 28
Alternative
Default
Coast
Latch
Manual
Table 27
Minimum
Maximum
Default
204 km/h
(127 mph)
204 km/h
(127 mph)
Coast
Latch
Manual
When the Engine Retarder Mode is programmed to
the coast mode, the engine retarder is enabled only
while the service brakes are being applied. When the
Engine Control Module (ECM) is programmed to the
latch mode, the engine retarder stays enabled after
the service brakes are released. A direct, immediate
pressure on the brake pedal latches the engine
retarder in the ON position and the engine retarder
will remain in the ON position until the accelerator
pedal is depressed.
When the ECM is programmed to the manual mode,
the cruise control switch is not required to be in the
ON position. When the ECM is programmed to the
manual mode, the engine retarder will activate when
all of the following conditions are met:
Illustration 11
g00631045
Hard limit
Soft limit
If the Engine Retarder Minimum VSL Type is
programmed to the hard limit, the engine retarder will
turn off when the value that is programmed into the
engine retarder minimum vehicle speed is reached.
If the Engine Retarder Minimum VSL Type is
programmed to the soft limit, the engine retarder
will remain on and the retarder will have a value
that is below the value that is programmed in the
engine retarder minimum vehicle speed. The engine
retarder will remain on until the parameters that
would normally turn off the engine retarder are met.
In both cases, the engine retarder will remain off until
vehicle speed is higher than the programmed value
of the engine retarder minimum vehicle speed and
the engine retarder has been engaged again.
42
Troubleshooting Section
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Minimum
Maximum
Default
0 km/h (0 mph)
204 km/h
(127 mph)
0 km/h (0 mph)
Illustration 12
Alternative
Default
Soft Limit
Hard Limit
Minimum
Maximum
Default
0 km/h (0 mph)
0 km/h (0 mph)
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43
Troubleshooting Section
Minimum
Maximum
Default
0 km/h (0 mph)
8 km/h (5 mph)
3 km/h (2 mph)
Cruise/Idle/PTO Switch
Configuration
Cruise/Idle/PTO Switch Configuration defines the
function of the Set/Resume switch for Accel mode
and Decel mode. This parameter affects cruise
control mode, idle mode and PTO mode.
Table 33
Alternative
Default
Set/Decel-Res/Accel
Set/Accel-Res/Decel
g00670797
Illustration 13
Table 34
Alternative
Default
No
Yes
Alternative
Default
Enabled
Disabled
44
Troubleshooting Section
SENR9698-09
i02183219
Brake switch
Table 36
Default
None
J1939
PTO Configuration
The PTO Configuration determines the features
that are available for dedicated PTO applications
and the input signals that are used for dedicated
PTO applications. When the PTO Configuration is
turned off, the application does not use the PTO.
The remaining PTO programmable options require a
PTO On/Off circuit that is connected to Input 1. A
PTO switch on lamp can also be connected to output
1 (J1/P1:30).
If the ECM is programmed to the cab switches, the
Engine Control Module (ECM) will use the signals
from the following two switches for PTO control and
for cruise control:
Accelerator
Cruise control switches
If the ECM is programmed to Remote Throttle, the
ECM will monitor J1/P1:68 for the remote accelerator
pedal. The ECM will monitor programmed signals
and the ECM will ignore all cab controls when the
PTO On/Off circuit is ON.
Alternative
Default
Cab Switches
Remote Switches
Remote Throttle
Off
Clutch switch
Table 37
Alternative
Minimum
Maximum
Default
2120 rpm
2120 rpm
SENR9698-09
45
Troubleshooting Section
Table 39
Minimum
Maximum
Default
0 rpm
Minimum
Maximum
Default
0 rpm
Minimum
Maximum
Default
0 rpm
Alternative
Default
Yes
No
46
Troubleshooting Section
SENR9698-09
Minimum
Maximum
Default
700 rpm
Table 45
Minimum
Maximum
Default
2 km/h (1 mph)
204 km/h
(127 mph)
2 km/h (1 mph)
Minimum
Maximum
Default
204 km/h
(127 mph)
204 km/h
(127 mph)
Torque Limit
Alternative
Default
Low Idle
TEL
PTO TEL
TEL
g00628600
Illustration 14
Operation of Torque limit
(1) Programmed torque limit
Minimum
Maximum
Default
270 Nm
(200 lb ft)
3400 Nm
(2500 lb ft)
3400 Nm
(2500 lb ft)
SENR9698-09
47
Troubleshooting Section
Minimum
Maximum
Default
3 minutes
1440 minutes
0 minutes
Table 50
Alternative
Default
Continuous
Normal
i02374194
Driver Reward
SMCS Code: 1901
Alternatives
Default
Disabled
Enabled
i02183252
Illustration 15
PTO Shutdown Timer Maximum RPM Graph
Table 49
Minimum
Maximum
Default
600 rpm
2120 rpm
2120 rpm
Vehicle ID
Vehicle ID is the identification of the vehicle that
is assigned by the customer. Vehicle ID is used
only for the customers reference. Vehicle ID is not
required by the Engine Control Module (ECM).
48
Troubleshooting Section
SENR9698-09
i02183257
Engine/Gear Parameters
SMCS Code: 1901
Minimum
Maximum
Default
1300 rpm
TEL rpm
TEL rpm
Table 52
Minimum
Maximum
Default
1100 rpm
TEL rpm
TEL rpm
Minimum
Maximum
Default
5 km/h (3 mph)
5 km/h (3 mph)
Minimum
Maximum
Default
204 km/h
(127 mph)
204 km/h
(127 mph)
Minimum
Maximum
Default
600 rpm
750 rpm
600 rpm
Transmission Style
Table 54
Minimum
Maximum
Default
1100 rpm
TEL rpm
TEL rpm
Minimum
Maximum
Default
8 km/h (5 mph)
8 km/h (5 mph)
Automatic option 1
SENR9698-09
49
Troubleshooting Section
Automatic option 2
Automatic option 3
Automatic option 4
The manual selection requires a clutch pedal position
switch to be connected to the ECM connector
J1/P1:24. The transmission selections with a neutral
switch require a transmission neutral switch to be
connected to the ECM connector J1/P1:62. J1/P1:62
is the input 12. The transmission selections with two
brake switches require a second brake switch to be
connected to the ECM connector J1/P1:64. J1/P1:64
is the input 13.
The Eaton Top 2 transmission is a manual
transmission and the Eaton Top 2 transmission
requires a clutch switch. The ECM operates two
outputs in order to control shifting between the top
two gears of an Eaton Top 2 transmission. A total of
four parameters must be programmed for the system
to operate correctly.
Table 59
Transmission Style
Parameter Setting
Use of Switch
Service Brake No. 1
Clutch
Neutral
Optional
Manual Option 1
Automatic Option 1
Automatic Option 2
Optional
Automatic Option 3
Automatic Option 4
Eaton Top 2
Optional
X
X
Table 60
Alternative
Automatic Option
Automatic Option
Automatic Option
Automatic Option
Eaton Top 2
Default
1
2
3
4
Manual Option 1
Optional
50
Troubleshooting Section
SENR9698-09
Table 61
Alternative
Default
Yes
No
Minimum
Maximum
Default
0.000
3.750
0.000
Transmission
Model
Top
Gear
Minus
Two
Ratio
Top
Gear
Minus
One
Ratio
Top
Gear
Ratio
RTLO-XX610B-T2
1.352
1.000
0.741
Table 62
RTLO-XX710B-T2
1.825
1.351
1.000
Minimum
Maximum
Default
RTLO-XX713A-T2
1.000
0.856
0.730
0.000
3.750
0.000
RTLO-XX718B-T2
1.000
0.856
0.730
Minimum
Maximum
Default
0.000
3.750
0.000
Governor Type
This parameter determines the type of governor that
controls the engine. Select Full Range for manual
transmissions and for electronically shifted manual
transmissions. Select Min/Max for automatic
transmissions.
The Min/Max with Speed Control option allows
the use of a full range governor when the vehicle is
not moving and the transmission is in neutral. The
Min/Max with Speed Control option is preferred
for applications that currently use the Min/Max
governor.
SENR9698-09
51
Troubleshooting Section
Table 66
Alternative
Default
Min/Max
Min/Max with Speed Control
Full Range
i02103626
Alternative
Default
Derate
Shutdown
Warning
Alternative
Default
Option 1
Warning Lamp
Alternative
Default
4 pin
2 wire Float Sensor
No
Alternative
Default
Enabled
Disabled
i01938915
Idle Parameters
SMCS Code: 1901
Minimum
Maximum
Default
2 km/h (1 mph)
2 km/h (1 mph)
52
Troubleshooting Section
SENR9698-09
Table 74
Minimum
Maximum
Default
5 rpm
500 rpm
20 rpm
i02183267
Input Selections
Table 72
Minimum
Maximum
Default
600 rpm
2120 rpm
2120 rpm
J1/P1:7(Input 4)
J1/P1:47(Input 5)
J1/P1:6(Input 6)
J1/P1:46(Input 7)
Idle rpm
PTO rpm
The parameter can be set to a value between 5 rpm
and 1000 rpm in one rpm increments.
Note: The parameter affects both idle control and
PTO control. The idle mode occurs if the engine rpm
is set by using the cruise control On/Off switch and
the Set/Resume switch. The PTO mode occurs if the
engine rpm is set by using the PTO On/Off switch
and the Set/Resume switch.
Table 73
Minimum
Maximum
Default
5 rpm/sec
1000 rpm/sec
50 rpm/sec
Alternative
Default
J1/P1:7
J1/P1:47
J1/P1:6
J1/P1:46
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None
SENR9698-09
53
Troubleshooting Section
Table 76
Alternative
Default
J1939
J1/P1:62
None
Alternative
Default
J1/P1:47
None
Alternative
Default
J1/P1:7
None
Diagnostic Enable
The J1939 data link and input 7 can be used
to connect the Diagnostic Enable. Diagnostic
flash codes can be prompted by using the
Diagnostic Enable. To initiate the flash codes,
depress the momentary Diagnostic Enable until
the check engine lamp begins to flash. Refer to
Troubleshooting, Diagnostic Codes for additional
information regarding flash codes.
Table 79
Alternative
Default
J1/P1:46
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None
Alternative
Default
J1/P1:56
Alternative
Default
J1/P1:58
Alternative
Default
J1/P1:60
54
Troubleshooting Section
SENR9698-09
Table 83
Alternatives
Default
J1/P1:6
J1/P1:46
J1/P1:58
J1/P1:60
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None
Alternative
Default
J1/P1:6
J1939 - Body Controller
J1939 - Cab Controller
J1939 - Instrument Cluster
None
Table 84
Alternatives
Default
J1/P1:6
J1/P1:46
J1/P1:58
J1/P1:60
None
Alternatives
Default
J1/P1:6
J1/P1:7
J1/P1:46
J1/P1:47
None
Alternative
Default
J1/P1:59
SENR9698-09
55
Troubleshooting Section
Table 91
engine lamp.
Alternative
Default
J1/P1:35 & 44
Alternative
Default
None
Alternative
Default
J1/P1:22
Alternative
Default
J1/P1:23 & 40
Cruise
Idle
PTO
Idle shutdown
Table 92
Alternative
Default
J1/P1:45
Alternative
Retarder Off/Low/Med/High
Switch
The input for the Retarder Solenoid Low/Hi Switch
and the input for the Retarder Solenoid Med/Hi
Switch are available for the connection of a selector
switch for engine retarder solenoid. The retarder
switch can be connecting using the J1939 data link
or using J1/P1:23 & 40. If J1/P1:23 & 40 is used, the
low/hi input must be connected to ECM connector
J1/P1:23 and the med/hi Input must be connected to
ECM connector J1/P1:40. This switch controls the
operation of the engine retarder solenoids.
Default
J1/P1:66
56
Troubleshooting Section
SENR9698-09
Alternative
Default
J1939 - ABS
J1939 - Trans
J1/P1:32 & 33
Table 96
Manual Distance
Minimum
Maximum
Default
8050 km
(5000 miles)
56325 km
(35000 miles)
24140 km
(15000 miles)
Table 97
Manual Hours
Minimum
Maximum
Default
100
750
300
i01945507
Maintenance Parameters
Table 98
Minimum
Maximum
Default
19 L (20 qt)
57 L (60 qt)
Refer to Table
99.
Alternative
Default
Manual Distance
Manual Hours
Automatic Distance
Automatic Hours
Off
PM 1 Interval
The PM 1 Interval allows a maintenance interval
(PM 1) to be specified by the user. This parameter
(PM 1 Interval) can be programmed only when the
Maintenance Indicator Mode is programmed to a
manual mode (distance or hours).
(1)
Engine Model
Default
34 L (36 qt)
C15
38 L (40 qt)(1)
SENR9698-09
57
Troubleshooting Section
i02183296
Output Selections
SMCS Code: 1901
Alternative
Default
J1/P1:10
J1/P1:12
J1/P1:13
None
Auxiliary Brake
The auxiliary brake output is for use with a
BrakeSaver or other aftermarket braking devices.
Output 3 is available for the connection of an auxiliary
brake relay. This parameter (Auxiliary Brake)
must be programmed to J1/P1:12. Operation of
the auxiliary brake and the relay is inhibited during
undesirable engine operating conditions. The time
period of fueling the engine is an undesirable engine
operating condition.
Table 102
Table 101
Alternative
Default
J1/P1:10
J1/P1:12
J1/P1:13
None
Default
J1/P1:12
None
Alternative
Alternatives
Default
J1/P1:10
J1/P1:12
J1/P1:13
None
Alternatives
Default
J2/P2:13
None
58
Troubleshooting Section
SENR9698-09
i02048633
Default
On/Off PWM
On/Off DC
Three-Speed Fan PWM
Three-Speed Fan DC
Variable Speed Fan
Option S
None
Rating Number
The rating number is the selected rating within a
power rating family. The personality module defines
the power rating family (242 kW (325 hp)) and the
personality module may contain only one or several
ratings. The rating number defines the power rating
that is used within the power rating family. The
following list illustrates examples of the power rating:
Table 105
Alternative
Alternative
Default
J1/P1:19
None
i02183321
Alternative
Default
Yes
No
Multi-Torque Ratio
This parameter is used to select the desired
multitorque trip point. Multitorque ratings allow
the engine to provide additional torque, additional
horsepower, and torque when the transmission is
operating in higher gear. The additional torque allows
the truck to crest a hill without downshifting and
increases fuel economy. The multitorque feature also
helps to reduce wear. The trip point is determined by
a ratio of engine speed versus vehicle speed. The
three programmable options represent the different
trip point values that are listed below.
Table 108
Programmable Option
MT-A
27.9
MT-B
33.0
MT-C
38.0
SENR9698-09
59
Troubleshooting Section
Table 109
Type of Engine
Rating
Alternatives
Standard
Ratings
Unavailable
Unavailable
Multitorque
Ratings
MT-B
MT-C
MT-A
Default
i02183325
Minimum
Maximum
Default
3 minutes
1440 minutes
0 minutes
Minimum
Maximum
Default
600 rpm
2120 rpm
2120 rpm
Table 110
Minimum
Maximum
Default
0 Volts
25.5 Volts
0 Volts
i02183329
Timer Parameters
SMCS Code: 1901
60
Troubleshooting Section
SENR9698-09
Alternative
Default
No
Outside Temperature Based
(J1587) Outside Temperature
Based
Yes
Minimum
Maximum
Default
40 C (40 F)
49 C (120 F)
49 C (120 F)
Table 115
Minimum
Maximum
Default
40 C (40 F)
49 C (120 F)
49 C (120 F)
Illustration 16
g00631057
Minimum
Maximum
Default
1 second
600 seconds
0 seconds
SENR9698-09
61
Troubleshooting Section
g00629908
Illustration 17
Table 117
Alternatives
Default
Yes
No
Table 118
Minimum
Maximum
Default
0 seconds
3 seconds
0 seconds
i02183335
Trip Parameters
SMCS Code: 1901
g00629939
Illustration 18
Table 119
Minimum
Maximum
Default
Alternative
Default
63.5
+63.5
Yes
No
Dash - PM 1 Reset
62
Troubleshooting Section
SENR9698-09
Table 121
Alternative
Default
Yes
No
Alternative
Default
Four Characters
A through Z
0 through 9
0000
Table 122
Alternative
Default
Yes
No
Alternative
Default
No
Yes
Alternative
Default
Yes
Auto-Enable
No
Table 126
Vehicle Speed
Cruise Status
Brake Switch
Alternative
Default
SENR9698-09
63
Troubleshooting Section
Minimum
Maximum
Default
204 km/h
(127 mph)
204 km/h
(127 mph)
i01762713
i02183346
Minimum
Maximum
Default
0 Minutes
1440 Minutes
0 Minutes
Minimum
Maximum
Default
2485 PPKM
(4000 PPM)
93226 PPKM
(150000 PPM)
8696 PPKM
(14000 PPM)
Minimum
Maximum
Default
43000
revolutions per
km
65000
revolutions per
mile
64
Troubleshooting Section
SENR9698-09
VSL Protection
Tachometer Calibration
Table 132
Minimum
Maximum
Default
6.550
Minimum
Maximum
Default
204 km/h
(127 mph)
204 km/h
(127 mph)
Minimum
Maximum
Default
1000 rpm
TEL rpm
TEL rpm
Minimum
Maximum
Default
12.0 PPR
500.0 PPR
113.0 PPR
Table 136
Alternative
Default
Yes
No
SENR9698-09
65
Troubleshooting Section
Minimum
Maximum
Default
1.00
19.99
1.00
Minimum
Maximum
Default
1.00
9.99
1.00
66
Troubleshooting Section
SENR9698-09
System Configuration
Parameters
i02306927
System Configuration
Parameters
SENR9698-09
67
Troubleshooting Section
Troubleshooting without a
Diagnostic Code
i02183349
Probable Causes
Note: If this problem occurs under load, refer to
Troubleshooting, Low Power/Poor or No Response
to Throttle.
The probable root causes are listed in order below:
VSL Protection
PTO Top Engine Limit with the PTO On/Off
Switch turned ON.
Diagnostic codes
Cold mode
Accelerator pedal position sensor
Vehicle speed signal
Fuel supply
Power train data link
Air intake and exhaust system
Recommended Actions
1. Check for diagnostic codes.
a. Connect the Caterpillar Electronic Technician
(ET) to the data link connector.
b. Check for active diagnostic codes and/or
logged diagnostic codes.
Certain diagnostic codes will limit the engine
speed.
c. Troubleshoot all active diagnostic codes before
continuing with this procedure.
2. Check customer specified parameters.
a. Verify that the complaint is not normal operation
(programmed parameter).
b. Access the Configuration screen on Cat ET.
c. Check the following parameters:
68
Troubleshooting Section
SENR9698-09
i02183361
Probable Causes
The probable root causes are listed in order below:
Diagnostic codes
Customer specified parameters (normal operation)
Cold mode
Electronic system problem
Fuel supply
Air intake system or exhaust system
Leakage in air-to-air aftercooler core
Recommended Actions
1. Check for diagnostic codes.
a. Connect the Caterpillar Electronic Technician
(ET) to the data link connector.
b. Turn the key switch to the ON position.
c. Check for active diagnostic codes and logged
diagnostic codes.
Certain diagnostic codes will limit the vehicle
speed to 45 mph.
d. Troubleshoot all diagnostic codes before
continuing with this procedure.
2. Check customer specified parameters.
a. Verify that the complaint is not due to normal
operation (programmed parameter).
b. Access the Configuration screen on Cat ET.
c. Check the following parameters:
SENR9698-09
69
Troubleshooting Section
70
Troubleshooting Section
SENR9698-09
i02183417
Probable Causes
The probable root causes are listed in order below:
PTO mode
A/C high pressure switch circuit
Manual fan override switch
Dyno mode
Probable Causes
Recommended Actions
Recommended Actions
Check the Circuit for the Check Engine
Lamp
Refer to Troubleshooting, Check Engine Lamp
Circuit - Test.
SENR9698-09
71
Troubleshooting Section
72
Troubleshooting Section
SENR9698-09
J1/P1:6
J1/P1:47
d. Access the status screen for the Fan Override
Switch.
If the status is ON, either the manual fan
override switch is ON or there is a short in the
circuit for the Fan Override Switch. Refer to
Troubleshooting, Cooling Fan Circuit and A/C
High Pressure Switch Circuit - Test.
5. Dyno Mode will cause the cooling fan to run
continuously. During a dyno run, the ECM should
be in Dyno Mode.
Dyno Mode will only be active for 30 minutes. After
30 minutes, the ECM will exit Dyno Mode. Dyno
Mode can only be enabled with the electronic
service tool.
i02183433
Probable Causes
The probable root causes are listed below:
Recommended Actions
1. When the cruise control or the idle control is
set with the cruise control on/off switch, use the
Caterpillar Electronic Technician (ET) in order
to check the Configuration. Check the following
parameters:
J1/P1:46
Set/resume switch
J1/P1:7
Cruise Kickout
If the cruise control pause switch was the cause
of the last kickout, the cruise control pause switch
may be preventing normal operation of the cruise
control.
a. Check the position of the cruise control pause
switch. If the switch is in the ON position, the
switch will prevent normal operation of the
cruise control. Change the switch to the OFF
position. Verify that the repair eliminates the
problem.
b. If the cruise control pause switch is in the OFF
position and the switch is still causing the
cruise kickout, the switch is bad or the wiring
is shorted.
SENR9698-09
PTO Configuration
PTO Vehicle Speed Limit
PTO Top Engine Limit
PTO Cab Controls RPM Limit
Refer to Troubleshooting, PTO Switch Circuit Test for additional information.
4. Connect Cat ET to the data link connector. Check
the status screen for the following controls:
73
Troubleshooting Section
74
Troubleshooting Section
SENR9698-09
i02127473
Driver Questionnaire
SMCS Code: 0336
Table 139
Ask the driver to answer the following questions before attempting to repair an intermittent problem, or a problem with
symptoms but no diagnostic codes. Use this and the response guideline to these questions on the next page.
Questions
1. Ask the driver if the check engine lamp turned on during the problem or
if the check engine lamp turned on after the problem.
The check engine lamp stays on for the following time period:
2. Ask the driver for the number of occurrences for this problem.
Ask the driver to duplicate the problem if the problem can be duplicated in
less than one hour.
3. Ask the driver if other shops have worked on the same problem.
If the answer is yes, ask the names of the shops. Also ask for the time
period for the work that was performed.
4. Ask the driver if the engine completely shut down. Ask the driver if the
restart required the use of the key switch.
Ask the driver for the waiting period before the driver could restart the
engine after the shutdown.
5. Ask the driver if the engine had a hesitation, a speed burp or a misfire
without a complete shutdown.
6. Ask the driver if the radio, dash gauges or lights momentarily turn off
during an occurrence of the problem.
Ask the driver if there are any other observations about the trucks
components.
7. Ask the driver if the problem occurs only at specific engine loads.
Ask the driver for additional details.
8. Ask the driver if the problem occurs at a specific engine operating
temperature.
If the problem occurs at a specific engine operating temperature, record
the engine temperature.
9. Ask the driver if the problem occurs only at specific outside
temperatures or temperature ranges.
If the problem occurs only at specific outside temperatures or temperature
ranges, record the outside temperature or temperature range.
10. Ask the driver if the problem occurs during any other specific
conditions.
11. Ask the driver if the problem occurs at a specific vehicle speed.
If the problem occurs at a specific vehicle speed, record the vehicle
speed.
12. Ask the driver if the vehicle kicked out of cruise control mode, idle
mode or PTO mode.
13. Ask the driver if the problem occurs during the use of the accelerator.
During this time, the engine is not in cruise control mode or PTO mode.
14. Ask the driver if the problem occurs at a specific engine rpm.
If the problem occurs at a specific engine rpm record the engine rpm.
Yes
Comments
SENR9698-09
75
Troubleshooting Section
i02127475
Driver Questionnaire
Response
SMCS Code: 0336
Table 140
1. If the check engine lamp turned on there will be a logged diagnostic code. Refer to Troubleshooting, Troubleshooting with
a Diagnostic Code in order to determine if the drivers indicated symptoms agree with the symptoms that are associated
with the diagnostic code. If the drivers symptoms do not match the symptoms of the diagnostic code, troubleshooting the
diagnostic code will not correct the problem. Review the snapshots that are associated with each diagnostic code in order to
determine the operating conditions of the engine during the occurrence of the problem. Try to duplicate these conditions. If
there are not any logged diagnostic codes check the battery connections for the Engine Control Module (ECM). Refer to
Troubleshooting, Ignition Key Switch Circuit and Battery Supply Circuit - Test.
2. If the problem is easily repeatable, take the vehicle for a test drive while Caterpillar Electronic Technician (ET) is
connected to the data link connector. Note the conditions when the problem occurs. The operator should be prepared to
take snapshot data by using Cat ET or the cruise control set/resume switches. Ensure that you operate the vehicle after
correcting the problem. During vehicle operation, duplicate the operating conditions before releasing the vehicle in order to
verify that the problem has been corrected.
3. If the vehicle has been to other shops for the same problem, call the other shops in order to determine the type of work that
has been done. Avoid replacing the same components again, unless you are absolutely sure that the components are the
problem. If a component has recently been changed, it is unlikely that the component will fail again.
4. Troubleshoot the reason that the engine will not start. Repair the reason that the engine does not start. When you repair
the reason that the engine did not start you should repair the reason that the engine shut down. If the engine shut down
completely, check the ECM battery connections, the ground connections, the fuel system, the fuel, the primary engine
speed/timing sensor and the secondary engine speed/timing sensor. If the engine will not restart, refer to Troubleshooting,
Engine Cranks but Will Not Start.
5. If the problem is easily repeatable, refer to Troubleshooting, Engine Misfires, Runs Rough or Is Unstable.
If the problem is not easily repeatable, refer to Troubleshooting, Intermittent Low Power or Power Cutout.
6. If other devices on the vehicle are affected, something is wrong with the vehicle wiring. Refer to Troubleshooting, Ignition
Key Switch Circuit and Battery Supply Circuit Test for information on inspecting the ECM battery connections.
7. Operate the engine under similar load conditions. Check the low pressure fuel lines for restrictions. Also check the
fuel/water separator and the fuel tanks for foreign objects that are blocking the fuel supply.
8. Operate the engine at this temperature. Attempt to duplicate the problem.
9. When possible, troubleshoot the problem in this temperature range.
10. If the problem seems to occur during the rain or a washing, thoroughly inspect the connectors for moisture. Refer to
Troubleshooting, Electrical Connectors - Inspect.
11. If the problem occurs at a specific vehicle speed, check the parameters that affect vehicle speed in order to verify that the
parameters are programmed close to the vehicle speed of the occurrence of the problem. Check the following parameters:
Vehicle Speed Limit
VSL Protection
Low Cruise Control Speed Set Limit
High Cruise Control Speed Set Limit
Idle Vehicle Speed Limit
PTO Vehicle Speed Limit
Engine/Gear Speed Limit
Set each parameter to the maximum value one at a time and verify that the problem is corrected.
12. If the vehicle kicks out of cruise control mode, idle mode or PTO mode and it can be duplicated, check the status screen
on the electronic service tool. Check the status of the Cruise Kickout, the Idle Kickout or the *PTO Kickout*. If the problem
can not be duplicated, inspect the vehicle speed circuit, the service brake circuit and the clutch switch circuit and switch
adjustment, the circuit for the neutral switch and the circuits for the cruise/idle/pto switches, as required.
13. Check for logged diagnostic codes that are associated with the accelerator pedal position sensor. Refer to
Troubleshooting, Accelerator Pedal (Throttle) Position Sensor Circuit - Test.
14. If the problem occurs at a specific engine rpm, check the VSL Protection, the Idle rpm Limit, the Top Engine Limit, the
PTO Top Engine Limit and the Progressive Shift Parameters. These parameters are programmable. Set each parameter
to the maximum value one at a time and verify that the problem is corrected.
76
Troubleshooting Section
SENR9698-09
i02319575
i02504511
Probable Causes
Probable Causes
Incorrect passwords
Recommended Actions
(ECM)
connector
hardware
Recommended Actions
Attempt to start the engine. If the engine starts, but
the ECM will not communicate with the Cat ET,
continue with this procedure. If the engine will not
start, refer to Troubleshooting, Engine Cranks but
Will Not Start. If the engine will not crank, refer to
Troubleshooting, Engine Will Not Crank.
Incorrect Passwords
SENR9698-09
77
Troubleshooting Section
Proper torque
connector.
Probable Causes
Theft deterrent
Diagnostic codes
Keyswitch
Communications between the Engine Control
Module (ECM) and the Caterpillar Electronic
Technician (ET)
Override Switches
Power to ECM
Fuel supply
78
Troubleshooting Section
Combustion problem
Recommended Actions
1. If the display screen on Messenger indicates
that the theft deterrent is enabled, the theft
deterrent passwords must be entered before the
engine will start. Ensure that the theft deterrent
(if equipped) is not active. Turn the keyswitch to
the ON position. Observe the display screen on
Messenger.
2. Check for active diagnostic codes.
a. Connect Cat ET to the data link connector.
b. Check for active diagnostic codes. Certain
diagnostic codes will prevent the engine from
starting.
c. Troubleshoot any diagnostic codes that are
present before continuing with this procedure.
3. Check the air inlet shutoff system.
a. If the engine was shut down due to the air inlet
shutoff system, the air inlet shutoff needs to
be manually reset.
4. Check that the latest version of the ECM flash file
has been installed.
SENR9698-09
SENR9698-09
79
Troubleshooting Section
Fuel supply
Probable Causes
The probable root causes are listed in order below:
Note: If the problem is intermittent and the problem
can not be duplicated, refer to Troubleshooting,
Intermittent Low Power or Power Cutout.
Recommended Actions
Perform the following diagnostic procedures in order:
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high rpm, full load
and engine operating temperature. Troubleshooting
the symptoms under other conditions can give
misleading results.
1. Check for an individual malfunctioning cylinder.
a. Ensure that the valve cover connectors are
fully connected and ensure that the connectors
are free of corrosion.
b. Ensure that the J2/P2 connectors for the
Engine Control Module (ECM) are fully
connected and free of corrosion.
c. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector. Access
the Cylinder Cutout Test by selecting the
Diagnostics Tests under the Diagnostic
menu. Run the Cylinder Cutout Test in
order to disable each cylinder. Disabling each
cylinder allows the technician to isolate the
misfiring cylinders.
If the misfiring cylinder can be isolated to a
specific cylinder, refer to Troubleshooting,
Injector Solenoid Circuit - Test.
2. Check the fuel supply.
a. Monitor the exhaust for smoke while the engine
is being cranked.
If white smoke is present, there may be a
problem with the fuel quality.
b. Check the fuel quality. Refer to Systems
Operation/Testing and Adjusting, Fuel Quality
- Test. Also refer to the Truck Application and
Installation Guide, LEBT5109.
c. Check the fuel pressure. Refer to Systems
Operation/Testing and Adjusting, Fuel System
Pressure - Test.
d. Ensure that the fuel system has been primed.
Refer to Systems Operation/Testing and
Adjusting, Fuel System - Prime.
80
Troubleshooting Section
SENR9698-09
Probable Causes
Programmable parameters
Engine retarder switches
Accelerator pedal position sensor
Clutch switch
PTO on/off switch
Recommended Actions
Check the Programmable Parameters
Use the Caterpillar Electronic Technician (ET) to
check the following parameters while the engine is
not running:
Engine Retarder Mode If the engine retarder
mode is programmed to Latch or to Coast, the
engine retarder will not activate unless the service
brake pedal is depressed. If the engine retarder
mode is programmed to Manual, service brakes are
not required to activate the engine retarder.
SENR9698-09
81
Troubleshooting Section
Off
Engine Vibration
SMCS Code: 1000-035
Low
Probable Causes
Medium
Fan blades
High
Mounting hardware
Recommended Actions
Check the Fan Blades
Verify that the engine is off. Inspect the fan blades.
Look for bent blades or broken blades. Replace
parts, if necessary.
82
Troubleshooting Section
SENR9698-09
Transmission
PTO
Engine accessory
Hydraulic cylinder lock
Recommended Actions
Check the Batteries
Probable Causes
Batteries
SENR9698-09
83
Troubleshooting Section
Air compressor
Power steering pump
Seizure
Broken components
Bent components
i02504514
Probable Causes
The probable root causes are listed in order below:
Personality module
Recommended Actions
Limit.
Limit.
84
Troubleshooting Section
SENR9698-09
Probable Causes
Vehicle operation
Environmental conditions
Engine load and vehicle aerodynamics
Fuel quality
Air inlet system or exhaust system
Recommended Actions
Check Vehicle Operation
Use the Caterpillar Electronic Technician to check the
histograms. Look for high values for these items:
Engine speed
Vehicle speed
High engine speeds and high vehicle speeds can
cause excessive fuel consumption.
SENR9698-09
85
Troubleshooting Section
Probable Causes
The probable root causes are listed in order below:
Normal operation
Fuel supply
Atmospheric pressure circuit
Combustion problem
Recommended Actions
86
Troubleshooting Section
SENR9698-09
Probable Causes
The probable root causes are listed below:
Recommended Actions
Perform the following diagnostic procedures in order:
SENR9698-09
87
Troubleshooting Section
Probable Causes
The probable root causes are listed in order below:
Module (ECM)
Recommended Actions
Perform the following diagnostic procedures in order:
1. Certain diagnostic codes may cause poor
performance. These diagnostic codes are
intended to protect the engine.
a. Connect the Caterpillar Electronic Technician
(ET) to the data link connector.
88
Troubleshooting Section
SENR9698-09
Limit.
SENR9698-09
89
Troubleshooting Section
i02183773
Low Power/Poor or No
Response to Throttle
SMCS Code: 1000-035
Probable Causes
The probable root causes are listed in order below:
Diagnostic codes
Intake valve actuation system
Cold mode
Customer specified parameters (normal operation)
Electronic system problem
Fuel supply
Fuel recirculation system (if equipped)
Recommended Actions
Diagnostic Codes
1. Connect the Caterpillar Electronic Technician (ET)
to the data link connector.
2. Check for active codes and/or logged codes.
Troubleshoot any codes that are present before
continuing with this procedure.
Note: Certain diagnostic codes may cause poor
performance. Also, certain diagnostic codes will limit
the engine speed to low idle.
90
Troubleshooting Section
Cold Mode
1. Start the engine.
2. Monitor the status screens on Cat ET.
3. Check for a Cold Mode flag at the top of any
status screen.
Note: The engine will not receive full power until the
Cold Mode flag becomes inactive.
Rating Number
Top Engine Limit
Vehicle Speed Limit
Lower Gears Engine RPM Limit
Intermediate Gears Engine RPM Limit
Gear Down Protction Engine RPM Limit
Note: If the Rating Number is programmed to 0, the
engine is limited to 119 kW (160 hp).
4. Set each parameter to the parameters maximum
value one at a time and determine whether the
problem is corrected.
SENR9698-09
SENR9698-09
Fuel Supply
1. Monitor the exhaust for smoke while the engine
is being cranked.
If no smoke is present, there may be a problem
with the fuel quality or there may be a problem
with the fuel supply.
2. Check the fuel quality. Refer to Testing and
Adjusting, Fuel Quality - Test. Also refer to
the Truck Application and Installation Guide,
LEBT5109.
3. Check the fuel pressure. Refer to Testing and
Adjusting, Fuel System Pressure - Test.
4. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, Fuel System Prime.
5. Check for fuel supply lines that are restricted.
6. Check the fuel filters.
7. If the temperature is below 0 C (32 F), check
for solidified fuel (wax).
8. Check for air in the fuel system. Refer to Testing
and Adjusting, Air in Fuel - Test.
91
Troubleshooting Section
Probable Causes
The probable root causes are listed in order below:
Diagnostic codes
Intake valve actuation system
Cold mode
92
Troubleshooting Section
SENR9698-09
Recommended Actions
Diagnostic Codes
1. Connect the Caterpillar Electronic Technician (ET)
to the data link connector.
2. Check for active codes and/or for logged codes.
Troubleshoot any codes that are present before
continuing with this procedure.
Note: Certain diagnostic codes may cause poor
performance.
Cold Mode
1. Start the engine.
2. Monitor the status screens on Cat ET.
3. Check for a Cold Mode flag at the top of any
status screen.
Note: The engine will not receive full power until the
Cold Mode flag becomes inactive.
SENR9698-09
93
Troubleshooting Section
Troubleshooting with a
Diagnostic Code
i01929511
Diagnostic Codes
SMCS Code: 1900
Table 141
Flash
Code
00
01
12
13
14
17
21
24
25
Diagnostic Code
SPN-FMI Code
52-11
52-11
84-14
84-14
166-14
166-14
171-03
171-03
171-04
171-04
171-11
171-11
246-11
597-11
247-11
603-11
385-01
2948-01
71-00
Description of Code
111-02
111-02
111-03
111-03
111-04
111-04
174-03
174-03
174-04
174-04
224-11
224-14
121-05
1072-05
121-06
1072-06
122-05
1073-05
122-06
1073-06
168-01
168-01
41-03
678-03
41-04
678-04
232-03
620-03
232-04
620-04
100-03
100-03
100-04
100-04
102-03
102-03
102-04
102-04
94
Troubleshooting Section
SENR9698-09
Flash
Code
Diagnostic Code
SPN-FMI Code
108-03
108-03
108-04
108-04
110-03
110-03
110-04
110-04
91-13
91-13
30-08
644-08
30-13
644-13
31
84-01
84-01
32
91-08
91-08
64-08
723-08
190-08
190-08
190-00
190-00
84-02
84-02
84-08
84-08
84-10
84-10
105-03
105-03
105-04
105-04
84-00
84-00
22-11
637-11
22-13
637-13
100-01
100-01
100-11
100-11
26
27
28
29
34
35
36
38
41
42
46
47
Description of Code
71-01
Idle Shutdown
71-14
PTO Shutdown
51
168-02
168-02
55
N/A
N/A
253-02
630-02
253-11
630-11
231-02
639-02
231-12
639-12
252-11
631-11
110-00
110-00
110-11
110-11
111-01
111-01
111-11
111-11
111-14
111-14
56
58
59
61
62
(continued)
SENR9698-09
95
Troubleshooting Section
Flash
Code
64
65
66
67
Diagnostic Code
SPN-FMI Code
Description of Code
105-00
105-00
105-11
105-11
174-00
174-00
54-05
706-05
54-06
706-06
55-05
707-05
55-06
707-06
68
191-07
71
43-02
72
73
74
91
92
93
1-05
651-05
1-06
651-06
2-05
652-05
2-06
652-06
3-05
653-05
3-06
653-06
4-05
0654-05
4-06
654-06
5-05
655-05
5-06
655-06
6-05
656-05
6-06
656-06
283-07
2949-07
285-05
2950-05
285-06
2950-06
285-07
2950-07
286-05
2951-05
286-06
2951-06
286-07
2951-07
287-05
2952-05
287-06
2952-06
287-07
2952-07
288-05
2953-05
288-06
2953-06
288-07
2953-07
96
Troubleshooting Section
SENR9698-09
Flash
Code
Diagnostic Code
SPN-FMI Code
289-05
2954-05
289-06
2954-06
289-07
2954-07
290-05
2955-05
290-06
2955-06
290-07
2955-07
385-03
2948-03
385-04
2948-04
283-05
2949-05
283-06
2949-06
284-05
2988-05
284-06
2988-06
94
95
97
98
Description of Code
i02127620
i02183816
System Response:
This code will not appear on Caterpillar Electronic
Technician (ET). The check engine lamp is used
to display the flash code. For more information on
flash codes, refer to Troubleshooting, Check Engine
Lamp Circuit - Test.
Possible Performance Effect:
None
Troubleshooting:
There are no problems that require troubleshooting.
Results:
OK STOP.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Possible Performance Effect:
Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.
SENR9698-09
97
Troubleshooting Section
Troubleshooting:
i02183822
Results:
OK STOP.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Possible Performance Effect:
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Possible Performance Effect:
Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.
Troubleshooting:
Engine misfires
Low power
Results:
OK STOP.
Troubleshooting:
i02183830
Results:
OK STOP.
98
Troubleshooting Section
SENR9698-09
System Response:
Troubleshooting:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
OK STOP.
i02183838
Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.
Troubleshooting:
Perform the following diagnostic procedure: Injector
Solenoid Circuit - Test
Results:
two seconds.
OK STOP.
System Response:
i02183835
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
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
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
two seconds.
Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.
Results:
OK STOP.
SENR9698-09
99
Troubleshooting Section
i02183847
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Engine misfires
Low power
System Response:
two seconds.
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Troubleshooting:
OK STOP.
Engine misfires
i02183884
Low power
The injector will not operate while this diagnostic
code is active.
Troubleshooting:
OK STOP.
two seconds.
i02183861
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.
100
Troubleshooting Section
SENR9698-09
Troubleshooting:
i02183910
Results:
OK STOP.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Possible Performance Effect:
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show an
OPEN during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Possible Performance Effect:
Engine misfires
Low power
The injector will not operate while this diagnostic
code is active.
Troubleshooting:
Engine misfires
Low power
Results:
OK STOP.
Troubleshooting:
i02183935
Results:
OK STOP.
SENR9698-09
101
Troubleshooting Section
System Response:
Troubleshooting:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will show a
SHORT during the Injector Solenoid Test. The
automatic Cylinder Cutout Test will not work.
Engine misfires
Low power
Expected Result:
Troubleshooting:
Results:
Results:
OK STOP.
System Response:
This code will not be logged. The check engine lamp
will illuminate while this diagnostic code is active.
The ECM will use the default timing.
Possible Performance Effect:
The engine may run rough when this code is active.
102
Troubleshooting Section
SENR9698-09
Expected Result:
Results:
STOP.
i02127666
STOP.
System Response:
This code will not be logged. The check engine lamp
will illuminate while this diagnostic code is active. The
ECM uses default timing.
Possible Performance Effect:
The engine may run rough or the engine may emit
white smoke in the exhaust.
Troubleshooting:
Perform the following diagnostic procedure: Engine
Speed/Timing Sensor - Calibrate
Expected Result:
Results:
OK STOP.
Results:
OK
SENR9698-09
103
Troubleshooting Section
i02127764
System Response:
seconds.
System Response:
The ECM returns the engine to low idle when the
problem is detected. DIAG will be displayed next
to the status for Throttle Position on Caterpillar
Electronic Technician (ET).
Results:
OK STOP.
i01942209
Results:
OK STOP.
i02127769
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. An
active diagnostic code may not cause any noticeable
effect on engine response unless the voltage is
above 12 or 13 VDC.
104
Troubleshooting Section
SENR9698-09
i02490821
OK STOP.
i02127795
System Response:
Engine shutdown
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. An
active diagnostic code may not cause any noticeable
effect on engine response unless the voltage drops
below 6.5 VDC.
Troubleshooting:
OK STOP.
OK STOP.
i01942207
SENR9698-09
105
Troubleshooting Section
System Response:
The solenoid that is currently enabled will remain in
the ON position until neutral is detected. Then manual
operation occurs until the system powers down.
Manual operation is defined as both solenoids OFF.
Possible Performance Effect:
Troubleshooting:
System Response:
The ECM will disable the unit injectors and the ECM
will activate the air inlet shutoff relay.
Possible Performance Effect:
Results:
OK STOP.
i02184006
Troubleshooting:
System Response:
The solenoid that is currently enabled will remain in
the ON position until neutral is detected. Then manual
operation occurs until the system powers down.
Manual operation is defined as both solenoids OFF.
Possible Performance Effect:
Troubleshooting:
Results:
OK STOP.
106
Troubleshooting Section
SENR9698-09
i02184021
System Response:
Troubleshooting:
Perform the following diagnostic procedure: Eaton
Top 2 Transmission Circuit - Test
Results:
OK STOP.
System Response:
The solenoid that is currently enabled will remain in
the ON position until neutral is detected. Then manual
operation occurs until the system powers down.
Manual operation is defined as both solenoids OFF.
Possible Performance Effect:
i01942351
Troubleshooting:
Perform the following diagnostic procedure: Eaton
Top 2 Transmission Circuit - Test
Results:
OK STOP.
i02184022
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will ignore the
secondary engine speed/timing sensor.
None
Note: If the signals from both engine speed/timing
sensors are lost, then the engine will shut down.
SENR9698-09
107
Troubleshooting Section
Troubleshooting:
Results:
OK STOP.
i02215914
Results:
OK STOP.
seconds.
System Response:
The idle shutdown timer stops counting. OVERRIDE
will be displayed next to the status for Idle Shutdown
Status on Caterpillar Electronic Technician (ET).
Note: The idle shutdown timer will not begin counting
again for shutdown until the vehicle is moved and the
accelerator pedal is depressed.
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:
None
Troubleshooting:
Perform the following diagnostic procedure: Idle
Shutdown Timer - Test
OK STOP.
i02127845
The timer for the PTO has expired and the engine
has shut down.
108
Troubleshooting Section
SENR9698-09
Troubleshooting:
System Response:
The ECM remains powered after the engine
shutdown. NOT ACTIVE will be displayed next
to the status for PTO Shutdown on Caterpillar
Electronic Technician (ET).
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:
Results:
OK STOP.
i02184035
Troubleshooting:
Perform the following diagnostic procedure: PTO
Shutdown Timer - Test
Results:
OK STOP.
i02138185
System Response:
The ECM will not energize the injector solenoids
while the diagnostic code is active. Vehicle Speed
Limit will be displayed on the status screen.
Customer passwords are required to clear this code.
Possible Performance Effect:
Injection is disabled until the vehicle speed falls
below the programmed Vehicle Overspeed.
over the J1939 data link for more than 0.5 seconds.
System Response:
The ECM will limit engine rpm to the programmed
VSL Protection. If the ECM is providing the
speedometer signal, the speedometer will show 0
rpm. DIAG will be displayed next to the status
for Vehicle Speed on the Caterpillar Electronic
Technician (ET).
SENR9698-09
109
Troubleshooting Section
Troubleshooting:
Troubleshooting:
Check the fuel pressure in order to ensure that a fuel
system restriction is not the cause of the problem
when the vehicle is not moving.
Perform the following diagnostic procedure: Vehicle
Speed and Speedometer Circuit - Test
Results:
Results:
OK STOP.
i02184042
OK STOP.
i02184041
System Response:
Vehicle speed is set to 0 km/h (0 mph). If the ECM is
providing the speedometer signal, the speedometer
will not display vehicle speed. DIAG will be
displayed next to the status for Vehicle Speed on
the Caterpillar Electronic Technician (ET).
Possible Performance Effect:
The ECM will limit the engine speed to the
programmed VSL Protection.
Troubleshooting:
System Response:
Results:
OK STOP.
110
Troubleshooting Section
SENR9698-09
i01863539
System Response:
The ECM records the engine speed, vehicle speed,
the throttle position, cruise control status, clutch
switch status and brake switch status.
None
Troubleshooting:
System Response:
Expected Result:
Results:
OK STOP.
Troubleshooting:
i02303725
OK STOP.
SENR9698-09
111
Troubleshooting Section
System Response:
i01921852
Troubleshooting:
Results:
OK STOP.
i02184044
Illustration 19
g00997504
seconds.
System Response:
The ECM sets Throttle Position to 0%. DIAG will
be displayed next to the status for Throttle Position
on the Caterpillar Electronic Technician (ET).
Possible Performance Effect:
The engine will remain at low idle while the diagnostic
code is active.
Troubleshooting:
Perform the following diagnostic procedure:
Accelerator Pedal (Throttle) Position Sensor Circuit Test
Results:
OK STOP.
Illustration 20
C15 low oil pressure
g00997505
112
Troubleshooting Section
System Response:
The Caterpillar Electronic Technician (Cat ET) will
display LOW OIL PRESSURE and DIAG next
to the status for Engine Oil Pressure. The check
engine lamp and the warning lamp will illuminate.
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:
None
Troubleshooting:
SENR9698-09
SENR9698-09
113
Troubleshooting Section
Expected Result:
Expected Result:
Results:
STOP.
STOP.
Expected Result:
Results:
STOP.
114
Troubleshooting Section
SENR9698-09
Results:
Results:
STOP.
SENR9698-09
115
Troubleshooting Section
seconds.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will default to
600 kPa (88 psi) for engine oil pressure.
Note: The engine oil pressure that is displayed on the
Caterpillar Electronic Technician (ET) is the default
value for engine oil pressure.
None
Troubleshooting:
None
Troubleshooting:
Results:
OK STOP.
Results:
i02195676
OK STOP.
i01921853
116
Troubleshooting Section
SENR9698-09
g00998095
Results:
System Response:
Expected Result:
Illustration 22
g00998096
Results:
to Test Step 3.
SENR9698-09
117
Troubleshooting Section
STOP.
Expected Result:
There are no diagnostic codes that are related to the
barometric pressure sensor (atmospheric pressure)
or the boost pressure sensor.
Results:
Expected Result:
The voltage is 5.0 0.16 VDC.
Results:
STOP.
Results:
STOP.
118
Troubleshooting Section
SENR9698-09
STOP.
Results:
Results:
to Test Step 7.
STOP.
STOP.
Expected Result:
The engine oil pressure is above the trip points in
Illustration 21 or Illustration 22.
Results:
SENR9698-09
119
Troubleshooting Section
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM will default to 100 kPa (14.5 psi) for boost
pressure.
Note: The boost pressure that is displayed on the
Caterpillar Electronic Technician (ET) is the default
value for boost pressure minus the atmospheric
pressure.
Results:
Results:
STOP.
OK STOP.
i02128311
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM will default to 100 kPa (14.5 psi) for boost
pressure.
Note: The boost pressure that is displayed on the
Caterpillar Electronic Technician (ET) is the default
value for boost pressure minus the atmospheric
pressure.
Possible Performance Effect:
The engine will experience low power when this
diagnostic code is active.
120
Troubleshooting Section
SENR9698-09
Troubleshooting:
Perform the following diagnostic procedure: Engine
Pressure Sensor Open or Short Circuit - Test
Results:
OK STOP.
Results:
i02504578
STOP.
System Response:
Results:
(210 F).
Troubleshooting:
STOP.
SENR9698-09
121
Troubleshooting Section
i02195490
i02195519
seconds.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will default to
40 C (104 F) for the intake manifold air temperature.
The ECM will turn on the cooling fan if the boost
pressure is above 70 kPa (10 psi).
This diagnostic code will be suppressed if the
following conditions exist:
None
Results:
Troubleshooting:
OK STOP.
OK STOP.
122
Troubleshooting Section
SENR9698-09
i02184086
Results:
seconds.
(210.0 F).
System Response:
DIAG will be displayed next to the status for
Intake Manifold Air Temperature on the Caterpillar
Electronic Technician (ET). The warning lamp will
turn on if the Engine Monitoring Lamps parameter
is programmed to Warning Lamp. The check engine
lamp will turn on if the Engine Monitoring Lamps
parameter is programmed to Option 1.
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:
None
Troubleshooting:
i01942355
Expected Result:
The engine coolant level is OK.
Results:
SENR9698-09
123
Troubleshooting Section
System Response:
Results:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM will default to 100 kPa (15 psi) for atmospheric
pressure.
OK STOP.
i02184094
Troubleshooting:
Results:
OK STOP.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM will default to 100 kPa (15 psi) for atmospheric
pressure.
seconds.
System Response:
DIAG will be displayed next to the status for Engine
Coolant Temperature on the Caterpillar Electronic
Technician (ET). The check engine lamp and the
warning lamp will illuminate.
Note: If a high coolant temperature lamp is installed,
the high coolant temperature lamp will turn on instead
of the warning lamp.
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:
The engine will be derated. The engine power and
the vehicle speed will be limited. The amount of
derate depends on the engine coolant temperature.
Note: If the Engine Monitoring parameter is
programmed to Warning, the engine power is not
affected.
Troubleshooting:
Results:
Troubleshooting:
OK STOP.
124
Troubleshooting Section
SENR9698-09
i01942347
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will default to
90 C (194 F) for engine coolant temperature. The
ECM will activate the cooling fan after this code has
been active for more than eight seconds.
Troubleshooting:
None
Perform the following diagnostic procedure: Engine
Temperature Sensor Open or Short Circuit - Test
Results:
OK STOP.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours. The ECM will default to
90 C (194 F) for engine coolant temperature. The
ECM will activate the cooling fan after this code has
been active for more than eight seconds.
None
Troubleshooting:
i02184109
Results:
System Response:
OK STOP.
i01942349
SENR9698-09
125
Troubleshooting Section
None
Troubleshooting:
OK STOP.
i02184299
System Response:
The ECM will display Low and DIAG next to the
status for Engine Coolant Level on the Caterpillar
Electronic Technician (ET). The check engine lamp
and the warning lamp will turn on while this code is
active.
Note: If a lamp for low coolant level is installed, the
lamp for low coolant level will turn on instead of the
warning lamp.
Factory passwords are required to clear this
diagnostic code.
Expected Result:
There are no leaks. There is no coolant in the engine
oil.
Results:
126
Troubleshooting Section
SENR9698-09
i02184407
STOP.
System Response:
System Response:
The ECM will default to OK for engine coolant
level. DIAG will be displayed next to the status for
Engine Coolant Level on the Caterpillar Electronic
Technician (ET).
Possible Performance Effect:
None
None
Troubleshooting:
Perform the following diagnostic procedure: Coolant
Level Sensor Circuit - Test
Results:
OK STOP.
Troubleshooting:
i02184416
Results:
OK STOP.
SENR9698-09
127
Troubleshooting Section
System Response:
seconds.
Troubleshooting:
None
Troubleshooting:
Expected Result:
The engine coolant level is normal.
OK STOP.
Results:
i02184422
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp
will illuminate while this diagnostic code is active.
The ECM will display Low next to the status for
Engine Coolant Level on the Caterpillar Electronic
Technician (ET).
Note: If a lamp for low coolant level is installed, the
lamp for low coolant level will illuminate instead of the
warning lamp.
Factory passwords are required to clear this
diagnostic code.
128
Troubleshooting Section
SENR9698-09
Troubleshooting:
Expected Result:
STOP.
Results:
i02129292
level is low.
SENR9698-09
129
Troubleshooting Section
position.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active.
Possible Performance Effect:
The engine retarder may not activate.
Troubleshooting:
System Response:
OK STOP.
i01945534
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active.
Troubleshooting:
Perform the following diagnostic procedure: Retarder
(Compression Brake) Solenoid Circuit - Test
Results:
OK STOP.
System Response:
i01945533
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active.
Possible Performance Effect:
Troubleshooting:
Results:
OK STOP.
130
Troubleshooting Section
SENR9698-09
i01945535
System Response:
The ECM will limit power.
System Response:
OK STOP.
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active.
Possible Performance Effect:
The engine retarder may not activate.
i02490820
Troubleshooting:
OK STOP.
i02504592
Troubleshooting:
This diagnostic code could indicate a faulty charging
system or poor battery connections.
Perform the following diagnostic procedure: Ignition
Keyswitch Circuit and Battery Supply Circuit - Test
SENR9698-09
131
Troubleshooting Section
Results:
i02184436
OK STOP.
i02184426
System Response:
The ECM will default to 65 C (149 F) for outside
air temperature. DIAG will be displayed next to
the status for Outside Temperature Sensor on the
Caterpillar Electronic Technician (ET).
System Response:
seconds.
Troubleshooting:
Results:
OK STOP.
Troubleshooting:
i02184441
Results:
OK STOP.
132
Troubleshooting Section
SENR9698-09
System Response:
i01956975
None
Troubleshooting:
Results:
OK STOP.
(15 F).
i02184446
System Response:
None
System Response:
DIAG is displayed next to the status for Fuel
Temperature on the Caterpillar Electronic Technician
(ET).
Customer passwords are required to clear this
diagnostic code.
Possible Performance Effect:
None
Troubleshooting:
Perform the following diagnostic procedure: Engine
Temperature Sensor Open or Short Circuit - Test
Results:
OK STOP.
i01956976
Troubleshooting:
No troubleshooting is required.
Results:
OK STOP.
SENR9698-09
133
Troubleshooting Section
System Response:
i02184454
None
Troubleshooting:
sensor has been lost and the engine speed did not
pass through the range of 350 rpm to 500 rpm.
Results:
OK STOP.
i02294513
System Response:
The ECM will use the default timing. The ECM will
use the secondary engine speed/timing sensor.
Possible Performance Effect:
None
Note: If the signals from both engine speed/timing
sensors are lost, then the engine will shut down.
Troubleshooting:
Perform the following diagnostic procedure: Engine
Speed/Timing Sensor Circuit - Test
Results:
OK STOP.
OK STOP.
i02504603
134
Troubleshooting Section
SENR9698-09
System Response:
Results:
OK STOP.
i02490295
Troubleshooting:
OK STOP.
i02490292
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM sets all of the pressure sensors to the default
values below:
System Response:
Low power
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM sets all of the pressure sensors to the default
values below:
Troubleshooting:
OK STOP.
SENR9698-09
135
Troubleshooting Section
i02129525
OK STOP.
System Response:
The diagnostic code is active only. The diagnostic
code will be active when the theft deterrent feature
is enabled.
Caterpillar Electronic Technician (ET) will not display
a status. The check engine lamp will be illuminated.
Possible Performance Effect:
i02184459
Troubleshooting:
programmed to J1939.
No Troubleshooting is required.
Results:
or
OK STOP.
136
Troubleshooting Section
SENR9698-09
System Response:
i02184467
Results:
seconds.
OK STOP.
i02129842
Troubleshooting:
System Response:
The ECM will disable features that require an input
from the J1939 device.
Results:
OK STOP.
i02184475
OK STOP.
SENR9698-09
137
Troubleshooting Section
Results:
OK STOP.
seconds.
i02504614
OK STOP.
Rating number
Engine serial number
Injector trim files
Note: If the Rating Number has not been
programmed, the ECM will limit the engine power
to 119 kW (160 hp).
Possible Performance Effect:
System Response:
Troubleshooting:
Results:
OK STOP.
Troubleshooting:
The flash file in the ECM is from the wrong engine
family.
Perform the following diagnostic procedure: ECM
Memory - Test
138
Troubleshooting Section
SENR9698-09
i01225847
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten hours.
None
OK STOP.
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 STOP.
i01945528
None
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuation System Oil Pressure Circuit - Test
Results:
OK STOP.
SENR9698-09
139
Troubleshooting Section
i01940032
System Response:
None
Results:
OK STOP.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot.
i01945531
None
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Response - Test
Results:
OK STOP.
System Response:
i01945530
The ECM will log the diagnostic code. The ECM will
continue to attempt to energize the engine coolant
diverter.
Possible Performance Effect:
None
Troubleshooting:
Results:
OK STOP.
140
Troubleshooting Section
SENR9698-09
i02184789
System Response:
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
Possible Performance Effect:
The engine will have low power. Engine power will be
restored if five consecutive attempts to energize the
intake valve actuator are successful.
Troubleshooting:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
OK STOP.
i02184794
OK STOP.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten seconds. The ECM will use a
default torque map.
Possible Performance Effect:
The engine will be derated while this diagnostic code
is active.
SENR9698-09
141
Troubleshooting Section
i02184796
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Response - Test
Results:
OK STOP.
two seconds.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
Possible Performance Effect:
The engine will have low power. Engine power will be
restored if five consecutive attempts to energize the
intake valve actuator are successful.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test
Results:
OK STOP.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test
Results:
OK STOP.
i02184797
142
Troubleshooting Section
SENR9698-09
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten seconds. The ECM will use a
default torque map.
Troubleshooting:
Results:
OK STOP.
i02184803
Troubleshooting:
Results:
OK STOP.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
Possible Performance Effect:
The engine will have low power. Engine power will be
restored if five consecutive attempts to energize the
intake valve actuator are successful.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test
Results:
OK STOP.
SENR9698-09
143
Troubleshooting Section
i02184806
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
Possible Performance Effect:
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten seconds. The ECM will use a
default torque map.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test
Results:
OK STOP.
i02184814
Results:
OK STOP.
i02184810
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
144
Troubleshooting Section
SENR9698-09
Results:
OK STOP.
Troubleshooting:
i02185408
OK STOP.
i02184815
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten seconds. The ECM will use a
default torque map.
Troubleshooting:
Results:
OK STOP.
SENR9698-09
145
Troubleshooting Section
i02185477
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than ten seconds. The ECM will use a
default torque map.
Possible Performance Effect:
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
OK STOP.
i02185503
Troubleshooting:
Results:
OK STOP.
i02185495
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
OPEN during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
146
Troubleshooting Section
SENR9698-09
i02185507
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test
Results:
OK STOP.
working properly.
i02185504
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
Caterpillar Electronic Technician (ET) will indicate
SHORT during the Intake Valve Actuator Solenoid
Test. The ECM will continue to attempt to energize
the intake valve actuator. The ECM will use a default
torque map while this diagnostic code is active.
Possible Performance Effect:
The engine will have low power. Engine power will be
restored if five consecutive attempts to energize the
intake valve actuator are successful.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Circuit - Test
Results:
OK STOP.
OK STOP.
i02185510
SENR9698-09
147
Troubleshooting Section
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM will use a default torque map.
Possible Performance Effect:
The engine will be derated while this diagnostic code
is active.
Note: Full power will be restored if the diagnostic
code becomes inactive.
Note: If this code is logged several times, the engine
will be derated until the code is cleared with the
Caterpillar Electronic Technician (ET). If the condition
is not resolved, the engine will be derated again.
Troubleshooting:
Perform the following diagnostic procedure: Intake
Valve Actuator Response - Test
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than four hours. The ECM will not use a
default value.
Possible Performance Effect:
None
Troubleshooting:
Perform the following diagnostic procedure: Engine
Pressure Sensor Open or Short Circuit - Test
Results:
OK STOP.
i01941381
Results:
OK STOP.
i01941380
System Response:
The ECM will log the diagnostic code and the ECM
will trigger a snapshot. The check engine lamp will
illuminate once this diagnostic code has been active
for more than four hours. The ECM will not use a
default value.
OK STOP.
148
Troubleshooting Section
SENR9698-09
Diagnostic Functional
Tests
i02490878
SENR9698-09
Illustration 23
149
Troubleshooting Section
g00970385
Schematic
Illustration 24
P2 ECM connector
g00970387
150
Troubleshooting Section
SENR9698-09
g00810608
Sensor connector
Expected Result:
Results:
SENR9698-09
151
Troubleshooting Section
Expected Result:
Expected Result:
Results:
Results:
152
Troubleshooting Section
SENR9698-09
STOP.
SENR9698-09
153
Troubleshooting Section
Remote switches
Remote throttle
Note: In the configuration for the cab switches, the
vehicles accelerator pedal can be used in order
to control the engine rpm for the PTO operation.
The accelerator pedal can also be ignored in the
Cab Switches PTO configuration. Programming
of customer parameters is required in order to
ignore the accelerator pedal in the Cab Switches
configuration.
The ECM is in PTO mode if the PTO On/Off Switch
is on. This can be checked with the Caterpillar
Electronic Technician (ET). Refer to Troubleshooting,
PTO Switch Circuit - Test for testing if the PTO is
being used.
g00642016
Illustration 26
Schematic for the accelerator pedal position sensor
Results:
154
Troubleshooting Section
SENR9698-09
Service
Calibrations
Monitor Throttle Position Sensor
C. While the duty cycle is being monitored, depress
the accelerator pedal and release the accelerator
pedal.
The correct duty cycle is 10 percent to 22 percent
when the accelerator pedal is released. The
correct duty cycle is 75 percent to 90 percent
when the accelerator pedal is depressed.
D. Turn the keyswitch to the OFF position.
Expected Result:
Cat ET is reporting the correct duty cycle for the
sensor.
Results:
Illustration 27
g01186024
SENR9698-09
155
Troubleshooting Section
g01255058
91-08
91-13
41-03
41-04
Illustration 29
g01159881
Sensor connector
Expected Result:
156
Troubleshooting Section
Results:
SENR9698-09
Results:
SENR9698-09
157
Troubleshooting Section
158
Troubleshooting Section
SENR9698-09
g00706977
Illustration 30
Accelerator pedal assembly
SENR9698-09
159
Troubleshooting Section
160
Troubleshooting Section
SENR9698-09
Expected Result:
Cat ET reported the correct diagnostic codes for the
conditions that were present.
Results:
SENR9698-09
161
Troubleshooting Section
i02049032
162
Troubleshooting Section
SENR9698-09
g01051166
Illustration 31
Schematic
g01017869
Illustration 32
P1 and P2 ECM connectors
SENR9698-09
163
Troubleshooting Section
Expected Result:
The status is On when the wires are connected.
The status is Off when the wires are disconnected.
Results:
Expected Result:
STOP.
164
Troubleshooting Section
SENR9698-09
Expected Result:
The relay is active.
Results:
Not OK
Illustration 33
g00850138
STOP.
Note: The output for the air inlet shutoff will be active
for only one second.
Expected Result:
Results:
the air inlet shutoff solenoid, but the air inlet shutoff
solenoid is not working. Proceed to Test Step 8.
SENR9698-09
165
Troubleshooting Section
Expected Result:
The resistance is between 5 Ohms and 10 Ohms.
Results:
Expected Result:
The resistance is between 15 Ohms and 20 Ohms.
Results:
Illustration 35
g00850154
Illustration 34
g00850059
Relay Terminals
Expected Result:
The voltage test lamp illuminates when the test is
active.
166
Troubleshooting Section
SENR9698-09
Results:
Illustration 37
g00850141
g00850141
Results:
STOP.
SENR9698-09
167
Troubleshooting Section
Results:
STOP.
Results:
STOP.
Expected Result:
i02507189
STOP.
168
Troubleshooting Section
SENR9698-09
Illustration 38
Schematic for ATA data link with 6-pin connector
g00650338
SENR9698-09
Illustration 39
169
Troubleshooting Section
g01186024
Illustration 40
g01255291
Terminal locations at the P1 ECM connector for the ATA data link
(8) ATA data link (+)
(9) ATA data link ()
170
Troubleshooting Section
SENR9698-09
g00650354
Illustration 41
Different types of data link connectors
SENR9698-09
171
Troubleshooting Section
Results:
Results:
172
Troubleshooting Section
SENR9698-09
Illustration 42
g01255300
Unswitched +Battery
Unswitched +Battery
Unswitched +Battery
Battery
Battery
Battery
Ignition keyswitch
SENR9698-09
173
Troubleshooting Section
Illustration 43
Schematic of the bypass harness
g01017846
174
Troubleshooting Section
SENR9698-09
g01104227
Illustration 44
Schematic of the ECM battery circuit
NOTICE
Do Not connect the Bypass Harness to the battery
until all three of the 10 Amp in-line fuses have been
removed from the +Battery line. If the fuses are not
removed before connection to the battery a spark may
result.
Expected Result:
Cat ET is operating correctly.
Results:
SENR9698-09
175
Troubleshooting Section
176
Troubleshooting Section
SENR9698-09
SENR9698-09
177
Troubleshooting Section
g01255307
Illustration 45
Typical circuit for the auxiliary brake output
Illustration 46
g01186024
g01255305
178
Troubleshooting Section
SENR9698-09
Auxiliary Brake
Engine Retarder Minimum Vehicle Speed (if
applicable)
Results:
STOP.
SENR9698-09
179
Troubleshooting Section
Diagnostics
Diagnostic Tests
Expected Result:
STOP.
180
Troubleshooting Section
SENR9698-09
i02504635
SENR9698-09
181
Troubleshooting Section
g01253817
Illustration 48
Schematic for the check engine lamp
Illustration 49
g01186024
g01253832
182
Troubleshooting Section
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, and of pinch points.
Results:
SENR9698-09
SENR9698-09
183
Troubleshooting Section
Results:
184
Troubleshooting Section
SENR9698-09
Setting For
Transmission
Style
Parameter
Necessary Switches
Service Service
Brake
Brake
(Switch (Switch
1)
2)
Manual Option
1
Automatic
Option 1
Automatic
Option 2
Automatic
Option 3
Automatic
Option 4
Eaton Top 2
Clutch
Neutral
X
X
X
Automatic Option 1
Automatic Option 2
Automatic Option 3
Automatic Option 4
The clutch pedal position switch connects to the ECM
at terminal location P1-22. The status of the clutch
pedal position switch can also be reported over the
J1939 data link.
SENR9698-09
185
Troubleshooting Section
g01255422
Illustration 51
Schematic for the clutch pedal position switch
186
Troubleshooting Section
SENR9698-09
Illustration 52
g01186024
Illustration 53
g01255450
SENR9698-09
Results:
187
Troubleshooting Section
Expected Result:
Expected Result:
Results:
Results:
the switch.
STOP.
STOP.
188
Troubleshooting Section
SENR9698-09
4-pin sensor
2-wire float sensor
The correct type of sensor must be programmed into
the monitoring system prior to use. If a coolant level
sensor is not installed or the coolant level sensor is
independent from the ECM, the parameter should be
programmed to None.
4-pin Sensor
The supply voltage for this sensor is connected to the
ECM through terminal P1-2 (+5 VDC) at the ECM
connector. The signals for the coolant level are wired
to terminal P1-54 (coolant level low) and terminal
P1-49 (coolant level normal) at the ECM connector.
The sensor return is connected to terminal location
P1-5 (AP sensor/switch sensor return).
SENR9698-09
189
Troubleshooting Section
190
Troubleshooting Section
SENR9698-09
g01255585
Illustration 54
Schematic for the 4-pin sensor
Illustration 55
g01186024
Illustration 56
g01255606
SENR9698-09
191
Troubleshooting Section
g01255609
192
Troubleshooting Section
SENR9698-09
SENR9698-09
193
Troubleshooting Section
194
Troubleshooting Section
SENR9698-09
g01255755
Illustration 58
Schematic for the 2-wire float sensor
Illustration 59
g01186024
Illustration 60
g01255763
SENR9698-09
195
Troubleshooting Section
STOP.
Expected Result:
Expected Result:
Results:
Results:
196
Troubleshooting Section
SENR9698-09
STOP.
Expected Result:
Results:
STOP.
SENR9698-09
197
Troubleshooting Section
198
Troubleshooting Section
SENR9698-09
Dyno mode
SENR9698-09
199
Troubleshooting Section
Illustration 61
g00675576
This schematic represents the ON/OFF fan with a direct solenoid connection to the ECM and the A/C Pressure Switch connected to
the ECM input.
Illustration 62
g00675579
This schematic represents the ON/OFF fan with a direct solenoid connection to the ECM and the A/C High Pressure Switch not connected to
the ECM input.
200
Troubleshooting Section
Illustration 63
SENR9698-09
g00675587
This schematic represents the ON/OFF fan with a direct solenoid connection to the ECM and the A/C Control Unit is connected to the ECM input.
Illustration 64
g00675591
This schematic represents the ON/OFF fan with a normally closed relay and the A/C High Pressure Switch not connected to the ECM input.
SENR9698-09
Illustration 65
201
Troubleshooting Section
g00675623
This schematic represents the ON/OFF fan with a normally open relay connection and an A/C High Pressure Switch connected to the ECM input.
Illustration 66
g00675640
This schematic represents the ON/OFF fan with a normally open relay connection and an A/C High Pressure Switch connected to the ECM input.
202
Troubleshooting Section
SENR9698-09
g00675642
Illustration 67
This schematic represents the ON/OFF fan with a normally closed relay connection and an A/C High Pressure Switch connected to
the ECM input.
Three-Speed Fan
Coolant temperature
Brake
Slip
Direct
SENR9698-09
203
Troubleshooting Section
Table 143
Intake Air
Temperature
91 C (196 F)
54 C (129 F)
102 C (216 F)
96 C (205 F)
52 C (126 F)
81 C (178 F)
0 C (32 F)
Mode
Intake Air
Temperature with
Boost that is Less
Than 70 kPa (10 psi)
Intake Air
Temperature with
Boost that is Greater
Than 70 kPa (10 psi)
82 C (180 F)
66 C (151 F)
204
Troubleshooting Section
SENR9698-09
g00675646
Illustration 68
Three-Speed Fan with Direct Solenoid Connection
SENR9698-09
205
Troubleshooting Section
g00675876
Illustration 69
Terminal locations for the ECM
Cooling fan
Not OK
206
Troubleshooting Section
SENR9698-09
Expected Result:
Results:
SENR9698-09
207
Troubleshooting Section
Expected Result:
STOP.
Not OK
Repair: Replace the A/C high pressure switch.
208
Troubleshooting Section
SENR9698-09
g00676088
Illustration 70
Connector for the breakout T
Not OK
Repair: Temporarily connect a test ECM. Ensure
that the A/C Pressure Switch Fan On-Time
parameter is programmed in the same manner as
the suspect ECM. Use Cat ET to check the ECM. If
the problem is resolved with the test ECM, install
the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM.
Verify that the repair eliminates the problem.
STOP.
SENR9698-09
209
Troubleshooting Section
g00676097
Illustration 71
Connector for the breakout T
Expected Result:
Results:
210
Troubleshooting Section
SENR9698-09
i02508931
Expected Result:
Results:
properly.
STOP.
Not OK
STOP.
SENR9698-09
211
Troubleshooting Section
212
Troubleshooting Section
SENR9698-09
Table 144
Setting For
Transmission
Style
Parameter
Necessary Switches
Service
Brake
(Switch
1)
Service
Brake
(Switch
1)
Manual
Automatic
Option 1
Automatic
Option 2
Automatic
Option 3
Automatic
Option 4
Eaton Top 2
Clutch Neutral
X
X
X
X
Automatic Option 1
Automatic Option 2
Automatic Option 3
Automatic Option 4
A service brake pedal position (switch 1) is required
for all configurations. The service brake pedal
position (switch 1) connects to the ECM through
connector P1-45. The service brake pedal position
(switch 2) connects to the ECM through connector
P1-64. The clutch pedal position switch connects
to the ECM through connector P1-22. The neutral
switch connects to the ECM through connector
P1-62. The status of both of the service brake pedal
switches, the clutch pedal position switch, and the
transmission neutral switch can also be reported over
the J1939 data link.
SENR9698-09
213
Troubleshooting Section
g00643881
Illustration 72
Schematic for the cruise control switch, the service brake pedal position (switch 1), and clutch pedal position switch
214
Troubleshooting Section
SENR9698-09
STOP.
Illustration 73
g01186024
SENR9698-09
215
Troubleshooting Section
Results:
Illustration 74
g01255944
Terminals at the P1 ECM connector that are for the cruise control
(P1-5) AP sensor/switch sensor return
(P1-35) Set
(P1-44) Resume
(P1-59) Cruise control on/off switch
216
Troubleshooting Section
SENR9698-09
Switch Status
Circuit
Off
Open
Set switch
On
Set switch
shorted
Resume switch
On
Resume switch
shorted
SENR9698-09
217
Troubleshooting Section
Switch Status
Circuit
Off
Open
On
On
Set switch
shorted
On
Resume switch
shorted
i02509246
218
Troubleshooting Section
SENR9698-09
g01256017
Illustration 75
Schematic for the diagnostic enable switch
SENR9698-09
219
Troubleshooting Section
Illustration 76
g01186024
Illustration 77
g01256021
220
Troubleshooting Section
SENR9698-09
SENR9698-09
221
Troubleshooting Section
222
Troubleshooting Section
SENR9698-09
Table 147
Top
Gear
Minus
Two
Ratio
Top
Gear
Minus
One
Ratio
Top
Gear
Ratio
RTLO-XX610B-T2
10 Over
1.352
1.000
0.741
RTL-XX710B-T2
10 Direct
1.825
1.351
1.000
RTLO-XX713A-T2
13 Over
1.000
0.856
0.730
RTLO-XX718B-T2
18 Over
1.000
0.856
0.730
Transmission
Model
SENR9698-09
223
Troubleshooting Section
g01256175
Illustration 78
Schematic for the outputs to the Eaton Top 2 transmission
Illustration 79
g01186024
224
Troubleshooting Section
SENR9698-09
Results:
Diagnostics
Diagnostic Tests
Illustration 80
g01256210
Special Tests
Shift Solenoid and Lockout Solenoid
E. Use the following procedure for either of the
following active diagnostic codes or logged
diagnostic codes:
SENR9698-09
225
Troubleshooting Section
OK
Repair: The ECM, the relay, and the solenoid
appear to be operating correctly at this time. There
may be an intermittent electrical problem in the
harness or in a connector. If an intermittent problem
is suspected, refer to Troubleshooting, Electrical
Connectors - Inspect for information that is related
to troubleshooting intermittent electrical problems.
STOP.
Diagnostics
Diagnostic Tests
Special Test
Shift Solenoid
F. While you monitor the voltage test lamp, cycle the
special test for the Shift Solenoid from the ON
position to the OFF position and back to the ON
position.
G. Stop the special test for the Shift Solenoid.
Note: When the keyswitch is turned on and the
solenoid connector is disconnected, the following
diagnostic code will occur during performance of the
special test for the Lockout Solenoid:
226
Troubleshooting Section
Diagnostics
Diagnostic Tests
Special Test
Lockout Solenoid
L. While you monitor the voltage test lamp, cycle the
special test for the Lockout Solenoid from the
ON position to the OFF position and back to the
ON position.
SENR9698-09
Expected Result:
Results:
Diagnostics
Diagnostic Tests
Special Test
Shift Solenoid
e. While you monitor the voltage test lamp, cycle
the special test for the Shift Solenoid from the
ON position to the OFF position and back to
the ON position.
f. Stop the special test for the Shift Solenoid.
g. Turn the keyswitch to the OFF position.
D. Use the following procedure for either of the
following diagnostic codes:
SENR9698-09
227
Troubleshooting Section
Diagnostics
Diagnostic Tests
Special Test
Lockout Solenoid
e. While you monitor the voltage test lamp, cycle
the special test for the Lockout Solenoid from
the ON position to the OFF position and back
to the ON position.
f. Stop the special test for the Lockout Solenoid.
g. Turn the keyswitch to the OFF position.
h. Restore the wiring to the original configuration.
Expected Result:
The voltage test lamp behaves in the following
manner:
not active.
Expected Result:
Results:
Top 2.
Results:
228
Troubleshooting Section
SENR9698-09
i02503713
ECM communications
Programmable Parameters
Programmable parameters are stored in permanent
memory. This includes both customer specified
parameters and system configuration parameters.
Refer to Troubleshooting, Customer Specified
Parameters for details on customer specified
parameters. Refer to Troubleshooting, System
Configuration Parameters for details on system
configuration parameters.
Logged Diagnostics
Input Circuits
Input circuits filter electrical noise for sensor signals.
Also, input circuits protect internal circuits from
potentially damaging voltage levels.
Output Circuits
Performance Maps
Power Circuits
SENR9698-09
229
Troubleshooting Section
Illustration 81
g01252833
Location of the ECM and the harness connectors (typical left side
engine view)
(1) J2/P2 ECM connectors
(2) J1/P1 ECM connectors
(3) ECM
g01252845
230
Troubleshooting Section
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion or of pinch points.
Results:
SENR9698-09
SENR9698-09
231
Troubleshooting Section
Results:
Results:
Expected Result:
232
Troubleshooting Section
SENR9698-09
Illustration 83
g01131211
SENR9698-09
Illustration 84
233
Troubleshooting Section
g01131276
Illustration 86
g01131165
Missing seals
Illustration 85
Seal for a three-pin connector (typical example)
g01131019
234
Troubleshooting Section
SENR9698-09
Expected Result:
Expected Result:
Results:
Results:
Results:
STOP.
Exposed insulation
Rubbing of a wire against the engine
Rubbing of a wire against a sharp point
B. Check all of the wiring harness fasteners in order
to verify that the harness is properly secured. Also
check all of the fasteners in order to verify that the
harness is not compressed. Pull back the harness
sleeves in order to check for a flattened portion
of wire. A fastener that has been overtightened
flattens the harness. This damages the wires that
are inside the harness.
4.
SENR9698-09
235
Troubleshooting Section
Illustration 87
g01131435
Illustration 88
g01131604
Expected Result:
Expected Result:
Each terminal and each connector easily withstands
45 N (10 lb) of pull and each wire remains in the
connector body.
Results:
236
Troubleshooting Section
SENR9698-09
Illustration 91
g01132863
Allen head screw for the 40 pin ECM connector (typical example)
Illustration 89
g01132827
Allen head screw for the 120 pin ECM connector (typical example)
a. Torque the allen head bolt for the 120 pin ECM
connector to 7.0 0.5 Nm (60 4 lb in).
Illustration 92
g01133047
Allen head screw for the 40 pin customer connector and the 70 pin
customer connector (typical example)
g01132849
Allen head screw for the 70 pin ECM connector (typical example)
SENR9698-09
237
Troubleshooting Section
i01921850
Expected Result:
Results:
Engine speed is 0.
indicated.
Vehicle speed is 0.
STOP.
238
Troubleshooting Section
SENR9698-09
g01012736
Illustration 93
Schematic
g01012737
Illustration 94
P2 ECM connector
Results:
Expected Result:
SENR9698-09
239
Troubleshooting Section
Results:
Results:
240
Troubleshooting Section
Results:
SENR9698-09
Expected Result:
Results:
STOP.
SENR9698-09
241
Troubleshooting Section
Results:
Expected Result:
Expected Result:
Results:
Proceed to Test Step 10.
Short.
Results:
STOP.
STOP.
242
Troubleshooting Section
SENR9698-09
i01939052
SENR9698-09
Illustration 95
243
Troubleshooting Section
g00970385
Illustration 96
P2 ECM connector
g00970387
244
Troubleshooting Section
SENR9698-09
g00810608
Sensor connector
Expected Result:
All connectors, pins and sockets should be completely
coupled and/or inserted and the harness and wiring
should be free of corrosion, abrasion or pinch points.
Results:
Expected Result:
None of the preceding diagnostic codes are active.
Results:
STOP.
SENR9698-09
Expected Result:
Either a voltage low diagnostic code (short circuit)
is active or a voltage high diagnostic code (open
circuit) is active.
245
Troubleshooting Section
Results:
Expected Result:
Results:
STOP.
Expected Result:
The resistance is greater than 20,000 ohms, or OL
is displayed on the multimeter.
Results:
246
Troubleshooting Section
SENR9698-09
STOP.
Expected Result:
Results:
SENR9698-09
247
Troubleshooting Section
Background Information
248
Troubleshooting Section
SENR9698-09
g00656153
Illustration 98
Schematic for the engine running output
Illustration 99
g01186024
SENR9698-09
249
Troubleshooting Section
g01256249
Results:
the current wiring for the circuit. The relay for the
engine running output is wired correctly. Proceed
to Test Step 3.
250
Troubleshooting Section
SENR9698-09
Results:
SENR9698-09
251
Troubleshooting Section
252
Troubleshooting Section
SENR9698-09
g00656155
Illustration 101
Schematic for the engine shutdown output
Illustration 102
g01186024
SENR9698-09
253
Troubleshooting Section
g01256249
Results:
the current wiring for the circuit. The relay for the
engine shutdown output is wired correctly. Proceed
to Test Step 3.
254
Troubleshooting Section
SENR9698-09
Results:
SENR9698-09
255
Troubleshooting Section
The engine will start and the engine will run when
only one sensor signal is present from either of the
sensors. The loss of the signal from both of the
sensors during engine operation will result in the
termination of injection and the shutting down of the
engine by the ECM. The loss of the signal from both
of the sensors during start-up will prevent the engine
from starting.
Both sensors are magnetic sensors with an integral
connector. The two sensors are not interchangeable.
Do not switch the positions of the sensor. If the
sensors are replaced, a timing calibration is not
necessary for the engine.
Note: When the sensors are being installed,
complete all of the following tasks:
256
Troubleshooting Section
SENR9698-09
g01255093
Illustration 104
C-15 schematic for engine speed/timing
g01255097
Illustration 105
C-11 and C-13 schematic for engine speed/timing
Illustration 106
g01146562
Typical C-11 and C-13 sensor locations (left side engine view)
(1) J2/P2 ECM connector
(2) Secondary engine speed/timing sensor
(3) Primary engine speed/timing sensor
SENR9698-09
257
Troubleshooting Section
Illustration 108
Typical C-15 sensor locations (left side engine view)
(4) J2/P2 ECM connector
(5) Secondary engine speed/timing sensor
(6) Primary engine speed/timing sensor
Illustration 107
ECM connector for the C-11 and C-13
(P2-48)
(P2-49)
(P2-58)
(P2-59)
g01146574
g01255124
258
Troubleshooting Section
SENR9698-09
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
Results:
g01146574
SENR9698-09
259
Troubleshooting Section
Expected Result:
One or more of the diagnostic codes that are listed
above are logged or active.
Results:
22-11
Expected Result:
The sensors and the bracket are properly installed.
Results:
Not OK
Repair: Perform the following procedure in order
to properly install the sensors and the bracket:
1. Loosen the bolt that holds the sensor mounting
bracket to the engine.
2. Seat the sensor and tighten the bolt.
If the sensor will not seat, repair the sensor or
replace the sensor, as required.
Note: The sensor must not be removed from the
bracket.
3. Ensure that the sensor is properly oriented
and that the harness is secured in the proper
location.
4. Verify that the repair eliminates the problem.
Illustration 110
g01255131
STOP.
260
Troubleshooting Section
SENR9698-09
SENR9698-09
OK
Repair: If the problem is resolved with the test
ECM and the problem returns with the suspect
ECM, replace the ECM.
Verify that the repair eliminates the problem.
STOP.
261
Troubleshooting Section
i01942352
262
Troubleshooting Section
Illustration 111
SENR9698-09
g00970545
Illustration 112
P1 and P2 ECM connectors
g00970546
SENR9698-09
263
Troubleshooting Section
Results:
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, or of pinch points.
Results:
264
Troubleshooting Section
SENR9698-09
Expected Result:
The resistance is greater than 20,000 Ohms or OL
is displayed on the multimeter.
Results:
STOP.
SENR9698-09
265
Troubleshooting Section
STOP.
Expected Result:
STOP.
Results:
i02504775
Results:
Expected Result:
cooling fan
266
Troubleshooting Section
SENR9698-09
g01253914
Illustration 113
Schematic for the fan override switch
Expected Result:
Results:
SENR9698-09
267
Troubleshooting Section
STOP.
Illustration 114
g01186024
268
Troubleshooting Section
SENR9698-09
Results:
Illustration 115
g01253945
Expected Result:
Results:
Expected Result:
STOP.
SENR9698-09
269
Troubleshooting Section
i02186010
270
Troubleshooting Section
SENR9698-09
Service
Configuration
b. Record the programmed time for the Idle
Shutdown Timer. The Idle Shutdown Timer
must be between 3 and 1440 minutes. If the
Idle Shutdown Timer is programmed to 0,
then the timer is disabled.
c. Record the programmed status of the
parameter for the Allow Idle Shutdown
Override and the Idle Shutdown Timer
Maximum RPM.
SENR9698-09
271
Troubleshooting Section
Results:
Service
Configuration
STOP.
272
Troubleshooting Section
SENR9698-09
i02509722
SENR9698-09
273
Troubleshooting Section
274
Troubleshooting Section
Illustration 116
Schematic for ECM battery circuit
SENR9698-09
g01104227
SENR9698-09
275
Troubleshooting Section
Illustration 117
g01186024
Illustration 118
g01256390
Unswitched +Battery
Unswitched +Battery
Unswitched +Battery
Battery
Battery
Battery
Keyswitch
276
Troubleshooting Section
Results:
SENR9698-09
Expected Result:
Expected Result:
One of the following diagnostic codes is active or
logged:
Results:
SENR9698-09
277
Troubleshooting Section
278
Troubleshooting Section
SENR9698-09
g01017846
Illustration 119
Schematic of the bypass harness
Expected Result:
Results:
Not OK
Repair: Connect the bypass to another battery and
verify if the problem is resolved. If the problem is
resolved, the problem is with the vehicle batteries.
If the problem still exists, temporarily connect
a test ECM. Remove all jumpers and replace
all connectors. Recheck the system for active
diagnostic codes and repeat the Test Step. If the
problem is resolved with the test ECM, reconnect
the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM.
Verify that the repair eliminates the problem.
STOP.
SENR9698-09
279
Troubleshooting Section
i02504880
280
Troubleshooting Section
SENR9698-09
g01254014
Illustration 120
Schematic for the ignore brake/clutch switch
Illustration 121
g01186024
SENR9698-09
281
Troubleshooting Section
g01254023
Expected Result:
Results:
Expected Result:
STOP.
282
Troubleshooting Section
SENR9698-09
Expected Result:
Results:
the switch.
SENR9698-09
283
Troubleshooting Section
Illustration 123
Electronic unit injector
g01109300
284
Troubleshooting Section
Illustration 124
SENR9698-09
g01098254
Illustration 125
Schematic for C15 engines
g01098255
SENR9698-09
285
Troubleshooting Section
g01110868
Illustration 126
P2 ECM connector
(P2-36) Injector 1 & 2 supply
(P2-37) Injector 3 & 4 supply
(P2-38) Injector 5 & 6 supply
g01107778
Illustration 127
Valve cover connectors for C11 and C13 engines
(P681-4)
(P681-5)
(P681-6)
(P681-7)
(P681-8)
Injector 1
Injector 2
Injector 3
Injector 3
Injector 1
return
return
return
& 4 supply
& 2 supply
(P682-3)
(P682-4)
(P682-5)
(P682-6)
(P682-7)
Injector 4
Injector 5
Injector 6
Injector 3
Injector 5
return
return
return
& 4 supply
& 6 supply
286
Troubleshooting Section
SENR9698-09
g01107792
Illustration 128
Valve cover connectors for C15 engines
(P681-1) Injector 1 return
(P681-2) Injector 2 return
(P681-3) Injector 3 return
g01109586
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Thoroughly inspect the J2/P2 ECM connector.
Thoroughly inspect the front and rear valve cover
connectors at the valve cover base. Refer to
Troubleshooting, Electrical Connectors - Inspect
for details.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated
with injector solenoids.
SENR9698-09
Expected Result:
One or more diagnostic codes that are related to the
injector solenoids have been logged:
1-05
1-06
2-05
2-06
3-05
3-06
4-05
4-06
5-05
5-06
6-05
287
Troubleshooting Section
6-06
Results:
Expected Result:
Diagnostics
Diagnostic Tests
Cylinder Cutout Test
E. Enable the cooling fan, if the fan is not controlled
by the ECM. If the ECM controls the cooling fan,
the cooling fan will start automatically when the
test begins.
Results:
288
Troubleshooting Section
SENR9698-09
Diagnostics
Diagnostic Tests
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Disconnect the connectors from the valve cover
base.
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Remove the valve cover.
C. Disconnect the harness from the suspect injector.
Disconnect the harness from the injector that
shares the same supply circuit as the suspect
injector.
Note: If both injectors that share a common supply
indicate Open, inspect the supply wire under the
valve cover for problems. The open circuit is probably
caused by an open in the supply wire.
D. Thoroughly clean the terminals on both injectors
and on the harness connectors.
E. Exchange the harness between the two injectors
that share the common supply.
SENR9698-09
289
Troubleshooting Section
Expected Result:
Expected Result:
Results:
STOP.
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Disconnect the P2 ECM connector from the ECM.
C. Remove the supply wire and the return wire for
the suspect injector from the P2 ECM connector.
Install a jumper wire into the P2 ECM connector in
order to provide a short between the supply and
the return of the suspect injector.
D. Reinstall the P2 ECM connector to the ECM.
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
290
Troubleshooting Section
SENR9698-09
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Disconnect the P2 ECM connector from the ECM
and check for evidence of moisture entry.
C. Turn the key switch to the ON position.
D. Perform the Injector Solenoid Test at least two
times.
Expected Result:
All cylinders indicate Open when the P2 ECM
connector is disconnected from the ECM.
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Remove the valve cover.
C. Disconnect each of the injectors that indicate a
Short from the wiring harness. Ensure that each
of the connectors from the disconnected injector
harness does not touch any other components.
Results:
Expected Result:
Results:
SENR9698-09
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
A. Turn the key switch to the OFF position. A strong
electrical shock hazard is present if the key switch
is not turned off.
B. Disconnect the P2 ECM connector from the ECM.
C. Locate the terminal for the supply of the problem
injector in the P2 connector. Measure the
resistance from the terminal to the engine ground
stud.
Expected Result:
The resistance is greater than 10 Ohms.
Results:
291
Troubleshooting Section
Engine speed is 0.
Vehicle speed is 0.
The neutral switch is in the Neutral position.
292
Troubleshooting Section
SENR9698-09
g01012666
Illustration 130
Schematic
g01012723
Illustration 131
P2 ECM connector
Results:
Expected Result:
SENR9698-09
293
Troubleshooting Section
Results:
Expected Result:
Results:
Expected Result:
Results:
294
Troubleshooting Section
SENR9698-09
Results:
Results:
Expected Result:
The resistance is greater than 6 Ohms for 12 volt
systems and the resistance is greater than 23 Ohms
for 24 volt systems.
Results:
STOP.
SENR9698-09
295
Troubleshooting Section
296
Troubleshooting Section
SENR9698-09
Engine speed is 0.
Vehicle speed is 0.
SENR9698-09
Illustration 132
297
Troubleshooting Section
g01098702
Illustration 133
Schematic for C15 engine
g01098709
298
Troubleshooting Section
SENR9698-09
g01110848
Illustration 134
P2 ECM connector for C11, C13, and C15 engines
(P2-20) Actuator 1 return
(P2-21) Actuator 2 return
(P2-28) Actuator 5 return
g01098714
Illustration 135
Valve cover connectors for C11 and C13 engines
(P681-9) Actuator 1 return
(P681-10) Actuator 2 return
(P681-11) Actuator 1 & 2 supply
(P681-13) Actuator 3 return
SENR9698-09
299
Troubleshooting Section
g01098716
Illustration 136
Valve cover connectors for the C15 engine
(P681-7) Actuator 1 return
(P681-8) Actuator 2 return
(P681-9) Actuator 1 & 2 supply
g01107530
Illustration 137
Location of components for C11 and C13 engines
(1) Actuator solenoids
300
Troubleshooting Section
SENR9698-09
g01107546
Illustration 138
Location of components for C15 engine
(1) Actuator solenoids
Expected Result:
and/or wiring.
SENR9698-09
Results:
301
Troubleshooting Section
Results:
Results:
Expected Result:
302
Troubleshooting Section
SENR9698-09
STOP.
STOP.
SENR9698-09
303
Troubleshooting Section
Expected Result:
The test indicated Not Active: Device Short with the
jumper wire in place.
Results:
Results:
304
Troubleshooting Section
SENR9698-09
STOP.
engine start-up
________________
Did the fault occur after the first heavy pull of the
day
________________
SENR9698-09
305
Troubleshooting Section
g01107195
Illustration 139
C11 and C13 engines (typical example)
(1) Check valve
(2) Actuator solenoid
306
Troubleshooting Section
SENR9698-09
g01106745
Illustration 140
C15 engine (typical example)
(1) Check valve
(2) Actuator solenoid
Results:
________________Result
________________Result
SENR9698-09
307
Troubleshooting Section
Illustration 141
g00997504
g00997505
Expected Result:
The engine oil pressure is above the trip point.
Results:
OK
Repair: The engine oil pressure is OK.
Record the engine oil pressure. ________________
Record the engine rpm. ________________
Proceed to Test Step 3.
308
Troubleshooting Section
SENR9698-09
________________
Pressure
not responding
Expected Result:
________________Result
2 283-07 is logged.
________________Result
3 385-01 is logged.
Expected Result:
________________Result
logged.
SENR9698-09
309
Troubleshooting Section
Results:
H. Verify that all of the ports in the oil rail are plugged.
Results:
actuators.
actuators.
________________
cover base.
________________
310
Troubleshooting Section
SENR9698-09
g01106067
Illustration 143
Typical example
(6) Sensor connector
(7) Intake valve actuation oil pressure sensor
(8) Fabricated tool
Air
Pressure
(psi)
Range Low
(VDC)
Typical
voltage
(VDC)
Range
High (VDC)
0.3
0.5
0.7
50
0.8
0.9
1.1
100
1.2
1.3
1.5
SENR9698-09
311
Troubleshooting Section
Illustration 144
g01105023
#1 cylinder
________________
#2 cylinder
________________
#3 cylinder
________________
#4 cylinder
________________
#5 cylinder
________________
#6 cylinder
Results:
312
Troubleshooting Section
SENR9698-09
#1 cylinder
________________
#2 cylinder
________________
#3 cylinder
________________
#4 cylinder
________________
#5 cylinder
________________
#6 cylinder
Note: The test will cycle two times. Once the test is
complete the engine speed will increase to 2100 rpm
for 15 seconds. An OK or Not OK will be displayed
once the test is complete.
Expected Result:
All cylinders indicate OK during the Intake Valve
Actuator Test.
Results:
#1 cylinder
________________
#2 cylinder
________________
#3 cylinder
________________
#4 cylinder
________________
#5 cylinder
________________
#6 cylinder
Current Mileage
________________
________________
#1
________________
#2
________________
#3
________________
#4
________________
#5
________________
#6
Results:
SENR9698-09
313
Troubleshooting Section
H. Verify that all of the ports in the oil rail are plugged.
Note: Some ports are located under the valve cover
base between the valve cover base and the cylinder
head. It may be necessary to have a second person
crank the engine while the technician checks for
leaks.
I. Verify that oil flows through the bleed orifice on
the intake valve actuator.
Expected Result:
________________Result
Results:
actuators.
________________
________________
actuators.
________________
cover base.
________________
314
Troubleshooting Section
SENR9698-09
Results:
________________
Multi-Torque - Test
SMCS Code: 1901-038
System Operation Description:
Background Information
SENR9698-09
315
Troubleshooting Section
Results:
Expected Result:
Results:
Results:
316
Troubleshooting Section
SENR9698-09
i02049755
Neutral
Setting For
Transmission
Style
Parameter
Switch Usage.
Service
Brake 1
Service
Brake 2
Manual
Option 1
Automatic
Option 1
Automatic
Option 2
Automatic
Option 3
Automatic
Option 4
Eaton Top 2
Clutch
Neutral
X
X
X
SENR9698-09
317
Troubleshooting Section
g00646460
Illustration 145
Schematic for transmission neutral switch
Expected Result:
The problem is due to a parameter setting or the
problem is due to a normal kickout.
Results:
Not OK
Idle Parameters
PTO Configuration
PTO Vehicle Speed Limit
Transmission Neutral Switch
D. Ensure that the vehicle is not experiencing
a problem due to one of these parameters.
Refer to Troubleshooting, Customer Specified
Parameters for a description of the parameters, if
necessary.
E. Check the status screen on the electronic service
tool that indicates the last cause of a kickout for
one of the following modes:
Cruise Kickout
Idle Kickout
PTO Kickout
318
Troubleshooting Section
SENR9698-09
g00705233
Illustration 146
Results:
SENR9698-09
319
Troubleshooting Section
Switch Status
Circuit
ON
Closed
OFF
Open
Expected Result:
Expected Result:
Step 4.
Specific Speed
Road Conditions
Weather Conditions
Take the vehicle for a road test in order to
duplicate these conditions and set the cruise
control. Operate the vehicle in cruise control until
the problem reoccurs.
Neutral
RESULT 2 The status for the kickout displays the
following result:
Brake
RESULT 4 The status for the kickout displays the
following result:
320
Troubleshooting Section
PTO Switch ON
RESULT 6 The status for the kickout displays the
following result:
Clutch
RESULT 7 The status for the kickout displays the
following result:
No Engine Speed
Results:
SENR9698-09
Result 7
Repair: Perform the following diagnostic
procedure:
Troubleshooting, Engine Speed/Timing Circuit Test
STOP.
Result 2
STOP.
Result 3
Repair: Perform the following diagnostic
procedure:
Troubleshooting, Service Brake Pedal Position
(Switch 1) Circuit - Test
STOP.
Result 4
Repair: Perform the following diagnostic
procedure:
Troubleshooting, Vehicle Speed Circuit - Test
STOP.
Result 5
Repair: Perform the following diagnostic
procedure:
Troubleshooting, PTO Switch Circuit - Test
STOP.
Result 6
SENR9698-09
321
Troubleshooting Section
Results:
to Test Step 6.
Expected Result:
Results:
Expected Result:
Results:
STOP.
322
Troubleshooting Section
SENR9698-09
STOP.
i02186433
Traction control
Transmission control
ABS
The required components are installed at the OEM
when the vehicle is built.
Power train data link sensors, off-engine control
modules, and wiring are installed by the vehicle
OEM. Refer to the vehicle OEM for questions that
are related to these components.
Anti-Lock Brake Systems (ABS)
SENR9698-09
323
Troubleshooting Section
Transmission Control
The following characteristics are determined by a
vehicle speed sensor in the transmission:
Engine rpm
Torque
Both engine rpm and torque
The presence of an active J1939 data link circuit can
be determined by observing the Power Train Status
screen on Cat ET. The status screen will display
Installed if the proper software is installed in the
ECM, and there is no action that is being requested
at that time by any of the control modules on the data
link.
If an action is being requested by one of the vehicle
control modules, the display will indicate the control
that is making the request (traction control or
transmission control) or a combination of the two
(traction control and transmission control). Power
train control is also displayed in the upper right hand
corner of the display status screen. This space is
replaced by the low oil pressure indicator, when a
condition of low oil pressure exists.
J1939 Data Link
SAE J1939 is standard on all engines.
Note: The wiring for the J1939 data link is a shielded
twisted pair cable and the wiring is not serviceable.
The wiring must be replaced when the wiring is
damaged.
Illustration 147
Schematic for power train data link
g00941844
324
Troubleshooting Section
Illustration 148
Diagnostic connectors
SENR9698-09
g00714306
SENR9698-09
325
Troubleshooting Section
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, or of pinch points.
Results:
g01105732
P1 ECM connector
(P1-34) J1939 Data Link
(P1-42) J1939 Data Link Shield
(P1-50) J1939 Data Link +
326
Troubleshooting Section
SENR9698-09
Expected Result:
The J1939 data link is used for the power train or for
switch inputs to the ECM.
Results:
Illustration 150
g01017846
Bypass harness
SENR9698-09
327
Troubleshooting Section
Results:
STOP.
Expected Result:
The ECM is setup for the J1939 data link and the
indicator is illuminated.
Results:
i02505102
328
Troubleshooting Section
SENR9698-09
SENR9698-09
329
Troubleshooting Section
g01254251
Illustration 151
Schematic of the switch circuit for the PTO engine RPM set speed Input A and Input B
330
Troubleshooting Section
SENR9698-09
Illustration 152
g01186024
g01254406
SENR9698-09
Results:
331
Troubleshooting Section
332
Troubleshooting Section
SENR9698-09
Service
Configuration
a. Record the programmed PTO shutdown time.
The PTO shutdown time must be between 3
and 1440 minutes. If the PTO shutdown time is
programmed to 0, the timer is disabled.
C. Start the engine. Allow the engine to warm up until
the coolant temperature is 38 C (100 F). Allow
the engine to operate at the programmed low idle
and turn off any unnecessary accessory devices.
D. Ensure that all unnecessary loads are turned off.
E. Use the following procedure in order to check the
operation of the PTO shutdown:
a. Park the vehicle.
b. Ensure that the PTO Configuration is
programmed to Cab Switches, Remote
Switches or Remote Throttle.
c. Ensure that the status for the PTO On/Off
Switch is ON.
d. Observe the status of the PTO Shutdown
Status.
Note: The PTO Shutdown Timer Maximum RPM
can be programmed in order to allow the timer
to be reset by increasing engine RPM above the
programmed limit. Ensure that the accelerator is not
being depressed in order to increase rpm beyond the
programmed limit.
SENR9698-09
333
Troubleshooting Section
Expected Result:
Expected Result:
Results:
Results:
Service
Configuration
b. Record the programmed PTO shutdown time.
The PTO shutdown time must be between 3
and 1440 minutes. If the PTO shutdown time is
programmed to 0, the timer is disabled.
c. Reprogram the PTO Shutdown Time to three
minutes for this test.
C. Observe the following items during the 90 second
period before the programmed shutdown time:
334
Troubleshooting Section
SENR9698-09
Results:
INPUT 2
INPUT 3
INPUT 1
P1-56 Input 1 is used for the circuit for the PTO on/off
switch when the PTO configuration is programmed to
Cab Switches, to Remote Switches, or to Remote
Throttle.
When the PTO on/off switch is on, the ECM will be
in dedicated PTO mode.
SENR9698-09
Low idle
PTO top engine limit
Top engine limit
The PTO Configuration Is Programmed To
Remote Switches or Remote Throttle.
When the PTO Configuration is programmed to
Remote Switches or to Remote Throttle and the
PTO on/off switch is on, the following circuits are
ignored:
335
Troubleshooting Section
336
Troubleshooting Section
SENR9698-09
Table 151
Troubleshooting
No Engine Speed
Neutral
Illustration 154
Typical circuit schematic for Cab Switches configuration
The return wire may be connected to P1-3, P1-5, or P1-18.
g00644420
SENR9698-09
337
Troubleshooting Section
g00644427
Illustration 155
Typical circuit schematic for Remote Switches configuration
The return wire may be connected to P1-3, P1-5, or P1-18.
g00644448
Illustration 156
Typical circuit schematic for Remote Throttle configuration
The return wire may be connected to P1-3, P1-5, or P1-18.
Expected Result:
Results:
338
Troubleshooting Section
SENR9698-09
Illustration 157
g01152436
P1 ECM connector
Results:
SENR9698-09
PTO Config
PTO On/Off Switch
C. Verify that each of the interlocks for the PTO are
set. Then, while the Cat ET status screen is being
monitored move the PTO on/off switch to the ON
position and move the PTO on/off switch to the
OFF position.
An example of an interlock for the PTO would be
a parking brake that is intended to allow the PTO
to control the engine under specific conditions.
Expected Result:
Result 1 The status of the PTO on/off switch on Cat
ET changes from OFF to ON when the PTO on/off
switch is turned to the OFF position and the ON
position, but the set/resume switch is not operating
correctly.
339
Troubleshooting Section
340
Troubleshooting Section
SENR9698-09
Results:
Expected Result:
When the PTO Configuration is programmed to
Cab Switches, the status parameter for the cruise
control set/resume switch on Cat ET behaves in the
following manner:
Illustration 158
g01105784
SENR9698-09
341
Troubleshooting Section
Illustration 159
Results:
g01105792
342
Troubleshooting Section
SENR9698-09
Expected Result:
STOP.
Results:
Illustration 160
g01105788
SENR9698-09
343
Troubleshooting Section
Results:
Expected Result:
344
Troubleshooting Section
SENR9698-09
Illustration 161
Typical circuit schematic for PTO switch on lamp
g00703413
SENR9698-09
345
Troubleshooting Section
g00834964
Illustration 162
Optional circuit for PTO switch on lamp
The return wire may be connected to P1-3, P1-5, or P1-18.
g01152445
STOP.
346
Troubleshooting Section
SENR9698-09
P1-63 -Battery
P1-65 -Battery
P1-67 -Battery
P1-69 -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.
Refer to Illustration 164.
Expected Result:
Result 1 The PTO switch on lamp turns on while the
jumper is connected to both sockets. Also, the PTO
switch on lamp turns off when the jumper is removed
from one of the sockets.
Result 2 The suspect lamp does not turn on while
the jumper is connected to both sockets.
Result 3 The lamp will stay on while the ECM
connector is disconnected.
Results:
Illustration 164
ECM connector P1
(30)
(48)
(52)
(53)
(55)
(63)
(65)
(67)
(69)
g01152452
SENR9698-09
347
Troubleshooting Section
Diagnostic Test
Special Test
H. Activate the special test for the PTO switch on
lamp. Observe the voltage test lamp. The lamp
should turn on when the test is active. Also, the
lamp should turn off when the test is inactive.
Note: Perform the same test procedure with terminals
P1-52, P1-53, and P1-55 unswitched +Batt.
Expected Result:
The test lamp turns on and the test lamp turns off
per the above description.
Illustration 165
g01152466
Diagnostics
Results:
348
Troubleshooting Section
SENR9698-09
SENR9698-09
Illustration 166
Typical schematic for remote accelerator pedal position sensor
The return wire may be connected to P1-3, P1-5, or P1-18.
349
Troubleshooting Section
g01042360
350
Troubleshooting Section
SENR9698-09
g01152475
STOP.
SENR9698-09
351
Troubleshooting Section
Service
Calibrations
Monitor Throttle Position Sensor
Expected Result:
Expected Result:
Results:
Results:
Test Step 3.
352
Troubleshooting Section
Results:
SENR9698-09
SENR9698-09
353
Troubleshooting Section
g00642019
Illustration 168
(1) Mounting screw holes
(2) Sensor slot
354
Troubleshooting Section
Expected Result:
When the sensor is removed from the accelerator
pedal assembly and the sensor slot is released, the
duty cycle is 10 percent or less. When the sensor slot
is moved to the maximum position, the duty cycle
increases to 90 percent or more.
Results:
SENR9698-09
Off
Low
Medium
Expected Result:
Results:
High
SENR9698-09
355
Troubleshooting Section
Engine speed is 0.
Vehicle speed is 0.
The neutral switch is in the Neutral position.
356
Troubleshooting Section
Illustration 169
SENR9698-09
g01148979
Illustration 170
Schematic for the C15 engine
g01148980
SENR9698-09
357
Troubleshooting Section
Illustration 172
P2 ECM connector for C11, C13, and C15 engines
(P2-9) Retarder solenoid return
(P2-10) Retarder solenoid MED/HI
(P2-11) Retarder solenoid LOW/HI
Illustration 171
P1 ECM connector for C11, C13, and C15 engines
(P1-5) AP sensor/switch sensor return
(P1-23) Retarder solenoid LOW/HI switch
(P1-40) Retarder solenoid MED/HI switch
g01107353
g01107356
358
Troubleshooting Section
SENR9698-09
g01098982
Illustration 173
Valve cover connectors for C11 and C13 engines
(P681-1) Retarder solenoid MED/HI
(P681-3) Retarder solenoid return
g01107406
Illustration 174
Valve cover connectors for C15 engines
(P681-10) Retarder solenoid MED/HI
(P681-11) Retarder solenoid LOW/HI
Results:
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359
Troubleshooting Section
Results:
Expected Result:
Results:
360
Troubleshooting Section
SENR9698-09
Results:
Results:
SENR9698-09
361
Troubleshooting Section
Results:
STOP.
Expected Result:
A high current diagnostic code (06) is logged at this
time.
362
Troubleshooting Section
SENR9698-09
Results:
Results:
Expected Result:
Expected Result:
Results:
SENR9698-09
363
Troubleshooting Section
Expected Result:
Results:
STOP.
Expected Result:
Expected Result:
Results:
Results:
OK
STOP.
364
Troubleshooting Section
SENR9698-09
Kickout Switches
i02049828
Neutral
SENR9698-09
365
Troubleshooting Section
Table 152
Setting For
Transmission
Style
Parameter
Switch Usage.
Service
Brake 1
Service
Brake 2
Manual
Option 1
Automatic
Option 1
Automatic
Option 2
Automatic
Option 3
Automatic
Option 4
Eaton Top 2
Clutch
Neutral
X
X
X
g00643881
Illustration 175
Schematic for cruise control switch, service brake pedal position (switch 1) and clutch pedal position switch
366
Troubleshooting Section
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:
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SENR9698-09
367
Troubleshooting Section
g00702676
Illustration 176
Results:
1))
368
Troubleshooting Section
SENR9698-09
OK
Repair: Replace the faulty switch.
Verify that the repair eliminates the problem.
STOP.
SENR9698-09
369
Troubleshooting Section
Expected Result:
The status for the Service Brake Pedal Position
Switch #1 is Off when the jumper wire is removed.
The status for the Service Brake Pedal Position
Switch #1 is On when the jumper wire is installed.
Results:
Setting For
Transmission
Style
Parameter
Switch Usage.
Service
Brake
1
Service
Brake
2
Manual
Option 1
Automatic
Option 1
Automatic
Option 2
Automatic
Option 3
Automatic
Option 4
Eaton Top 2
Clutch
Neutral
X
X
X
370
Troubleshooting Section
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g00646450
Illustration 177
Schematic for service brake pedal position (switch 2)
g00704926
Illustration 178
Terminal locations for ECM
SENR9698-09
371
Troubleshooting Section
Switch Status
Circuit
ON
Shorted
OFF
Open
372
Troubleshooting Section
SENR9698-09
Switch Status
Circuit
Terminal 64 is Open.
OFF
Open
ON
Shorted
SENR9698-09
373
Troubleshooting Section
Table for Input Status of the Service Brake Pedal Position (Switch 2)
Switch Position or Pedal Position
Switch Status
Circuit
OFF
Open
ON
Shorted
OK
Repair: Perform the following repair:
Replace the faulty switch. Verify that the repair
eliminates the problem.
STOP.
Table for Input Status of the Service Brake Pedal Position (Switch 2)
Switch Position or Pedal Position
Switch Status
Circuit
OFF
Open
ON
Shorted
374
Troubleshooting Section
SENR9698-09
i02375768
SENR9698-09
Illustration 179
Schematic for Starting Aid Output
375
Troubleshooting Section
g00681335
376
Troubleshooting Section
SENR9698-09
Illustration 180
g01105860
SENR9698-09
Personal injury or death can result from not following the proper procedures.
To avoid the possibility of injury or death, follow
the established procedure.
A. Access the Starting Aid Output Special Test on
Cat ET. The Starting Aid Output Special Test
will enable the starting aid output when the test
is active.
Disconnect the starting aid canister in order to
prevent accidental discharge.
B. Begin the Starting Aid Output Special Test and
listen for the solenoid or the relay to click. You
may need to be near the engine in order to hear
the click.
Expected Result:
The solenoid or the relay activates when the special
test is enabled.
Results:
377
Troubleshooting Section
STOP.
Expected Result:
The voltage test lamp turns On when the Starting
Aid Output Special Test is active. The voltage test
lamp turns Off when the Starting Aid Output Special
Test is disabled.
Results:
is OK.
STOP.
378
Troubleshooting Section
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i02505634
SENR9698-09
379
Troubleshooting Section
g01254431
Illustration 181
Schematic for the starting aid switch
Illustration 182
g01186024
380
Troubleshooting Section
SENR9698-09
Results:
Illustration 183
g01253945
SENR9698-09
381
Troubleshooting Section
382
Troubleshooting Section
SENR9698-09
Illustration 184
g00649121
Illustration 185
Schematic No. 2 for tachometer
g00649123
SENR9698-09
383
Troubleshooting Section
Expected Result:
RESULT 1 The dash tachometer indicates
approximately 1500 150 rpm and the dash
tachometer is stable.
RESULT 2 The tachometer does not indicate an
engine rpm or the tachometer is erratic.
RESULT 3 The tachometer rpm is stable but the
tachometer rpm is not within 50 rpm of 1500 rpm.
Results:
g01105864
Results:
STOP.
Diagnostics
Diagnostic Tests
Special Test
D. While the dash tachometer is being monitored,
begin the test.
384
Troubleshooting Section
P1-38
P1-39
Refer to Illustration 186.
C. Check the ECM connector (allen head screw) for
the proper torque of 6.0 Nm (55 lb in).
SENR9698-09
Results:
Expected Result:
Results:
Diagnostics
Diagnostic Tests
Special Test
I. Attach the positive lead of the multimeter to the
jumper wire from P1-38.
J. Attach the negative lead of the multimeter to the
jumper wire from P1-39.
K. While the Tachometer Circuit Test is being run,
observe the reading on the multimeter.
L. Turn the key switch to the OFF position.
SENR9698-09
385
Troubleshooting Section
STOP.
386
Troubleshooting Section
SENR9698-09
SENR9698-09
387
Troubleshooting Section
g00682363
Illustration 187
Schematic for torque limit switch
P1-7
P1-18
C. Check the ECM connector (allen head screw) for
the proper torque of 6.0 Nm (55 lb in).
D. Check the harness and the wiring for abrasion and
for pinch points from the battery to the ECM. Then,
check from the ignition key switch to the ECM.
Refer to Illustration 188 for terminal locations for
the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion or of pinch points.
Results:
g01105866
388
Troubleshooting Section
SENR9698-09
Expected Result:
Results:
STOP.
Expected Result:
Results:
Expected Result:
Results:
STOP.
SENR9698-09
389
Troubleshooting Section
i02375785
STOP.
390
Troubleshooting Section
SENR9698-09
Illustration 189
g01165076
g01165080
SENR9698-09
391
Troubleshooting Section
Results:
Expected Result:
Results:
Results:
Step 3.
392
Troubleshooting Section
SENR9698-09
Expected Result:
Results:
Expected Result:
Results:
SENR9698-09
393
Troubleshooting Section
Refer to Troubleshooting, Vehicle Speed Circuit Calibrate if the vehicle speed is being calibrated
in ppm (pulses per mile) or PPKM (pulses per
kilometer).
The following background information is related
to this procedure:
The vehicle speed circuit consists of the vehicle
speed source and associated wiring. The vehicle
speed source is installed by the vehicle OEM. Usually,
a sensor reads movement of the transmission output
shaft from the teeth on a chopper wheel. The Engine
Control Module (ECM) converts the signal from the
vehicle speed source into vehicle speed for the
following functions:
Cruise control
Driver reward
Speedometer
Progressive shift
394
Troubleshooting Section
P1-36 (Speedometer +)
P1-37 (Speedometer )
Note: Some speedometers require only one of the
ECM signal lines to operate. Other speedometers
may require both of the ECM signal lines to operate.
Speedometer Special Test
If the vehicle speedometer is driven by ECM output,
the speedometer circuit can be checked by using
Caterpillar Electronic Technician (ET). The 55 mph
VSP/Speedometer Test will drive the speedometer to
approximately 55 mph under the following conditions:
SENR9698-09
SENR9698-09
Illustration 191
395
Troubleshooting Section
g00643046
Schematic for a single coil speed sensor and an ECM driven speedometer
Illustration 192
g00643048
Schematic for a single coil speed sensor and a second single coil sensor for a speedometer
Illustration 193
Schematic for a single coil speed sensor and a data link driven speedometer
g00643050
396
Troubleshooting Section
Illustration 194
SENR9698-09
g00643051
Schematic for an electronic vehicle speed source and an ECM driven speedometer
Illustration 195
Schematic for an electronic vehicle speed source and a speedometer
g00643052
SENR9698-09
397
Troubleshooting Section
Illustration 196
g01105872
Expected Result:
Results:
STOP.
398
Troubleshooting Section
SENR9698-09
P1-36 (Speedometer +)
P1-37 (Speedometer )
If there is a connection to either of the speedometer
terminals continue with the procedure.
B. Connect Cat ET to the data link connector.
C. Access the 55 mph VSP/Speedometer Test by
accessing the following display screens in order:
Diagnostics
Diagnostic Tests
Special Test menu
D. Activate the test and observe the speedometer.
Note: Some types of speedometers only require one
ECM signal line to be connected to the speedometer.
Either of the ECM terminals can be used for these
speedometers.
Refer to Illustration 196.
Expected Result:
The speedometer indicates 80 to 96 km/h (50 to 60
mph).
Results:
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399
Troubleshooting Section
400
Troubleshooting Section
SENR9698-09
Illustration 197
g00643436
SENR9698-09
401
Troubleshooting Section
Diagnostics
Diagnostics
Diagnostic Tests
Diagnostic Tests
Expected Result:
Expected Result:
Results:
Results:
402
Troubleshooting Section
SENR9698-09
The lamp not only turns on, but the lamp stays on.
The lamp will flash on and off.
If the lamp turns on continuously, the engine is in
warning mode. If the lamp begins to flash, the ECM
has begun to derate engine speed, vehicle speed,
or power.
If the parameter for engine monitoring is programmed
to Warning, the lamp will not flash. The lamp only
flashes when the engine is programmed to Derate
or Shutdown.
Connecting the Warning Lamps to the ECM
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:
SENR9698-09
403
Troubleshooting Section
g01254695
Illustration 198
Schematic for the warning lamps
Illustration 199
g01186024
g01254702
404
Troubleshooting Section
SENR9698-09
the suspect lamp does not turn off per the above
description. Check that the bulb for the lamp is not
blown. Check any circuit protection that may be
tripped. If the bulb is OK and the circuit protection
is not tripped, then there is a problem in the circuit
for the suspect lamp. Proceed to Test Step 3.
Expected Result:
Results:
Expected Result:
SENR9698-09
405
Troubleshooting Section
406
Troubleshooting Section
SENR9698-09
Calibration Procedures
Table 159
Crankshaft Rotation
Engine
Model
Number of
Degrees
Direction of Rotation
C7
100
Normal Rotation
C-9
85
Normal Rotation
C-10
60
C11
75
Normal Rotation
C-12
60
C13
75
Normal Rotation
C-15
60
C15
60
C-16
60
C18
30
i02435131
(1)
Description
7X-1171
Transducer Adapter
6V-2197
Transducer
7X-1695
Cable As
170-3519
Harness
(1)
SENR9698-09
407
Troubleshooting Section
Table 160
Crankshaft
Counterweight
Engine Location
C7
Left Side
C-9
Left Side
C-10
Right Side
C11
Left Side
C-12
C13
Locations on
the 70pin P2
Connector
Locations on
the 120pin P2
Connector
Right Side
White
22
26
Left Side
Yellow
23
36
C-15
Left Side
C15
Left Side
C-16
Left Side
C18
Left Side
408
Troubleshooting Section
SENR9698-09
Expected Result:
Results:
Service
Calibrations
Timing Calibration
C. To calibrate the timing, select Continue on Cat
ET. Wait until Cat ET indicates that the timing is
calibrated.
Expected Result:
Cat ET indicates that the timing is calibrated.
Results:
STOP.
i02290105
SENR9698-09
409
Troubleshooting Section
An injector is replaced.
Service
Calibrations
Injector Trim Calibration
D. Select the appropriate cylinder.
Serial Number
Confirmation Code
1
2
5
6
Expected Result:
9
10
11
12
Expected Result:
All of the information is obtained for each injector.
Continue to the next test step.
Results:
410
Troubleshooting Section
SENR9698-09
i02502770
Cruise control
PTO operation
Vehicle speed limiting
Speedometer
Progressive shift
Idle shutdown
Operation of the air inlet heater
Secure idle theft deterrent
Trip data
Maintenance data
There are three different methods that can be used
to obtain the information for the ECM to use for
calculating vehicle speed. The ECM can calculate
vehicle speed by either of the following means:
Vehicle Speed Calibration The ECM monitors
the signal from a vehicle speed sensor in pulses
per kilometer (mile). The vehicle speed sensor is
connected to the vehicle speed input circuit (terminals
32 and 33 of the ECM).
Vehicle Speed Cal (J1939-Trans) The ECM
receives a message over the J1939 data link from
the Transmission control module that represents
revolutions per kilometer (mile) of the transmission
output shaft.
Vehicle Speed Cal (J1939-ABS) The ECM
receives a message over the J1939 data link from
the Anti-lock Brake System (ABS) that contains
information about the wheel speed.
Each of these methods require a specific calibration
number to be programmed into the ECM to calculate
vehicle speed.
SENR9698-09
411
Troubleshooting Section
Results:
STOP.
412
Troubleshooting Section
Results:
SENR9698-09
STOP.
Not OK
Repair: Reprogram the speedometer to the correct
setting for the pulses per kilometer (mile). Verify
that the speedometer is accurately reporting the
vehicle speed.
STOP.
SENR9698-09
413
Index Section
Index
Numerics
0001-05 Cylinder #1 Injector current low (72) ....... 96
0001-06 Cylinder #1 Injector current high (72) ...... 97
0002-05 Cylinder #2 Injector current low (72) ....... 97
0002-06 Cylinder #2 Injector current high (72) ...... 97
0003-05 Cylinder #3 Injector current low (73) ....... 98
0003-06 Cylinder #3 Injector current high (73) ...... 98
0004-05 Cylinder #4 Injector current low (73) ....... 99
0004-06 Cylinder #4 Injector current high (73) ...... 99
0005-05 Cylinder #5 Injector current low (74) ....... 99
0005-06 Cylinder #5 Injector current high (74) .... 100
0006-05 Cylinder #6 Injector current low (74) ..... 100
0006-06 Cylinder #6 Injector current high (74) .... 100
0022-11 Primary to Secondary Engine Speed Signal
Calibration (42) .................................................. 101
0022-13 Engine Speed Signal Calibration Not
Performed (42)................................................... 102
0030-08 PTO Throttle signal invalid (29)............. 103
0030-13 PTO Throttle out of calibration (29) ....... 103
0041-03 8 Volt Supply voltage high (21).............. 103
0041-04 8 Volt Supply voltage low (21) ............... 104
0043-02 Key Switch Fault (71) ............................ 104
0052-11 Air Inlet Shutoff Shutdown (00).............. 104
0054-05 Auxiliary Output #06 current low (66) .... 105
0054-06 Auxiliary Output #06 current high (66)... 105
0055-05 Auxiliary Output #07 current low (67) .... 106
0055-06 Auxiliary Output #07 current high (67)... 106
0064-08 Secondary Engine Speed loss of signal
(34) .................................................................... 106
0071-00 Idle Shutdown Override (01) ................. 107
0071-01 Idle Shutdown (47) ................................ 107
0071-14 PTO Shutdown (47)............................... 107
0084-00 Vehicle Overspeed Warning (41) .......... 108
0084-01 Vehicle Speed loss of signal (31) .......... 108
0084-02 Vehicle Speed signal invalid (36) .......... 109
0084-08 Vehicle Speed signal out of range (36).. 109
0084-10 Vehicle Speed signal rate of change
(36) ..................................................................... 110
0084-14 Quick Stop Occurrence .......................... 110
0091-08 Throttle Position Invalid (32)................... 110
0091-13 Throttle Position out of calibration (28)... 111
0100-01 Low Oil Pressure Warning (46) .............. 111
0100-03 Oil Pressure voltage high (24)................ 114
0100-04 Oil Pressure voltage low (24) ................. 115
0100-11 Very Low Oil Pressure (46)..................... 115
0102-03 Boost Pressure voltage high (25) ........... 119
0102-04 Boost Pressure voltage low (25) ............ 119
0105-00 High Intake Manifold Air Temperature
Warning (64) ...................................................... 120
0105-03 Intake Manifold Air Temperature voltage
high (38)............................................................. 121
0105-04 Intake Manifold Air Temperature voltage low
(38) .................................................................... 121
0105-11 Very High Intake Manifold Air Temperature
(64) .................................................................... 122
0108-03 Barometric Pressure voltage high (26).. 122
0108-04 Barometric Pressure voltage low (26) ... 123
0110-00 High Coolant Temperature Warning
(61) .................................................................... 123
414
Index Section
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415
Index Section
Engine/Gear Parameters.......................................
Eaton Top 2 Override with Cruise Switch ........
Gear Down Protection RPM Limit....................
Gear Down Protection Turn On Speed............
Governor Type.................................................
Intermediate Gears Engine RPM Limit ............
Intermediate Gears Turn Off Speed ................
Low Idle Engine RPM ......................................
Lower Gears Engine RPM Limit ......................
Lower Gears Turn Off Speed...........................
Top Gear Minus One Ratio ..............................
Top Gear Minus Two Ratio ..............................
Top Gear Ratio ................................................
Transmission Style ..........................................
Excessive Black Smoke ........................................
Probable Causes ...............................................
Recommended Actions......................................
Excessive Fuel Consumption ................................
Probable Causes ...............................................
Recommended Actions......................................
Excessive White Smoke ........................................
Probable Causes ...............................................
Recommended Actions......................................
48
49
48
48
50
48
48
48
48
48
50
50
50
48
83
83
83
84
84
84
85
85
85
F
Factory Passwords ................................................ 26
Factory Passwords Worksheet.............................. 27
Fan Override Switch Circuit - Test ....................... 265
Flash Programming ............................................... 27
Programming a Flash File.................................. 28
I
Idle Parameters ..................................................... 51
Idle RPM Limit ................................................. 52
Idle Vehicle Speed Limit .................................. 51
Idle/PTO Bump RPM ....................................... 52
Idle/PTO RPM Ramp Rate .............................. 52
Idle Shutdown Timer - Test.................................. 269
Ignition Keyswitch Circuit and Battery Supply Circuit Test .................................................................... 272
Ignore Brake/Clutch Switch Circuit - Test ............ 279
Important Safety Information ................................... 2
Injector Code - Calibrate...................................... 408
Injector Solenoid Circuit - Test............................. 282
416
Index Section
SENR9698-09
O
Output Selections ..................................................
Air Inlet Shutoff Relay Control .........................
Auxiliary Brake.................................................
Engine Running Output ...................................
Engine Shutdown Output.................................
Fan Control Type .............................................
PTO Active Output...........................................
Starting Aid Output ..........................................
57
57
57
57
57
58
58
57
P
Poor Acceleration or Response............................. 91
Probable Causes ............................................... 91
Recommended Actions...................................... 92
Powertrain Data Link Circuit - Test ...................... 322
Programming Parameters ..................................... 23
PTO Engine RPM Set Speed (Input A and Input B)
Circuit - Test....................................................... 327
PTO Shutdown Timer - Test ................................ 332
PTO Switch Circuit - Test..................................... 334
PTO Switch ON Lamp Circuit - Test .................... 343
R
N
Neutral Switch Circuit - Test ................................ 316
No Diagnostic Code Detected (55)........................ 96
SENR9698-09
417
Index Section
Table of Contents..................................................... 3
Tachometer Circuit - Test..................................... 381
Test ECM Mode ..................................................... 23
Timer Parameters .................................................. 59
A/C Switch Fan-On Time ................................. 60
Allow Idle Shutdown Override ......................... 59
Engine Retarder Delay .................................... 61
Fan with Engine Retarder in High Mode.......... 61
Idle Shutdown Time ......................................... 59
Idle Shutdown Timer Maximum RPM .............. 59
Maximum Idle Shutdown Outside
Temperature.................................................... 60
Minimum Idle Shutdown Outside
Temperature.................................................... 60
Torque Limit Switch Circuit - Test ........................ 386
Trip Parameters ..................................................... 61
Dash - Change Fuel Correction Factor............ 61
Dash - Fleet Trip Reset ................................... 62
Dash - PM 1 Reset .......................................... 61
Dash - State Selection..................................... 62
Fuel Correction Factor..................................... 61
Quick Stop Rate .............................................. 62
Theft Deterrent Password................................ 62
Theft Deterrent System Control....................... 62
Vehicle Overspeed Threshold ......................... 63
Troubleshooting Section.......................................... 6
Troubleshooting with a Diagnostic Code ............... 93
Troubleshooting without a Diagnostic Code .......... 67
Two Speed Axle Switch Circuit - Test .................. 389
V
Vehicle Activity Report Parameters ....................... 63
Minimum Idle Time .......................................... 63
Vehicle Speed and Speedometer Circuit - Test ... 393
Vehicle Speed Circuit - Calibrate......................... 410
418
Index Section
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419
Index Section
2006 Caterpillar
All Rights Reserved
Printed in U.S.A.