3406e, c-10, c-12, c-15, c-16 and c-18 ts manual
TRANSCRIPT
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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).
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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.
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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 :
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code in a very short per iod of t ime.
11
Troubleshoot ing Sect ion
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
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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.
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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
Troubleshoot ing Sect ion
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.
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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.
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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
Troubleshoot ing Sect ion
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 .
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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.
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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 .
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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.
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1 9
Troubleshoot ing Sect ion
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.
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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 .
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21
Troubleshoot ing Sect ion
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.
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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.
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2 3
Troubleshoot ing Sect ion
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.
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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 .
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25
Troubleshoot ing Sect ion
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 .
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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".
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. 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
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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
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29
Troubleshooting Section
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
Troubleshooting Section
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
Troubleshooting Section
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.
Resu l t 2 - Pr oce ed to Test Step 10.
Resu l t 3 - Pr oce ed to Test Step 12.
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
Troubleshoot ing Sect ion
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