3406E, C-10, C-12, C-15, C-16 AND C-18 TS Manual

7/25/2019 3406E, C-10, C-12, C-15, C-16 AND C-18 TS Manual

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CATERPILLAR3406E, C-10, C-12, C-15, C-16 AND C-18 TRUCK ENGINE

TROUBLESHOOTINGTABLE OF CONTENTS

DESCRIPTION PAGE

TROUBLESHOOTING............................................................................................................................................................ 5

PROGRAMMING PARAMETERS .........................................................................................................................................

38

CUSTOMER SPECIFIED PARAMETERS .............................................................................................................................. 45

SYSTEM CONFIGURATION PARAMETERS ......................................................................................................................... 82

TROUBLESHOOTING WITHOUT A DIAGNOSTIC CODE ..................................................................................................... 83

TROUBLESHOOTING WITH A DIAGNOSTIC CODE........................................................................................................... 115

DIAGNOSTIC FUNCTIONAL TESTS .................................................................................................................................. 155

CALIBRATION PROCEDURES .......................................................................................................................................... 403

ALPHABETICAL INDEX ..................................................................................................................................................... 410


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i 0 1 6 5 8 1 4 6

Im portant S afety In form at ion

r o p e r o p e r a t i o n , l u b r i c a t io n , m a i n t e n a n c e o r r e p a i r o f t h i s p r o d u c t c a n b e d a n g e r o u s a n d

r e s u l t in i n j u r y o r d e a t h .

a n d u n d e r s t o o d t h e o p e r a t i o n , l u b r i c a t i o n , m a i n t e n a n c e a n d r e p a i r i n f o r m a t i o n .

nd wa rn ing s are prov ide d in th is manual and on the prod uct . I f these hazard

GE R", "WARNING" or "CAU TION ". The Safety Aler t "WARNING" label i s show n below.

B e c o m e A l e r t Y o u r S a f e t y i s I n v o l v e d .

a r c a n n o t a n t i c i p a t e e v e r y p o s s i b l e c i r c u m s t a n c e t h a t m i g h t in v o l v e a p o t e n t ia l h a z a r d . T h e

i n g s i n t h i s p u b l i c a t i o n a n d o n t h e p r o d u c t a r e , t h e r e f o r e , n o t a ll i n c l u s i v e . I f a t o o l, p r o c e d u r e ,

m u s t s a t i s f y y o u r s e l f th a t i t i s s a f e f o r y o u a n d f o r o t h e r s . Y o u s h o u l d a l s o e n s u r e t h a t t h e

t w i ll n o t b e d a m a g e d o r b e m a d e u n s a f e b y t h e o p e r a t io n , l u b r i c a t io n , m a i n t e n a n c e o r

ormation, spe c i f i cat ions, a nd i llus t ra t ions in th is pub l icat ion are on the b as is of in format ion tha t

asurem ents, ad justmen ts, il lus tra tions, and other items can cha ng e at any t ime. These cha nge s can

W h e n r e p l a c e m e n t p a r ts a r e r e q u i re d f o r t h is

p r o d u c t C a t e r p il la r r e c o m m e n d s u s i ng C a t e r p i l-

l a r r e p l a c e m e n t p a r t s o r p a r t s w i t h e q u i v a l e n t

s p e c i f i c a t i o n s i n c l u d i n g , b u t n o t l im i te d t o , p h y s -

i c a l d i m e n s i o n s , t y p e , s t r e n g t h a n d m a t e r i a l .

F a i l u r e t o h e e d t h i s w a r n i n g c a n l e a d t o p r e m a -

t u r e f a i l u r e s , p r o d u c t d a m a g e , p e r s o n a l i n j u r y o r

d e a t h .


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CATERPILLAR3406E, C-10, C-12, C-15, C-16 AND C-18 TRUCK ENGINE

TROUBLESHOOTINGTABLE OF CONTENTS

DESCRIPTION PAGE

SYSTEM OVERVIEW ............................................................................................................................................................. 5

GLOSSARY ......................................................................................................................................................................... 16

ELECTRONIC SERVICE TOOLS..........................................................................................................................................

23

REPLACING THE ECM ........................................................................................................................................................25

SENSORS AND ELECTRICAL CONNECTORS ....................................................................................................................27

ENGINE WIRING HARNESS DIAGRAM ...............................................................................................................................34

VEHICLE WIRING HARNESS DIAGRAM.............................................................................................................................. 36


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ronic Trou bleshoo t ing

e m O v e r v ie w

S C o d e : 1 9 00

5

Troubleshoot ing Sect ion

i 01914266

Torque curves

Other charac ter i s ti cs

The des i red eng ine speed i s t yp ica l l y determined

by one of the fol lowing condi t ions:

The pos i t i on o f the acce lera tor pedal

The des i red veh ic le speed in c ru ise cont ro l

The des i red eng ine rpm in PTO cont ro l

Timing C onsiderations

Onc e t he gov erno r has de t e rm i ned t he amoun t o f

fuel that is requi red, the governor must determine

the t iming of the fuel inject ion. Fuel inject ion t iming

is determined by the ECM af ter cons ider ing input

f rom the fo l lowing components :

Coolant Temperature Sensor

Intake Mani fold Ai r Temperature Sensor

A tm osphe r i c Pressure Sensor

Boo s t Pressure Sensor

At s tar t -up, the ECM determines the top center

pos i t ion of the number 1 cy l inder f rom the s ignal

f rom the secondary eng ine speed/ t im ing sensor .

A f ter s tar t -up, the ECM determines the top center

pos i t i on o f the number 1 cy l i nder f rom the pr imary

engine speed/ t im ing sensor . The ECM dec ides

when fuel in ject ion should occur relat ive to the top

center pos i t i on and the ECM prov ides the s igna l to

the in jector at the des i red t ime. The ECM adjusts

t im ing for the bes t eng ine per formance, the bes t

fue l economy and the bes t cont ro l o f wh i te smoke.

Ac tua l t im ing cannot be v iewed wi th the Caterp i l la r

Elect ronic Technic ian (Cat ET), and des i red t iming

cannot be v iewed wi th Cat ET.

Fue l Inject ion

The ECM controls the amount of fuel that is in jected

by vary ing the s ignals to the in jectors . The in jectors

wi l l pump fuel only i f the in jector solenoid is

energ ized. The ECM sends a h igh vo l tage s igna l

to the so leno id . Th is h igh vo l tage s igna l energ izes

the solenoid. By cont rol l ing the t iming and the

durat ion of the high vol tage s ignal , the ECM can

control in ject ion t iming and the ECM can cont rol the

amount of fuel that is in jected.

The personal i t y module ins ide the ECM sets cer ta in

l imi ts on the amount of fuel that can be in jected. The

FRC L imi t (Fue l ) i s based on the boos t pressure.

The FRC Limi t (Fuel ) is used to cont rol the ai r / fuel

rat io for cont rol of emiss ions. When the ECM senses

a h igher boos t pressure, the ECM inc reases the

FRC Limi t (Fuel ) . A higher boost pressure indicates

that there is more ai r in the cy l inder. The ECM al lows

more fue l i n to the cy l i nder when the ECM inc reases

the FRC Limit (Fuel).


5/419

m

(1) TC Reference

~ 2 Speed Timing

) Signol

L F l l

I

, Electricol Current

~ 5 ) to the Injector

Solenoid

Injection

(4) Pressure

~ . . . . ~ / .~...-." Curve

reference

Electr ical current to injector solenoid

900628178

The signals and the t iming of I llustration 1 are

C u s t o m e r P a r a m e t er s A n d E n g i n e S p e e d

G o v e r n i n g

A unique feature wi th electronic engines is customer

speci f ied parameters. These parameters al low the

vehicle owner to f ine tune the ECM for engine

operat ion. F ine tuning the ECM for engine operat ion

a l lows the veh ic le owner to accommodate the

typical usage of the vehicle and the power t rain of

the vehicle.

Many of the customer parameters provide addi t ional

restr ict ions on the act ions that wi l l be performed

by the ECM in response to the dr iver 's input. For

example, the "PTO Top Engine Limit" is an engine

rpm limit. The "PTO Top Engine Limit" is an engine

rpm limit that is used by the ECM as a cutoff for

the fuel. The ECM wil l not fuel the injectors above

this rpm.

Some parameters are intended to not i fy the dr iver

of potent ia l engine damage ("Engine Moni tor ing

Parameters") . Some parameters enhance fuel

economy ("Vehicle Speed Parameters", "Cruise

Control Parameters", "Engine/Gear Parameters" and

"Smart Id le Parameters") . Other parameters are

used to en han ce the engin e installation into the

vehicle. Other parameters are also used to provide

engine operat ing informat ion to the t ruck engine

owner.

Eng ine Mon itoring

Caterpi l lar provides a factory instal led engine

moni tor ing system. The Caterpi l lar engine moni tor ing

system moni tors engine oi l pressure, coolant

temperature, intake m ani fold ai r temperature, and

coolant level (opt ional device) . Opt ional devices are

OEM installed.

The oi l 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 opt ional component

of Caterpi l lar engine monitoring. Coolant level

is se lected through a customer programmable

parameter.

Caterp i l la r eng ine moni tor ing can be programmed

to four di f ferent modes. These four modes of

programming are the fol lowing modes: OFF,

WARNING, DERATE, and SHUTDOWN. The coolant

temperature sensor, the oi l pressure sensor and the

coolant level sensor (optional device) wil l operate in

the engine moni tor ing mode that is selected.


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sor or the coo lant leve l sensor detec ts

7

Troubleshooting Section

DER ATE O pera tion

I f t he sys tem i s programmed to DERATE, the ECM

causes the warn ing lamp to turn ON. The warn ing

lamp does not f lash. A lso, the ECM begins f lash ing

the check eng ine lamp. The f lash ing check eng ine

lamp ind icates that a prob lem has been detec ted

by the eng ine moni tor ing sys tem.

This response i s i dent i ca l to the response when the

sys tem is i n the WARNING mode.

The DERATE mode a l ters the eng ine per formance

when any of the fol lowing condi t ions ex is t :

O il p ressure beco me s Very Low Oil Pressure.

OFF , the ECM wi l l not f lag low oil pressure,

warn ings wi ll occu r even though cond i t i ons

NOV01 and newer sof tware does not a l low

p ; M D P 1 - U p ; M E P 1 - U p) .

R NING Opera t ion

Coolant level becomes Very Low Coolant Level .

Coo l an t t empera t u re bec omes H i gh Coo l an t

Temperature.

Coolant temperature becomes Very H igh Coolant

Temperature.

Whenever the warn ing lamp i s f lash ing, the ECM is

l imi t ing or derat ing the engine.

The ECM l im i t s the max imum veh ic le speed and the

ECM reduces the ava i lab le power when any o f the

fol lowing condi t ions ex is t :

H igh Coolant Temperature

H igh Coolant Temperature

High Intake Man i fold Ai r Tem perature

Lo w Oi l Pressu re

Very H igh Coolant Temperature

Very Low Coolant Leve l

I f the ECM detec ts Very Low Oi l Pressure, the ECM

l imi ts the fol lowing parameters :

Max imum veh ic le speed

Ava i lab le power

Eng ine rpm

This derat ing o f eng ine per formance i s prov ided in

order to get the dr iver 's at tent ion so the dr iver can

take ac t ion in order to avo id eng ine damage.

SHUTDO WN Op era tion

I f t he sys tem i s programmed to SHUTDOWN, the

ECM takes al l the act ion that is indicated for the

DERATE mode and the ECM wi l l eventual ly shut

down t he eng i ne und er s ome c ond it ions .

The S H UTDOWN mode w i l l s hu t down t he eng i ne

when any of the fol lowing condi t ions ex is t :

O il p ressure becom es Very Low Oil Pressure.


7/419

Temperature.

( 1 ) S t a r t / R e s t a r t

Wor nin9 Derote

Rated

i i i i i i i i i i i i i i i i i i l i l i i i i i i i i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i

o: ::::::::::30 Second:::::::::

,., :i:i:i:i:i: :i:i: :O loy: :i:i:i:i:i:i:i:i:i:

l Y l

I Z I X X X X X X X I X X X I X X I I

v . v . v . . v : : . . v . v . v . v . v , . . . v . v . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . j

0 1 0 2 0 3 0

40

Time (seconds)

Maximum rote wi l l

(2 ) not exceed I0% per

7 se co n d .

(3)

Shutdown

I

50 6 0

/

tion 2 g00628179

engine m onitoring coolant temperature

tart or Restart warning derate

maxim um rate will not exceed 10 percent per second.

Shutdown

0

eL .

(Deg

(De9

Temperature Ef fect

Maximum rote wi l l

n o t

exceed 10% per

second.

Rated ,~

- 2 5 %

-50%-

-7 5% - 160 ho (119kW}

45 mph (72.5 kin/h)

- 1 0 0 %

,

( 1 ) S h u t

o w n

F ) 2 1 6 2 1 7 2 1 9 2 2 1 2 2 3 2 3 0

C) 102 10 ) 104 105 106 110

C o o l a n t T e m p e r a t u r e

tion 3 g00628181

and C-12 Graph of en gine mon itoring coolant temperature

Rated

- 2 5 %

)

-

5 0 % .

0

o . - 75g "

- I 0 0 %

( D e q F )

( D e g C )

Temperature Ef fect

Maximum rote wi l l

'~- not exce ed 10% p e r

I second.

I I I

225 226 228 230 233

107 108 109 110 111

160 ho (119kW)

45 mph (72 .5 k in /h )

1 - ' " _ ( 1 ) S h . t d o w n

2 ) 4

I 1 2

C o o l a n t

Temperature

tion 4 g00628184

E, C-15 , C-16 and C -18 Graph of en gine monitoring coolant

Low Level Ef fect

(1) Wornin9

D e ro t e '~ Ma ximu m ro t e w il l

Rated ~ (2) not ex ce ed 10% per

~ second.

160 hp (11 9 kW}

45 mph (72.5 kin/h)

k

Q

(3 ) Shutdown

I I

Low Very

Low

illustra tion 5 g00628189

Graph of engine m onitoring coolant level

(1) W arning derate

(2) The max imum rate will not exceed 10 percent per second.

(3) Shutdown

Maximum rote will

n o t exc eed lOg per

(1~ Star t /R es ta rt second.

"" ~ ~ ~ W a r n i n gr i p p e d ~ : 7 /

R t e d ~ ~ ~ l G O hp (119 kW)

~(Smph(72.Skm/h)

,.

I

o J~,~.30 Se c0 nd T/~ ~L~.~, ~ l

T ime (seconds) (2) Shutdown

Illustration 6

Graph of engine m onitoring coolant level t ime

(1) S tart or Restart warning tripped

(2) Shutdown

g00628190


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9

T r o u b l e s h o o t i n g S e c t i o n

25

2C

~-~-15

4" 10

8

(1)

j J ~

Low Oi l Pressure j ~_

/ ' ( 2 ) V ery Low Oi l Pressure

/ / /

/

. . . . . . J

1000 1500 2000

E n g i n e r p m

7 g00732031

3O

27

2 4

~ 2 1

G, 18

15

~-

12

o 9

3

0

100

( 1 ) Lo w O i l P r e s s u r e

o w O i l P r e s s u r e

6 0 0 1 0 0 0 1 5 0 0 2 0 0 0

En g i n e r p m

tion 8 g00628191

oil pressure

5 0

45

40

~ 35

0 .

G, 30

L .

~, 25

O~

P

. 2 0

o 15

10

5

0

( 1 )

L o w O i l P r e s s u r e

P r e s s u r e

100 6 00 1000 1500 2 000

En g i n e r p m

Illustration 9

3406E, C-15, C-16 and C -18 Graph of low oil pressure

(1) Low oil pressure

(2) V ery low oil pressure

g00628192

16o

(119 kW)

45 m p h

( 72 .5 km /h )

1350 r p m

S t o r t / R e s t o r t

~

) W a r n i n g De r o t e

/ ~ ( 2 )

Shutdown

/ I /

0

10 20

30 40 50

Time

( s e c o n d s )

I

6O

Illustration 10

Graph of Very low oil pressure start-up or resta rt

(1) Warning derate

(2) Shutdown

g00628193

Mon ito ring Fu e l Tem per a tu re

T h e f u e l t e m p e r a t u r e s e n s o r m o n i t o r s t h e f u e l

tem pera tu re . T he fue l ra te tha t i s ca lcu la ted by

t h e E C M i s a d j u s t e d i n o r d e r t o c o m p e n s a t e f o r

changes in fue l t empera tu re . The fue l ra te i s a lso

a d j u s t e d f o r c o n s t a n t p o w e r . T h e s e n s o r i s a l s o u s e d

t o w a r n t h e o p e r a t o r o f e x c e s s i v e f u e l t e m p e r a t u r e

w i t h a d i a g n o s t i c e v e n t c o d e b e c a u s e e x c e s s i v e

f u e l t e m p e r a t u r e s c a n a d v e r s e l y a f f e c t e n g i n e

p e r f o r m a n c e . C a t E T c a n b e u s e d t o t e m p o r a r i l y

d i s a b l e t h e a d j u s t m e n t o f f u e l t e m p e r a t u r e . T h i s

c o u l d b e n e c e s s a r y f o r t e s t i n g a v e h i c l e o n a

d y n a m o m e t e r w i t h f u e l t e m p e r a t u r e c o m p e n s a t i o n .


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0

e d i agnos t i c c odes requ ire pas s w ords t o

E n g i n e S n a p s h o t D a t a

Whenever mos t d iagnos t i c codes occur , the ECM

records the t ime in eng ine hours o f the occur rence.

A lso, the ECM records the operat ing parameters o f

the eng ine for 9 .6 seconds before the d iagnos t i c

c ode and 3 . 4 s ec onds a f t e r t he d i agnos t i c c ode .

The operat ing parameters o f the eng ine that are

recorded are s im i lar to the operat ing parameters o f

the eng ine that are d isp layed in the s ta tus sc reens

on Cat ET. Not al l of the s tatus screens on Cat ET

or pa ramet e rs a re rec o rded . The E ng i ne S naps ho t

can a lso be t r i ggered f rom the Cru ise Cont ro l

Set /Resume swi tch. In order to t r i gger the Engine

Snapshot f rom the Cru ise Cont ro l Set /Resume

swi tch, quick ly toggle the swi tch to the Set pos i t ion.

Then, qu ick ly togg le the swi tch to the Resume

posi t ion. You can also toggle the Cruise Control

Set /Resume swi tch f rom the Resume pos i t i on to

the Set pos i t i on . The Engine Snapshot can a lso be

t r iggered f rom Cat ET.

E f f e c t O f D i a g n o s t i c C o d e s O n

E n g in e P e r fo r m a n c e

The d iscuss ion on eng ine moni tor ing ment ions that

the check Engine Lamp f lashes when a spec i f i c

cond i t i on ex is ts . When the ECM detec ts the eng ine

prob lem, the ECM generates an ac t i ve d iagnos t i c

code. A lso, the ECM logs the d iagnos t i c code

in order to ind icate the t ime of the prob lem's

occur rence. The ECM a lso logs the number o f

occur rences o f the prob lem. There are two types o f

d iagnos t i c codes . There are fau l t codes and event

c odes .

D i a g n o s t ic F a u l t C o d e s

Diagnos t i c fau l t codes are prov ided in order to

indicate that an elect r ical problem or an elect ronic

prob lem has been detec ted by the ECM. In some

cases , the eng ine per formance can be a f fec ted

when the cond i t i on that i s caus ing the code ex is ts .

More f requent ly , the dr iver cannot detect any

d i f fe rence in the eng ine per formance.

I f the check eng ine lamp i s f lash ing and the dr i ver

ind icates that a per formance prob lem occurs , the

d iagnos t i c code may ind icate the cause o f the

prob lem. The prob lem should be cor rec ted.

I f the dr iver does not indicate a problem wi th

t he eng i ne pe r f o rmanc e and a d i agnos t i c c ode

is logged by the ECM, the s i tuat ion indicates

that the ECM detec ted an abnormal cond i t i on,

but the abnormal cond i t i on d id not a f fec t eng ine

per formance.

In th is s i tuat ion, the system has no faul ts except

when ei ther of the fol lowing condi t ions ex is t :


10/419

code in a very short per iod of t ime.

11


present t ime.

ic Ev ent Co des

84-00 Vehic le Oversp eed W arn ing

100-11 V ery Lo w Oi l Pressu re

105-11 Very H igh Intake Man i fold Ai r Tem perature

110-11 Very H igh Coo lant Tem perature

111-11 Very Lo w Coo lant Level

190 -00 Engine Ove rspee d Warn ing

"Total T ime" (Eng ine Ho urs)

"Total Dis tance" Data requi res a vehic le speed

sensor or an e lec t ron ic veh ic le speed source to be

connec ted to the ECM. The same sensor i s used for

ECM veh ic le speed. Dis tance can be d isp layed in

mi les or k i lometers .

"PTO T ime" and "PTO Fuel " are logged when the

engine rpm i s set by the use o f the c ru ise swi tches

and the eng ine i s operat ing under some load. A lso,

"PTO T ime" and "PTO Fuel " are logged when the

PTO On/Of f Sw i tch is in the Q N po s i t ion a nd veh ic le

speed i s wi th in the range o f the "PTO Vehic le Speed

Limit" Parameter.

" Id le T ime" and " Id le Fue l " can inc lude operat ing

t ime when al l of the fol lowing condi t ions are met :

When eng ine speed i s set by us ing the c ru ise

swi tches and the veh ic le speed i s wi th in the

range of the " Id le Vehic le Speed Limi t " Parameter.

The eng ine i s not operat ing under a load.

Fuel Informat ion can be displayed in US Gal lons

or liters.

"Total Fuel" is the total amount of fuel that is

consumed by the eng ine dur ing operat ion.

"Total Max Fuel" is the maximum amount of fuel that

c ou l d hav e been c ons umed by t he eng i ne du r i ng

operat ion.

"Average Load Fac tor " prov ides re la t i ve eng ine

operat ing in format ion. "Average Load Fac tor "

compares ac tua l eng ine operat ion in format ion to

the maximum engine operat ion that is avai lable.

"Average L oad F ac tor" i s determ ined by us ing

"Total Ma x Fuel", "Id le Fuel", a nd "To tal Fuel".

A l l of these parameters are avai lable on Cat ET.

These parameters are ava i lab le wi th in the menu for

"Current Totals".

T r ip D a t a T h a t I s S t o r e d In T h e E C M

The Trip d ata a l lows the t rack ing o f eng ine operat ion

by the vehic le owner over intervals that are def ined

by the vehic le owner. Two types of Tr ip Data are

stored in the ECM, Dr iver Tr ip Data and F leet Tr ip

Data. Al l of the Tr ip Data is s tored in memory and

the Tr ip Data i s main ta ined through the Unswi tched

Bat tery L ines when the igni t ion swi tch is OFF An

internal bat tery wi l l maintain th is informat ion whi le

the Unswi tched Bat tery L ines are d isconnec ted.

Driver Tr ip Data

Driver Tr ip Data is known as the Dr iver Tr ip

Segment . The Dr iver Tr ip Segment inc ludes data for

the fol lowing parameters :

Total Time


11/419

2

Idle Time

PTO Time

Percent PTO T ime

Max imum Vehic le Spe ed

Max i mum E ng i ne S peed

End Time

Start Odo meter

E nd Odom et e r

ip Da t a

ip Se gmen t exce pt that the F leet Trip Se gme nt can

Three h is tograms are ava i lab le . One h is togram

records eng ine hours versus the eng ine speed. The

s ec ond h i s t og ram rec o rds eng i ne hours v e rs us

veh ic le speed. The th i rd h i s togram records eng ine

hours v e rs us eng i ne s peed and v eh i c l e s peed .

Cat ET ca lcu la tes the percentage o f t ime that i s

spent i n each o f the eng ine rpm or veh ic le speed

ranges . Cus tom Data i s ava i lab le . Cus tom Data

a l lows the record ing o f eng ine parameters that are

spec i f i ed by the veh ic le owner . The ECM records

the Cus tom Data.

A reset of the F leet Tr ip Data which inc ludes the

F leet Trip Segme nt , the H is tograms, and the C us tom

Data can be done in severa l ways . The fo l lowing

tools can be used to reset the F leet Tr ip Data:

Ca t E T wh i c h m ay requ ire Cus tomer Pas s w ords

Caterpi l lar F leet Informat ion Sof tware (FIS)

CAT ID which requ i res Cus tomer Parameters

Prog rammi ng t o p rov i de ac c es s

When the data i s reset , the ECM records the Current

Totals at the t ime of the reset . These Totals are used

as the s tart ing point for the F leet Tr ip. The fol lowing

too ls access the recorded s tar t i ng po in t :

Cat ET

Caterp i l lar F leet Informat ion Sof tware (FIS)

CAT I D

The too l then subt rac ts the recorded s tar t i ng po in t

f rom the Current Totals in the ECM in order to

calculate the F leet Tr ip Data. Reset t ing the F leet Tr ip

Da t a requ i res Cus t omer p as s wo rds i f t he pas s w ords

are p rog rammed.

F l e e t T rip C u s t o m D a t a

Fleet Tr ip Custom Data is part of the F leet Tr ip

Segment . F leet Tr ip Cus tom Data a l lows the owner

of the vehic le to set f ive customized methods of

recording data for the vehic le. Refer to I l lus t rat ion

11 for the bas ic program.


12/419

S U M

1 W H EN I S B E T W E E N

A N D 4 A N D W H E N 5

I S B E TW E E N _ A N D 7

13


11 g0062819 4

"Dis tan ce Traveled"

Refer to the example o f a Cus tom Data program, as

shown be low.

" F u e l B u r n e d w h e n F u e l T e m p e r a t u r e is b e t w e e n

7 a n d 6 7 C ( 4 5 a n d 1 2 0 F ) a n d V e h i c l e S p e e d

is b e t w e e n 8 7 a n d 1 3 7 k m / h ( 5 5 a n d 8 5 m p h ) "

The Cus tom Data programs are pro tec ted by

Cus tomer Passwords . The programs are s tored in

permanent memory . The programs are not reset

when the F leet Tr ip Segment is reset , but the data

that is recorded for the Tr ip is reset .

F u e l C o r r e c t i o n F a c t o r

A F ue l Co rrect ion Fa ctor is avai lab le for f ine

tun ing the ca lcu la t ions for fue l consumpt ion. The

Fuel Correc t ion Fac tor i s pro tec ted by Cus tomer

Pa sswords . The Fuel Correc t ion Fa c tor enha nces

the accu racy o f the ca lcu la t ion for fue l consum pt ion.

A l ter ing the Fue l Correc t ion Fac tor doe s not a ffec t

data that is al ready s tored in the ECM. Al ter ing

the F ue l Correc t ion Fac tor on ly a f fec ts d ata that i s

s tored in the ECM af ter the Fue l Correc t ion Fac tor

is entered.

N o te: The Fue l Correc t ion Fa c tor shou ld be ad jus ted

by the use of a long interval , data f rom the fuel tank

and recorded data in the ECM.

Q u i c k S t o p R a t e

A Customer Parameter is avai lable in order to

rec o rd t he Q u i c k S t op oc c u r renc es . The Paramet e r

determines the ra te o f change in veh ic le speed that

E ng i ne RPM

F uel Temperature

Inlet M ani fold Ai r Temperature

PTO

Engine Retarder

i s used b y the E CM in order to record a Q u ick S top

Event Co de an d a Q u ick S top Snapshot . Refer to

Troubleshoot ing, "ECM Snapshot " .

M a i n t e n a n c e I n d i c a t o r D a t a

The ECM records the Current Tota ls when a reset

occurs for the fol lowing three levels of maintenance:

P M 1

P M 2

Cool ing System Clean/F lush

The ECM uses the prev ious po in t o f main tenance in

order to ca lcu la te the t im ing o f the nex t scheduled

maintenance work .

The ma i n t enanc e I nd i c a t o r mode i s p rog rammab l e

to hours or d i s tance. The PM1 main tenance i s

programmable to the Of f , Automat i c Dis tance,

Automat i c Hours , Manual D is tance, or Manual

Hours set t i ng.


13/419

4

ainten ance interval. I f the

CM a lso uses the E ngine Oi l Capac i ty .

An avai lable feature of the CAT ID is the Thef t

Deterrent . The Thef t Deterrent al lows the dr iver

to input a password pr ior to shutdown. The Thef t

Deterrent wi l l prevent the engine f rom restart ing

unt i l the password is successful ly entered. The CAT

ID mus t have the vers ion o f so f tware that is capa ble

of support ing th is feature.

An "Auto-Enable" opt ion is avai lable as a Thef t

Deter rent on Personal i t y Modules which are dated

OCT99 and newer. I f th is opt ion is selected,

the Thef t Deterrent Feature wi l l automat ical ly be

ac t i va ted when the eng ine i s shut down. The dr i ver

mus t i nput the cor rec t password in order to s tar t

the eng ine.

"Secure Idle" is another Thef t Deterrent Feature.

Th is a l lows the dr i ver to br ing the eng ine to an id le

condi t i on. The dr i ver then enters the password. The

engine wi l l remain at low id le unt i l the password is

re-entered. I f t he eng ine i s shutdown, a password

wi l l be requi red to go above low id le af ter s tart -up.

F l e e t In f o r m a t io n S o f t w a r e ( F I S )

The Caterpi l lar F leet Informat ion Sof tware (FIS) is

another method that can be used to rev iew the t r i p

informat ion. The ent i re F leet Tr ip Segment , which

inc ludes the fo l lowing e lements o f data can be

accessed wi th the Caterp i l la r F IS :

H i s t og rams

Cus tom Data

In format ion that is tag ge d by the ID cod e

Informat ion that is tag ge d by the s tate of t ravel

Main tenance Ind icator i n format ion can a lso be

accessed by the use o f the Caterp i l la r F IS .

When the Caterp i l la r F IS downloads the in format ion,

the Caterpi l lar FIS also resets the ECM in order to

prepare the ECM for the next t r ip. The informat ion

c an be down l oaded t o a c ompu t e r w i t h t he

Caterp i l lar FIS prog ram , or the informat ion can b e

downloaded to an Argo Mobi le Data Tool (MDT) .

The Argo Mobi le Data Tool (MDT) i s then connec ted

to a computer i n order to download the in format ion.


14/419

r R eward Feature automat i ca ll y ad jus ts the

ner 's spec i f i ca tions , the VSL i s automat i ca ll y

i r e le s s C o m m u n i c a t io n E n a b le "

Curre nt Totals

Fleet Trip Da ta

E c onomy Mode l

ar F IS . The f reque ncy and

15


P r o g r a m m a b l e P a r a m e t e r s

Cer ta in parameters that a f fec t the eng ine operat ion

may be changed wi th Cat ET. The parameters

are s tored in the ECM, and the parameters

are pro tec ted f rom unauthor i zed changes by

passwords . These parameters are e i ther Sys tem

Conf igurat ion Parameters or Cus tomer Parameters .

Sys tem Conf igurat ion Parameters are set a t the

factory . System Conf igurat ion Parameters af fect

emiss ions or power rat ings wi th in an engine fami ly .

Fac tory Passwords mus t be obta ined and fac tory

Pas s words mus t be us ed t o c hange t he S y s t em

Conf igurat ion Parameters .

Cus tomer Parameters are var iab le . Cus tomer

Parameters can be used to a f fec t the fo l lowing

character is t ics of the engine wi th in the l imi ts that

are set by the factory , Caterpi l lar Engine Moni tor ing,

and PTO operat ion:

Cruise cont rol

Vehic le speed l imi ts

Progress ive shi f t ing

RPM ra t ings

Pow er ra t ings

Cus t omer Pas s words may be requ i red t o c hange

Cus tomer Spec i f i ed Parameters .

Some of the parameters may a f fec t eng ine operat ion

in an unusual way. A dr iver might not expect th is

type of ef fect . Wi thout adequate t ra in ing, these

parameters may lead to power compla in ts or

pe r f o rmanc e c omp l a i n t s ev en t hough t he eng i ne ' s

performance is to the spec i f icat ion.

Refer to Troub leshoot ing, "Cus tomer Spec i f i ed

Parameters" .

P a s s w o r d s

Sys tem Conf igurat ion Parameters are pro tec ted

by Fac tory Passwords . Fac tory passwords are

ca lcu la ted on a computer sys tem that i s ava i lab le

on ly to Caterp i l la r dea lers . S ince fac tory passwords

conta in a lphabet i c charac ters , on ly Cat ET may

change Sys tem Conf igurat ion Parameters . Sys tem

Conf igurat ion Parameters a f fec t the power ra t ing

fami ly or emiss ions.

Cus tomer Parameters can be pro tec ted by

Cus t omer P as s words . The Cus t omer Pas s words a re

p rog rammed by t he c us t omer . F ac t o ry Pas s words

can be used to change Cus tomer Passwords i f

Cus tomer Passwords are los t .


15/419

6

i 01909059

1 9 0 0

C H i gh P res s u re S w i tc h - The A /C h i gh p res s u re

- A d v a n c e d C o m b u s ti o n E m is s io n s

ve Diagnos t ic Co de - A n ac t ive d iagno s t i c code

Af tercooler - An ai r - to-ai r af tercooler is

Amer ican Wi re Gauge (AWG) - AWG is a measure

of the diameter of e lect r ical wi re. AWG is also

a measure o f the cur rent car ry ing capac i t y o f

elect r ical wi re. When the AWG number is smal ler ,

the diameter of the wi re is larger. When the AWG

number is larger, the diameter of the wi re is smal ler .

Analog Sensors - A na l og s ens ors p roduc e a DC

output s igna l . The sensors detec t changes in

temperature or pressure. The change i s conver ted

by the sensor to an elect r ical s ignal .

A n a l og S e n s o r R e t ur n - T h e c o m m o n l in e ( g r o un d )

for the ana log sensor f rom the ECM is used as a

ground for the ana log sensors .

Analog Sen sor Supply - The +5 vo lt supp ly from

the ECM prov ides power to the ana log sensors .

Ant i -Lock Brake Sys tem (ABS) - An ant i - lock brake

sys tem is a brake sys tem that a t tempts to reduce a

sk id dur ing brake operat ion. A p ow er t ra in e lec t ron ic

control can turn of f the engine retarder, i f necessary.

Also, a power t ra in elect ronic cont rol can s ignal the

engine ECM to deac t i va te the eng ine re tarder .

ATA

Da ta L ink (Am er ican T ruck ing Associa t ion ) -

T h e

ATA data l ink is a two wi re elect r ical connect ion

for communicat ion wi th o ther mic roprocessor

based dev ices . These dev ices are compat ib le wi th

Standards for the Amer ican Truck ing Assoc ia t ion

and S t andards f o r t he S A E (J 1 5 8 7 and J 1 70 8 ) s uc h

as t r ip recorders , e lec t ron ic da shbo ards , p ow er

t ra in cont ro ls , and main tenance sys tems. The

data l i nk i s a lso the ser ia l communicat ion medium

that i s used for programming and t roub leshoot ing

Caterp i l la r t ruck eng ines .

A t mos pher ic P res s u re S ens or - The a t mos pher i c

pressure sensor measures baromet r i c pressure.

The sensor sends a s igna l to the Engine Cont ro l

Module (ECM). The s igna l i s used in eng ine cont ro l

and in eng ine operat ion.

Aux i li a ry Pressure Senso r - Th is sensor i s an

addi t i ona l pressure sensor that i s i ns ta l led by the

engine owner .

Aux i l i a ry Retarder Relay - The brakes ' so leno ids

are dr iven by an OEM instal led relay, which is dr iven

by the ECM.

Aux i l i a ry Temperature Sensor - Th is sensor i s an

addi t ional temperature sensor that is ins tal led by

the eng ine owner .

Before Top Center (BTC) - BTC i s the 180 degrees

of c rankshaf t ro ta t ion before the p is ton reaches

the top center pos i t ion in the normal di rect ion of

rotat ion.


16/419

17

T r o u b l e s h o o t i n g S e c t i o n

- T h e d i ff e renc e be t ween t he t u rboc harge r

- The boos t pressure sensor

Ci rcui t - A bypass c i rcui t is a c i rcui t that is

a t ion -C al ib ra t i on i s an e lec t ron ic ad jus tment

D r i v e r I n f o r m a t i o n D i s p l a y ( C A T I D ) -

Caterpi l lar Dr iver Informat ion Display is a

E l e c t ro n i c T e c h n i c i a n ( C a t E T ) - Cat ET

E n g i n e M o n i t o r i n g - Caterpi l lar Engine

Pedal Pos i t ion Swi tch - T h e swi tch is

- Refer to the Diagnos t i c Fau l t Code and the

Cold Mode - Co ld mode i s a mode for co ld s tar t i ng

and for co ld eng ine operat ion that i nc ludes t im ing

that is retarded and low id le that is ra ised. This

mode i s used for eng ine pro tec t ion, reduced smoke

emiss ions and fas ter warm up t ime.

Com municat ion Adapter Tool - The commu nicat ion

adapter prov ides a communicat ion l i nk between the

ECM and Cat ET.

Cont ro l Area Network (CAN) Data L ink - The CAN

Data Link is a ser ia l communicat ions port that is

used for communicat ion wi th o ther mic roprocessor

base d dev ices . Th is i s a lso re fer red to as the J 193 9

Data Link.

C o o l a n t L e v e l S e n s o r - This OEM instal led sensor

detec ts the absence or presence o f coo lant a t the

probe. The sensor then sends a s igna l to the ECM.

C o o l a n t T e m p e r a t u r e S e n s o r - Th is sensor detec ts

the eng ine coo lant

temperature

or Co l d Mode

operat ion and the Caterp i l la r Eng ine Moni tor ing.

The Caterp i l la r Eng ine Moni tor ing mus t be enabled

for the coo lant temperature sensor to be used for

moni tor ing purposes .

C o o l i n g F a n Overr ide Swi tch - This swi tch overr ides

control of the cool ing fan relay so the cool ing fan

operates cont inuous ly . Th is swi tch i s supp l ied and

instal led by the OEM.

C o o l i n g F a n Relay -Th is re lay i s cont ro l led by

the ECM which uses in format ion f rom the coo lant

temperature sensor , the eng ine re tarder and the

ai r condi t ioning high pressure swi tch. The ai r

cond i t i on ing h igh pressure swi tch i s not a lways

instal led. The relay and the ai r condi t ioning high

pressure swi tch i s supp l ied and ins ta l led by the

OEM.

Crankshaf t Pos i t ion Sensor - Refer to Pr imary

Engine Speed/Timing Sensor.

Cru ise Cont ro l Range - The c ru ise contro l range

is the speed range that i s moni tored by the c ru ise

control . This speed range is typical ly the ant ic ipated

speed range on the open road. The c ru ise cont ro l

range can be programmed wi th the low c ru ise l im i t

and the high cruise l imit .

Custom Data - Custom data is part of the f leet t r ip

data that is s tored in the E C M This capabi l it y a l lows

the veh ic le owner to spec i f y operat ing

parameters

f o r moni tor ing purposes whi le the eng ine i s i n

service.

Cus tomer Spec i f i ed Parameter - A Cus t omer

Spec i f i ed Parameter i s a va lue that can be set and

changed by the cus tomer . The parameters can be

pro t ec t ed by Cus t omer Pas s words .


17/419

8

- T h e d e s i r e d e n g i n e s p e e d

RPM -The des i red rpm i s i npu t t o t he

on sensor , the e ng ine spe ed sensor , the c ru ise

Fault Co de - A d iagnos t i c fau lt cod e

F lash Cod e - The d iagnos t i c f lash code s

Lamp - A d iagnos t i c lamp i s some t imes

i ta l S ens or Re t u rn - T h e c omm on l ine (g round)

it al S ens or S upp l y - T h e s upp l y f rom t he E CM i s

by Deu t s c h .

he t ransmiss ion. The s ensor co nta ins two co il s .

Cyc le - Refer to Pulse Width Mod ulat ion.

E lec tron ic Engine Cont ro l - T h e e lec t ron ic eng ine

control is a complete elect ronic system. The

elec t ron ic eng ine cont ro l moni tors the eng ine

operat ion under al l condi t ions. The elect ronic

eng ine cont ro l a lso cont ro ls the eng ine operat ion

under al l condi t ions.

Elect ronic Serv ice Tool - Refer to "Caterpi l lar

Elect ronic Technic ian" (Cat ET).

Elect ronical ly Control led Uni t In jector - The

elect ronical ly cont rol led uni t in jector is an

in jec t ion pump which i s a mechanica l l y ac tuated,

elect ronical ly cont rol led uni t in jector. This uni t

combines the pumping, e lec t ron ic fue l meter ing

and in ject ing elements in a s ingle uni t .

Eng ine Cont ro l Module (ECM) - The ECM is the

engine 's cont ro l computer . The ECM prov ides power

to the elect ronics. The ECM moni tors data that is

input f rom the eng ine 's sensors . The ECM ac ts as a

governor in order to cont ro l eng ine rpm.

Engine Coolant D iverter - The eng ine coo lant

diverter is a normal ly open valve that al lows coolant

to f low through a radiator that cools the intake ai r .

The rad ia tor i s located a f ter the turbochargers

and before the ai r - to-ai r af tercooler. Energiz ing

the so leno id prevents the f low of coo lant through

the rad ia tor i n order to prevent overcoo l ing o f the

engine when co ld ambient a i r temperatures ex is t .

Eng ine M oni toring S y s t e m - The Engine Moni tor ing

Sys tem is a programmable sys tem that a l lows the

ECM to take ac t ions i f an eng ine param eter i s out o f

a certain range. The act ions are Warning, Derate,

and S hu t down.

Engine Oil Pressure Sen sor - Th is sensor mea sures

engine o i l p ressure and the sensor sends a s igna l

to the ECM.

Engine Retarder So leno ids - The eng ine re tarder

so leno ids are ins ta l led by Caterp i l la r and the

so leno ids are dr i ven by the ECM. These so leno ids

are used in place of relays such as the aux i l iary

brake that is ins tal led by the OEM.

E ng i ne S peed / T im i ng S ens or -T h i s s ens or p rov ides

a var iab le ampl i tude and Pu lse Width Modula ted

s ignal to the ECM. The ECM interprets th is s ignal as

the c rankshaf t pos i t i on and the eng ine speed.

E r a s a b le P r o g r a m m a b l e R e a d O n ly M e m o r y

(E PRO M) - A n E PROM is a t y pe o f c ompu t e r

memory ch ip .

Est imated Dynam ic T iming - The es t imated dyn am ic

t iming is the est imate that is prov ided by the ECM

of the actual in ject ion t iming.


18/419

1 9


us t Brake Relay - The brake so leno ids are

y an O EM ins ta l led re lay , wh ich i s dr i ven

( F M I ) - This Ident i f ier

normal operat ional range

1 The data i s va lid but the data i s be low the

normal operat ional range

2 The d ata is errat ic , intermi t tent , or incorrect .

shor ted h igh

shor ted low

5 The current is below normal or the c i rcui t is

o p e n

g r o u n d e d

proper ly

9 A bnorma l upd a t e

10 Abnorm al ra te o f chan ge

11 The fai lure m ode is not iden t i f iable

1 2 Dam aged dev i c e o r c ompo nen t

13 The dev ice or the compo nent i s not ca l ib ra ted

14 and 15 These loc at ions are reserve d for a

fu ture ass ignment

F lash Code (FC) - The flash co des are propr ie tary

Caterp i l la r code numbers that are f lashed on the

d iagnos t i c lamp. The f lash codes are f lashed on the

check eng ine lamp. These f lash codes ind icate a

mal func t ion in the e lec t ron ic sys tem or an eve nt that

i s detec ted by the ECM.

F lash Programm ing - F lash program ming i s the

met hod o f p rog rammi ng o r upda t i ng an E CM w i t h

Cat ET over the data l i nk ins tead o f rep lac ing

com ponen ts . F lash program ming ins ta l ls the

spec i f i c Personal i t y Module that i s used to cont ro l

the eng ine. The Personal i t y Module conta ins

spec i f i c per formance maps and features for a

selected rat ing.

F leet Informat ion Sof tware (FIS) - F IS is a sof tware

program that operates on a personal computer

(PC) . Th is program a l lows the user to rev iew the

t r ip informat ion. The pro gram also al lows the user

to reset the t r i p i n format ion which inc ludes the

Maintenance Ind icator i n format ion.

Fue l Pos i t i on -Th is i s an in terna l s igna l w i th in

the ECM. The s igna l comes f rom the e lec t ron ic

governor and the s igna l then goes to the fue l

in ject ion cont rol . The informat ion that is gathered

is based on the Des i red RPM, the FRC L imi t , the

Rated Fu e l L im it , and the ac tua l eng ine rpm.

Fuel Rat io Con trol (FRC) - The F RC is a l imi t that

is based on the cont rol of the fuel to ai r rat io. The

FRC is used for purp ose s o f emiss ion contro l. When

the ECM senses a h igher boos t pressure (more a i r

i n to the cy l i nder ) , the FRC inc reases the FRC L imi t

(more fuel into the cy l inder) .

Fue l Temperature Sensor - Th is sensor detec ts

the fuel temperature. The ECM moni tors the fuel

temperature and the ECM adjus ts the ca lcu la ted

fuel rate accordingly .

F u ll Load S e tt ing (F LS ) - T h e F LS is t he number

that represents the fuel system adjustment . This

ad jus tment i s made at the fac tory in order to he lp

ensure the m ax imum fue l d e l i very o f the fue l sys tem.

The cor rec t va lue for th i s parameter i s s tamped on

the eng ine in format ion ra t ings p la te . Th is parameter

mus t be program med . I f the param eters are not

p rog rammed, t he d i agnos t i c c ode t ha t i s 2 5 3 -0 2

Check Cus tomer or Sys tem Parameters wi l l be

act ive.

Ful l Torque Set t ing (FTS) - The FTS is s imi lar to

the Fu l l Load Set t ing. Th is param eter m us t be

programm ed. If the parameters are not program me d

t he d i agnos t i c c ode t ha t i s 2 5 3 -0 2 Chec k Cus t omer

or Sys tem Parameters wi l l be ac t i ve .

Gear Down Protec t ion - Th is feature cons is ts o f the

H i g h Gear L imi ts that are programmable. H igh Gear

L imi ts are used in order to promote dr i v ing in h igher

gears for increased fuel economy.


19/419

0

( H z ) - Hertz is the measure of e lect r ical

u re O il Man i fo l d - T h e h i gh p res s u re

il Pum p - The h igh pre ssure o il

ec tor (HEU I ) - T h e HEUI is an in jec t ion pu mp

e Shutdo wn T ime - Th is prog ram mab le

e / PTO Bum p rpm -T h i s p rog ramm ab l e pa ramet e r

ion Actuat ion P ressu re Con trol Valve - This is a

ec t ion Ac tuat ion Pressure S ensor

-

An elect r ical

In jector Co de s - The in jector cod es or in jector tr im

c odes a re numer i c c odes o r a l phanumer i c c odes

that are e tched or s tamped on ind iv idua l i n jec tors .

These codes are used to f ine tune the fuel del ivery .

Injector Trim F i les - Injector tr im f i les are

downloaded f rom a d isk to the ECM. The t r im f i les

compensate for var iances in manufac tur ing o f the

injector. The engine ser ia l number must be know in

order to obtain the correct t r im f i le.

Intake Mani fold Ai r Tem perature Se nso r - This

sensor detec ts the a i r i n le t temperature . The

ECM moni tors the in le t a i r temperature and o ther

data in order to adjust in ject ion t iming and other

per formance func t ions .

Intake Valve Actuat ion System Oi l Pressure Sensor -

Moni tors the pressure wi th in the oi l ra i l for the intake

va lve ac tuator . The sensor can detec t mechanica l

prob lems wi th the in take va lve ac tuat ion sys tem

such as leak ing face seals .

Intake Valve Actuat ion System Oi l Pressure

Solenoid - Solenoid mounted at the end of the oi l

ra i l for the intake valve actuator. The solenoid is

normal ly c losed to a l low pressure to bu i ld up in

the rail.

Intake Valve Actuator - An actuator that al lows the

ECM to cont rol the amount of t ime that the intake

va lve i s open. The ac tuator t raps eng ine o i l i n order

to ho ld the in take va lve open. The ECM can vary

the t ime that the intake valve is open in order to

opt im ize eng ine per formance.

Integrated Elect ronic Controls - The engine is

des igne d w i th the e lec t ron ic cont ro ls as a neces sary

par t o f the sys tem. The eng ine wi l l no t operate

wi thout the elect ronic cont rols .

J1922 Data Link - This data l ink is an SAE

diagnos t i c communicat ions data l i nk that i s used to

c ommun i c a t e be t ween t he e l ec t ron i c eng i ne and

the power t ra in components . Examples o f power

t ra in components are the ABS/ t rac t ion cont ro l

sys tem and the t ransmiss ions . Th is a l lows the

power t ra in component to cont ro l the eng ine dur ing

reduced t ract ion or t ransmiss ion shi f ts .

J1939 Data Link - This data l ink is an SAE

diagnos t i c communicat ions data l i nk that i s used to

communicate between the e lec t ron ic eng ine, the

t ransmiss ion, i ns t rument c lus ters , and/or the power

t rain cont rols .

Key Swi tch Input - When the input is energ ized, the

E CM i s powered up .


20/419

21


h Mode - T h i s i s a p rog rammab l e pa ramet e r

- Logged d i agnos t i c

Clear Sw i tch - The main tenance

Ove rdue Lamp - Th is lamp wi ll t u rn on

ec tor (ME UI ) - The MEUI i s an in jec tion pu m p

- Messenger i s a d ig i ta l d i sp lay that

Ver i fy - This feature is used to test the

- A parameter is a value or a l imi t that

Param eter Ident i f ie r (P ID) - The P ID is a two d ig i t

c ode o r a t h ree d i g i t c ode wh i c h i s as s i gned t o

each component i n order to ident i f y data v ia the

data l ink to the ECM.

Pass ive Magnet i c S p e e d S e n s o r - This sensor is a

speed sensor that does not requ i re a power and a

ground connec t ion. The sensor produces a s igna l

that i s based on the change in magnet i c f lux o f a

ferrous metal gear near the sens ing t ip.

Pas s word -A pas s word i s a g roup o f numer i c

charac ters or a group o f a lphanumer ic charac ters

that i s des igned to res t r i c t access to parameters .

The e lec t ron ic sys tem requ i res cor rec t passwords

in order to change Cus tomer Spec i f i ed Parameters

(Cus tomer Passwords ) or cer ta in eng ine

spec i f i ca t ions (Fac tory Passwords ) . Passwords are

a lso requ i red to c lear cer ta in d iagnos t i c codes .

Personal i t y Module o r Rat ings P ersonal i ty Module -

Th is module i s a t tached to the ins ide o f the

ECM. The module conta ins a l l t he ins t ruc t ions

(sof tware) for the ECM and the module conta ins the

per formance maps for a spec i f i c horsepower fami ly .

Power Cy c led - Power c y c led happe ns when

power to the ECM is cyc led: on, o f f , and on. Power

cyc led re fers to the ac t ion o f cyc l ing the keyswi tch

f rom any pos i t i on to the OFF pos i t i on, and to the

START/RUN pos i t ion.

Pow er Take-Off (PTO) - The PTO operates w i th

the c ru ise cont ro l swi t ches and the ded icated

PTO On/Of f swi t ch. Th is mode permi ts the set t i ng

o f c ons t an t eng i ne s peeds o r t he mode pe rm i t s

vary ing the speed wi th e i ther the acce lera tor pedal

in the cab or a remote accelerator.

Pow er Train Data L ink - Refer to J1922 Data L ink

or J1939 Data L ink .

P o w e r e d Down - Powered down oc c u rs when

power i s remov ed f rom t he E CM. Powered down

refers to the act ion of cyc l ing the keyswi tch f rom

any pos i t i on to the OFF /RESET pos i ti on.

P o w e r e d Up - Powered up oc c u rs when power

i s app l ied to the ECM. Powered up re fers to the

ac t ion o f cyc l ing the keyswi tch f rom the OFF/RESET

pos i t ion to the START pos i ti on.

P r imary Engine Speed /T iming Sens or - Determines

the p os i t ion o f the c ranksha f t fo r i n jec t ion t im ing and

eng i ne s peed . The p r i mary eng i ne s peed / t i m i ng

sensor i s pr imar i ly use d a fter the en g ine has s tar ted.

Pro-Link - Pro-Link is an elect ronic serv ice tool that

i s hand-he ld . The too l i s manufac tured by Mic ro

Processor Systems, Inc. (MPSI) . This tool is suppl ied

wi th a Caterp i l la r car t r i dge in order to serv i ce a

Caterpi l lar engine that is elect ronical ly cont rol led.


21/419

2

Shi f t i ng -Th is i s a method o f qu ick ly

ing throug h the lower gea rs wi thout excess ive

Con f igu ra ti on - T h i s i s a p rog rammab l e

Width Modula t ion (PW M) - The PWM is a

3111,0,

TIME

T I M E

/ I l l /

.

19o.~

O F F

TIME

g00284479

Fuel L im i t -Th is term ind icates the max imum

- The Reference Vo l tage i s a

S hu t down -The E CM d i s ab l es t he f ue l

R e m o t e S t a t i o n O p e r a t i o n

- This is a locat ion that

is outs ide of the vehic le cab. The funct ions such

as the eng ine speed cont ro l are t yp ica l l y used for

some type o f PTO operat ion that i s for pumping

or for some other app l i ca t ion that uses the eng ine

power . These func t ions are cont ro l led f rom the

remote s tat ion.

Retarder Enable S igna l - The re tarder enable s igna l

interfaces the ECM to the engine retarder. This

wi l l res t r i c t operat ion o f the eng ine brake dur ing

undes i rab le eng ine operat ing cond i t i ons . One

operat ing cond i t i on i s a t a t ime when the eng ine

is being fueled.

Re t a rde r S o l eno i ds -Th i s re f e rs t o t he eng i ne

retarder that is ins tal led by Caterpi l lar . The solenoids

are dr iven di rect ly by the Caterpi l lar ECM. The

so leno ids are not dr i ven through an OEM ins ta l led

relay such as the aux i l iary retarder.

S e c o n d a r y E n g i n e S p e e d / T i m i n g S e n s o r -

Determines the pos i t i on o f the camshaf t dur ing

s tar t -up. The secondary eng ine speed/ t im ing sensor

wi l l be used i f the s ignal f rom the pr imary engine

speed/ t iming sensor is los t .

S e n s o r

- T h e sensor is a dev ice that i s used

to detec t a change in pressure, temperature , or

mechanical movement . The informat ion that is

detected is converted into an elect r ical s ignal .

Serv ice Brake Pedal Posi t ion Swi tch - This swi tch

is t yp ica l l y a pressure swi tch that i s supp l ied and

instal led by the OEM. This swi tch is normal ly c losed

when the brake pedal i s i n the re leased pos i t i on.

Depress ing the brake wi l l open the c i rcu i t .

Serv ice

P r o g r a m M o d u l e

(SPM) - The serv i ce

program module i s a sof tware program that i s used

to adapt the elect ronic serv ice tool to a spec i f ic

eng ine app l i ca t ion.

Sho rt Ci rcui t - A short c i rcui t is a cond i t ion that has

an elect r ical c i rcui t that is inadvertent ly connected

to an undes i rab le po in t . An example o f a shor t

c i rcui t is a wi re which rubs against a vehic le f rame

and th i s rubb ing eventua l l y wears o f f the wi re

insulat ion. Elect r ical contact wi th the f rame is made

and a short c i rcui t resul ts .

S igna l -The s igna l i s a vo l tage or a waveform that

is used in order to t ransmi t informat ion typical ly

f rom a sensor to the ECM.

S p e e d

Burp - A Spe ed Bu rp is a sudden , brie f,

unwan t ed c hange i n t he eng i ne rpm.

S t a n d a r d S A E D i a g n o s t i c C o m m u n i c a t i o n s D a t a

Link - Refer to the ATA Data Link.


22/419

2 3


d Swi tch - This swi tch is used for in ject ion

Timing - Stat ic t iming is the bas is for correct

- A Subsys tem that is used in th i s

i s the thro tt le subsys tem.

Vol tage - The sup ply vo l tage i s a cons tant

Conf igurat ion Parameters - Sys tem

on Param eters are Parameters that a f fec t

t he eng i ne s peed / t i m i ng

Ce nter - This refers to the cranksh af t pos i t ion

L i m it - T h i s is a p rog ramm ab l e pa ramet e r

Total Tattletale - The Total Tattletale is the total

number o f changes to a l l t he Cus tomer Spec i f i ed

Parameters that are s tored in the ECM.

Transd ucer (T iming Cal ibrat ion Prob e) - This is

a dev ice that conver ts a mechanica l s igna l to

an e lec t r i ca l s igna l . Th is probe requ i res a power

source in order to operate .

Transm iss ion Sty le - The "Transm iss ion Sty le" is

a p rog rammab l e pa ramet e r t ha t des i gna t es t he

type of t ransmiss ion in the vehic le and the var ious

c i rcu i t s that are connec ted to the ECM The re lay for

the t ransmiss ion, cruise cont rol , PTO/ idle set speed,

and the operat ion o f the exhaus t brake are a f fec ted

by this parameter set t ing.

Tr ip Recorder -The t r i p recorder i s an a f termarket

dev ice that i s ded icated to record ing the parameters

of the veh ic le and the parameters o f the operat ing

engine dur ing the veh ic le serv i ce. The t r i p recorder

is used to analyze the dr iv ing habi ts and the

recorder i s used in order to produce the logs o f the

driver.

Var iable Valve Actuat ion - A l lows the engine to

vary the c los ing of the valves in order to opt imize

emiss ions and eng ine per formance.

Vehic le Speed Sensor - The veh ic le speed sensor

i s an e lec t romagnet i c p i ckup that measures veh ic le

speed f rom the rotat ion of gear teeth in the dr ive

train of the vehicle.

Wastegate

Solenoid - P revents press ur ized ai r f rom

reaches the turbocharger was tegate . A l lows the

engine to bu i ld boos t pressure beyond the preset

was tegate set t i ng.

E l e c t r o n i c S e r v i c e T o o l s

SM CS Co d e: 0 7 85

i01921225

Caterp i l la r e lec t ron ic serv i ce too ls are des igned

to he lp the serv i ce techn ic ian wi th the d iagnos is

and repai r of e lect ronic engines. Several tools are

avai lable to ass is t the serv ice technic ian.


23/419

4

e q u i re d S e r v i c e T o o ls

P a r t N u m b e r

N/A

6 V - 2 1 9 7

D e s c r i p t i o n

4 mm A l len Wrench

Transducer(Timing Calibration

Probe)

7X - 1 1 71 T ra ns d u c er A d a p t e r ( T i m i n g

Ca l ib ra t ion Probe )

7X - 1 6 9 5 C a b l e ( T i m i n g C a li b ra ti o n)

1 U - 5 8 0 4 C r i m p T o o1 (1 2 t o 1 8 A W G )

1 U - 5 8 0 5 W i r e R e m o v a l T o o1 (1 4 A W G W i r e )

1 51 - 6 3 2 0 W i re R e m o v a l T o o l( 16 a n d 1 8 A W G

W i r e )

1 6 7 - 9 2 2 5 H a rn e s s ( S e rv i c e T o o l A d a p t e r )

1 4 0 - 2 2 6 6 C a b l e ( S e v e n t y - P i n B re ak o u t)

9U - 73 3 0 D ig ita l Mu l t imeter

o r D i gi ta l M u l t i m e t e r ( R S - 2 3 2 )

1 4 6 - 4 0 8 0

1 9 0 - 8 9 0 0 C o n n e c t o r R e p a i r K i t

s i o n w i r e m a y a l s o b e

e d t o c h e c k t h e c o n t i n u i t y o f s o m e w i r i n g

terpi llar Electronic Tech nician (C at ET )

i a g n o s t i c c o d e s

E n g i n e ra t i n g h i s t o r y

D r i v e r a n d f l e e t t r ip s e g m e n t s

s t o m d a t a

E C M d a t e / t im e c l o c k

M a i n t e n a n c e i n te r v a ls

i a g n o s t i c t e s t s

s o r c a l i b r a t i o n s

F l a s h p r o g r a m m i n g

S e t p a r a m e t e r s

C o p y t h e c o n f i g u r a t i o n f o r E C M r e p l a c e m e n t .

D a t a l o g g i n g

S n a p s h o t re c o r d e r

T h e f o l l o w i n g c o m p o n e n t s a r e r e q u i r e d t o u s e C a t

E T t o s e r v i c e t h e e n g i n e .

Table 2

R e q u i r e d E l e c t r o n i c S e r v i c e T o o l s f o r

t h e U s e o f C a t E T

P a r t D e s c r i p t i o n

N u m b e r

C a t e r p i l l a r E l e c t r o n i c T e c h n i c i a n

JERD2124 "E lectron ic Techn ic ian Program" (Ca t ET)

JERD2125

o r

JERD2129

"Electronic Tech nician Truck Engine Data

Subscription"

"Electronic Technician

E n g i n e /M a c h i n e

Da ta Subscr ip t ion"

171 -4400(1) Comm unica tion Ad apter It Gp

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

N o t e : F o r m o r e i n f o r m a t i o n r e g a r d i n g t h e u s e o f C a t

ET and the PC requ i remen ts fo r Ca t ET , re fe r t o

t h e d o c u m e n t a t i o n t h a t a c c o m p a n i e s y o u r C a t E T

so f twa re .


24/419

25


C a t E T a n d th e C o m m u n i c a t i o n

O p t i o n a l S e r v i c e T o o l s

Table 3

P a r t N u m b e r D e s c r i p t i o n

7X - 63 7 0 Adapter Cable As(3 Pin DT Breakout)

8 T - 8 7 2 6 A d a p t e r C a b l e A s ( 3 P i n B r ea ko u t)

5P - 7277 Voltage Tester

9U - 5103 Socke t (Slot ted)

7X - 1710

Mul t imeter Probe

1 U -5 7 1 8 V a c u u m u m p

1U- 8757 Tu be( Flu id ampling)

169- 73 72 F luid Sampl ing Bot t le

9 S -9 0 8 2 Engine Turn ing Tool

1 9 8 - 4 2 4 0 D i g i t a l

ressure Indicator

o r

1U- 5470 Engine Pressure Group

6V- 9130

Tempera ture Adapter

124 - 5643 Cab le(Serv ice ool Breakout)

125- 3662 C a b l e ( S e n s o r B y p a ss )

157 -48 29 Cable Adapter(9 Pin J1939

D a s h )

7X - 1403 A da pt er ab le As (9 P in Nav is tar

D a s h )

7 X- 1686 Cable Adapter(6 Pin

D a s h )

C a b l e A d a p t e r 0

139- 4166 Data Link C a b l e A s ( E i g h t e e n Feet)

2

- . . . .

I l l . . . . I

13

Personal computer

(PC)

Adapter Cable As (PC Ser ia l )

Comm unicat ion Adapter

II

Adapter Cable As

g00647144

I tems (2) , (3) , and (4) are part of the

i01905996

- 4 4 0 0 Com mun i c a t ion A dap t e r II Gp .

the keyswi tch i s not p laced in the OFF/RESET

posi t ion, the engine may s tart .

end o f c ommun i c a t i on adap t e r ( 3 ) and t he

RS232 ser ia l port of PC (1) .

Conne c t c ab le (4 ) be t ween t he " DA TA L I NK" end

o f c ommun i c a t i on adap t e r ( 3 ) and t he s e rv i c e

tool connector.

Ca t E T and t he c ommun i c a t ion adap t e r do

not communicate wi th the ECM, re fer to

Troubleshoot ing, "Elect ronic Serv ice Tool Wi l l Not

Communicate Wi th ECM".

R e p l a c i n g t h e E C M

S M C S C o d e : 1 9 0 1 - 5 1 0

R e p l a c in g t h e E C M w i th t h e U s e o f

th e E C M R e p la c e m e n t F e a t u re

.

Ensure that the ECM is the problem by f i rs t

connec t ing a tes t ECM. Th is i s a temporary

connec t ion. Hang the tes t ECM on the s ide o f

the eng ine. Refer to Troub leshooting, "Tes t ECM

Mode" .

,

I f t he tes t ECM repa i rs the prob lem, reconnec t

the suspect ECM. Ver i fy that the problem returns

when t he s us pec t E CM i s rec onnec t ed .

,

Selec t the ECM Replacement Feature under the

"Serv ice /Copy Conf igurat ion" menu and load the

parameters f rom the fa i led ECM.

,

Tempora ri ly c onne c t t he new E CM by c onne c t ing

both ECM connec tors . Do not mount the ECM

on the eng ine yet .


25/419

6

new ECM i f the personal i ty module is not already

installed. The new ECM is shipp ed wi th a blank

personal i ty module.

Caterpi l lar Electronic Technician (Cat ET) in order

to program the new ECM.

parameter into the new ECM.

parameters that have not been programmed.

Performed is not active, install the new ECM

on the engine. Otherwise, perform a t iming

calibration first.

e p l a ci n g th e E C M w i t h o u t t h e U s e

t h e E C M R e p l a c e m e n t F e a t u r e

connect ing a test ECM. This is a temporary

connect ion. Hang the test ECM on the side of the

engine. F lash program the ident ical personal i ty

module that was used in the suspect ECM into

the test ECM. Program any parameters that

are necessary to use the ECM for the test . For

example, veh ic le speed parameters need to be

programmed to check the veh ic le speed c i rcu i t .

Program the parameters in the test ECM to be

equal to the parameters in the suspect ECM.

the suspect ECM. Ver i fy that the problem returns

when the suspect ECM is reconnected.

C .

Use the Troubleshoot ing, "Customer Speci f ied

Parameters Worksheet" to record the customer

parameters.

d . Record the in jector codes. The injector

codes can be found in the "Injector

Codes Cal ibrat ion" in "Cal ibrat ions" under

the "Service" menu on Cat ET. Refer to

Troubleshoot ing, " Injector Code - Cal ibrate"

for more information.

4. Record ECM li fet ime totals.

a. Use the Troubleshoot ing, "Customer Speci f ied

Parameters Worksheet (Current Totals

Worksheet)" in order to record the old "ECM

Current Totals".

.

Temporar i ly connect the new ECM by connect ing

both ECM connectors. Do not mount the ECM to

the engine unt i l the t iming cal ibrat ion has been

performed.

.

Flash program the personal i ty module into the

new ECM i f the personal i ty module is not already

installed. The new EC M is shipp ed wi th a blank

personal i ty module.

7 . Obta in factory passwords when the passwords

are required.

Note: The fol lowing parameters can be programmed

on a new ECM without factory passwords: "Ful l

Load Sett ing (FLS)", "Full Torque Sett ing (FTS)",

and "Engine Ser ial Number". System conf igurat ion

parameters must be entered before the customer

speci f ied parameters are entered. I f customer

parameters are entered before the system

configuration parameters, the Total Tatt letale wil l

change. I t wi l l then be necessary to obtain another

set of factory passwords in order to change system

conf igurat ion parameters.

8. Perform the fol lowing operat ions.

ECM.

a .

a. Obta in the customer passwords and record

the customer passwords. I f the customer

(owner) has lost the passwords or i f

the customer (owner) has forgot ten the

passwords, proceed to Troubleshoot ing,

"Customer Passwords, for more detai ls.

b. Access the "Conf igurat ion" screen on Cat ET

and record the customer parameters f rom

the ECM that is being replaced. I f the ECM

does not communicate wi th Cat ET, obtain the

required parameter l ist f rom the OEM.

b .

Use the Troubleshoot ing, "Factory Passwords

Worksheet" to record the fol lowing informat ion

from the engine information plate: "Full Load

Setting (FLS)", "Full Torque Setting (FTS)",

and "Engine Ser ial Number".

Record the mi leage from the vehicle

odometer. Access the "Conf igurat ion" screen

on Cat ET. When the screen for the "Factory

Passwords" appears, record the fol lowing

information: "ECM Serial Num ber", "En gine

Serial Num ber", "ET Serial Num ber", "Total

Tatt letale", and "Reason Code".


26/419

. Leave Cat ET on the sc reen for the "Fac tory

Passwords" and obta in the fac tory passwords .

Complete the Troub leshoot ing, "Fac tory

Passwords Worksheet " .

a,

b .

2 7

Troubleshoot ing Sec t ion

c ,

d .

e.

Access the "Conf igurat ion" sc reen on Cat

ET. Enter the fol lowing parameters that are

recorded on the worksheet : "Fu l l Load Set t i ng

(FLS)", "Ful l Torque Sett ing (FTS)", and

"Engine Ser ia l Number" .

Enter the cus tomer spec i f i ed parameters and

the or ig ina l cus tomer passwords that are

recorded on the worksheet .

Use Cat ET to access cur rent to ta ls f rom the

"Read/Change Current Tota ls " main menu.

Record the in format ion on the Troub leshoot ing,

"Fac tory Passwords Worksheet " i n order to

obta in the fac tory passwords . Enter the to ta ls

f rom the or ig ina l ECM that are recorded on

the worksheet .

Program the in jector codes on Cat ET. Select

the fol lowing screens in order: "Serv ice" ,

"Cal ibrat ions" , " In jector Codes Cal ibrat ion" .

Refer to Troubleshoot ing, " In jector Code -

Calibrate for more information.

Selec t the fo l lowing sc reens in order to

cal ibrate the engine t iming: "Serv ice" ,

"Cal ibrat ions" , and "Timing Cal ibrat ion" .

Cal ibrate the t iming. Refer to Troubleshoot ing,

"Engine Speed/T iming Sensor - Ca l ib ra te" for

t he p roper p roc edure .

Instal l the n ew ECM on the eng ine.

S e n s o r s a n d E l e c t r i c a l

C o n n e c t o r s

S M C S C o d e : 1 90 0- N S ; 7 5 5 3 - W W

i01907619

Table 4

C o n n e c t o r F u n c t i o n

J1/P1 ECM Connector

J2/P2 ECM Connector

JIO O/ P IO0 Engine Coolant Temperature Sensor

J103 /P103 Intake Manifold Air T em p er a tu r e

Sensor

J105/P105 Fuel Temperature Sensor

J200/P200 Boost Pressure Sensor

J2 01 /P 20 1 Engine Oi l Pressure Sensor

J203 /P203 Atmospheric Pressure Sensor

J300 /P3 00 Injector Solenoid Harness

J400/P400 Timing Calibration Probe

J4 01 /P 40 1 Primary Engine Speed/Timing

Sensor

J402/P402 Secondary Engine Speed/Timing

Sensor

J403 /P403 Accelerator Peda l Posit ion Sensor


27/419

ng Section

. .'= .=. .~. SAE J1587 Da ta Link

3 Retarder Solenoids

6 Electronic Unit Injectors

Primary Engine Speed/Timing Sensor

ry Engine Speed/Timing Senso

Atmospheric P ressure Sensor

Engine Oil P ressure Sensor

Boost Pressure Sensor

Coolant Temperature Sensor

Fuel Tempera_tureSensor

Intake Manifold Air Temperature Sensor

E ' e c t r n i c

Control ] 1

Module

L ~ f U

i ~ ~ SAE J1922~l~Data ink

O~ SAE J193 9 Data Unk

Y

BATTERIES

Cruise Control On/O ff & Set/Resume Switches

o ~

C~

Ignition Key

2 Passive Temperature

Sensor

Engine Retarder Level Switches

g g ~

Accelerator P edal Pos ition SensoJ

and Service Brake Switches

Coolant Level Sensor

Check Engine & Warning Lamps

Speedometer & Ta___chometer

Cooling Fan

1.5A

Vehicle Speed Sensor

A/C H igh P ressure Switch

Remote Accelerator Position Sensor

2, 0.3 A Outputs

7 Switch Inputs

3, 1.0A Outputs

3, 1.5A Outpu ts

tion 14 g00995055


28/419

29


o f components

Fuel

T e m p e r a t u r e

Sensor

Unit

I n j e c t o r

Connec to r

Secondary

Engine

Speed /T im in ,

Sensor

P r im a r y

Engine .

Speed~Timing

Sensor

LEFT SIDE VIEW

Engine Oil

Pressure

Sensor

ECM

Connec to r

J 2 / P 2

ECM

Connec to r

J1/P1

w (typical example)

g00992601


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0

Engine Coolant

Temperature

Sensor

Intake Manifo ld

Air Temperature

Sensor

Boost

Pressure

Sensor

@ @ @

@

TOP

VTEW

Atmospheric

Pressure

Sensor

(typical example)

g00992610


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in e

P r i m o r y

Engine

S p e e d / T i m i n g

Sensor '

Fuel

Temperoh

Sensor

A t m o s p h e r

P r e s s u r e

Sensor

31


Secondory

Engine ,

S p e e d / T i m i n g

Sensor

B o o s t

P r e s s u r e

Sensor

E l e c t r o n i c

Uni t

I n j e c t o r

C o n n e c t o r

I n t e k e

Moni fo ld Ai r

T e m p e r o t u r e

Sensor

@

J 2 / P 2 '

ECM

Connec to r

exam ple)

Enqine

C o n t r o l

J1/P1

ECM

g00995059


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2

Engine

Cootont

Temperature

~ D n e ~ r

R I G H T S ID E V I E W

iL

F R O N T V I E W

(typical example)

g00995060


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3 3


Secondary Boost Unit

Engine Pressure In je c to r

Speed /T im ing

Sensor Sensor Con nector

/

In take Manifo ld

Air Temperature

Sensor

, c985-BU--K, ~ +8 v

ACCELERATORPEDAL POSITIONbWH-- C I ) I C986-B R ~A CC EL ER AT OR PEDAL POSITION

J40 3 P 403 P1 J1

accelera tor peda l posit ion s e n s o r

g00642016


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~ o o o o o o 3 o ~ e o . ~ ~ , ~

] 1 1 i , 9 0 0 0 0 1 1~ ' ~ 0 0 0 0 0 ~ o 0 ~ 0 0 , 4

LL ; o o o o o o O O o O o ,,i

I I

ECM S ide

, 88 88 '1

C 5 ~ r l l

] ~

H o r n e s s S i d e

AP SENSOR /SWI TCH SEN SOR COMMON

I N P U T S E N S O R CO M MO N ~ 2

+ 8 V

ACCELERATOR PEDAL

P O S I T I O N

V e h i c le H o r n e s s C o n n e c t o r P 1

+ 8 V

AP SEN SOR /SWI ICH SENSOR COMMON

I N P U T S E N S O R CO M M ON | 2

ACCELERATOR PEDAL P O S I T I O N

n 43

ocat ions or

ECM

e s t S t e p 1 . M o n i to r t h e S t a t u s f o r t h e

c c e l e r a to r P e d a l P o s i t i o n "

l ink connector.

Posit ion".

acce lera tor pedal and re lease the acce lera tor

pedal .

R e s u l t :

g00668027

R e s u l t s :

OK -The ac c e l e ra t o r peda l pos i t i on s ens or i s

operat ing correct ly .

R e p a i r :

f the problem is intermit tent, refer to

Troubleshoot ing, "E lec t r i ca l Connec tors - Inspec t " .

Ver i fy that the engine is not in PTO mode. PTO

mode may cause the acce lera tor pedal pos i t i on

sensor to be ignored.

Ver i fy that al l requi red parameters are

p rog rammed. Cer t a i n unprog rammed pa ramet e rs

may cause the engine to be l imi ted to low id le.

Refer to Troubleshoot ing, "System Conf igurat ion

Parameters" .

STOP.

Not OK - The acce lera tor pedal pos i t ion sensor

is not operat ing correct ly . Proceed to Test Step 2.


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e s u l t 1 91-08 or 91 -13 i s Ac t i ve .

41-03 is Act ive.

41-04 is Act ive.

Resu l t 1 - Pr oce ed to Test Step 5.



C h e c k th e S u p p l y V o l ta g e

h e S e n s o r f o r th e A c c e l e r a t o r P e d a l

s it io n S e n s o r

acce lera tor pedal pos i t i on sensor connec tor

J 4 0 3 / P4 0 3 .

re ference to termina l "B" (Acce lera tor /Swi tch

S ens or Comm on) .

OK - P rocee d to Test Step 6.

Not OK - The sensor is not rece iving the cor rec t

vol tage.

Repai r : Inspec t the e lec t r i ca l connec tors and

wir ing.

Repai r the faul ty wi r ing.

Ver i fy that the repai r e l iminates the problem.

S T O R

C h e c k t h e D u t y C y c l e a t t h e

B .

Remove the s igna l w i re for the acce lera tor pedal

pos i t ion sensor ( terminal "C") f rom P403. This

i s the harness s ide o f the acce lera tor pedal

pos i t i on sensor connec tor .

C .

Ins tal l a breakout T wi th 3 terminals between the

J 4 0 3 and t he P4 0 3 A c c e l e ra t o r peda l pos i t i on

sensor connec tor .

D .

Connec t the mul t imeter probes to termina l "C"

(Acce lera tor Pedal Pos i t i on) and termina l "B"

(Acce lera tor /Swi tch Sensor Common) o f the

breakout T.

E . Whi le the duty cyc le i s be ing moni tored on the

multimeter, dep ress the acce lera tor p edal an d

re lease the acce lera tor pedal .

E x p e c t e d R e s u l t :

The du t y c y c l e i s be t ween 1 0 % and 2 2 % when t he

accelerator pedal is fu l ly released. The duty cyc le is

be t ween 75 % and 9 0 % when t he ac c e l e ra t o r peda l

is fu l ly depressed.

R e s u l t s :

O K - T h e ac c e l e ra t o r peda l pos it ion s ens or is

work ing correct ly .

Repai r : Insert the s ignal wi re into terminal C of

the P403 connec tor .

Proceed to Test Step 7.

No t OK - Leav e the PWM probe c o nnec t ed t o

the breakout T. Insert the wi re ( terminal C) into

the veh ic le harness connec tor . The acce lera tor

pedal pos i t i on sensor or the acce lera tor pedal

assembly is faul ty . Proceed to Test Step 8.

T e s t S t e p 7 . C h e c k t h e D u t y C y c l e o f t h e

A c c e l e r a t o r P e d a l P o s i tio n S e n s o r a t t h e

E C M

Note: Per forming cer ta in s teps wi th in th i s procedure

requi res the use of a mul t imeter that is capable of

measur ing a PWM duty cyc le .

A, Turn the key swi tch to the OFF pos i t ion.

B, Remove the wi re for the acce lera tor pedal

pos i t ion sensor P1:66.

Note: You may be requ i red to d i sconnec t the P1

ECM connec tor i n order to remove the termina l fo r

the s igna l i nput o f the acce lera tor pedal pos i t i on

sensor.


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165


removed wi re and P1 :5 (Acce lera tor /Swi tch

S ens or Comm on) .

pedal pos i t i on sensor i s be ing moni tored on the

mul t imeter , depress the acce lera tor pedal and

re lease the acce lera tor pedal .

connector.

R esult:

OK - A good s i gnal f rom the ac c e l e ra t o r peda l

pos i t ion sensor is reaching the ECM. Ver i fy that

the ECM is receiv ing the proper bat tery vol tage. I f

the ECM is receiv ing the proper bat tery vol tage,

temporar i l y co nne c t a tes t ECM and ver if y that the

prob lem i s reso lved. If the prob lem d isap pea rs

wi th the tes t ECM, reconnec t the suspec t ECM.

I f the prob lem re turns wi th the suspec t ECM,

rep lace the ECM. STOR

Not OK - There is a problem wi th signal wi re

for the acce lera tor pedal pos i t i on sensor in the

vehic le wi r ing harness. Proceed to Test Step 9.

S t e p 8 . R e m o v e t h e A c c e l e ra t o r

o r P e d a l A s s e m b l y

f rom the acce lera tor pedal assembly . Note

sensor or ienta t ion in the acce lera tor pedal

assembly , and the sensor pigtai l rout ing pr ior to

sensor removal . Thoroughly inspect the pigtai l

for s igns

Documents

3406E, C-10, C-12, C-15, C-16 AND C-18 TS Manual