Renr1367 11 01 All PDF

RENR1367-11
November 2005
Troubleshooting
3126B and 3126E On-highway Engines
BKD1-Up (Engine)
G3E1-Up (Engine)
DPF1-Up (Engine)
1AJ1-Up (Engine)
8YL1-Up (Engine)
CKM1-Up (Engine)
CRP1-Up (Engine)
7AS1-Up (Engine)
8SZ1-Up (Engine)
9SZ1-Up (Engine)
i01658146
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

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

ture failures, product damage, personal injury or
death.
RENR1367-11 3
Table of Contents
Table of Contents Excessive Black Smoke ........................................

Excessive Valve Lash ...........................................
77
78
Excessive White Smoke ....................................... 79
Intermittent Cruise Control, Idle, or PTO Kickout .. 80
Troubleshooting Section Intermittent Engine Shutdown ............................... 82
Intermittent Low Power or Power Cutout .............. 83
Electronic Troubleshooting
Low Power/Poor or No Response to Throttle ....... 85
System Overview .................................................... 5
Poor Acceleration or Response ............................ 87
Electronic Service Tools ........................................ 12
Replacing the ECM ............................................... 15
Troubleshooting with a Diagnostic Code
Sensors and Electrical Connectors ....................... 16
Diagnostic Codes .................................................. 90
0001-11 Cylinder #1 Injector current fault (72) ..... 92
Programming Parameters
Programming Parameters ..................................... 19
Customer Passwords ............................................ 19
ECM Date/Time Stamped Information .................. 19
ECM Snapshot ...................................................... 20
Factory Passwords ............................................... 21
0022-11 Primary to Secondary Engine Speed Signal
Factory Passwords Worksheet ............................. 22
Calibration (42) ................................................... 94
Flash Programming .............................................. 22
0022-13 Engine Speed Signal Calibration Not
Service Information Report ................................... 23
Performed (42) .................................................... 95
0030-08 PTO Throttle signal invalid (29) .............. 95
Customer Specified Parameters
0030-13 PTO Throttle out of calibration (29) ........ 96
Customer Specified Parameters ........................... 25
0041-03 8 Volt Supply voltage high (21) ............... 96
Customer Specified Parameters Table ................. 26
0041-04 8 Volt Supply voltage low (21) ................ 96
Customer Specified Parameters Worksheet ......... 31
0042-11 Injection Actuation Pressure output
Cruise Control Parameters ................................... 34
fault ..................................................................... 97
Data Link Parameters ........................................... 35
0043-02 Key Switch Fault (71) ............................. 97
Dedicated PTO Parameters .................................. 36
0064-02 Secondary Engine Speed loss of signal
Engine/Gear Parameters ...................................... 39
(34) ...................................................................... 97
Engine Monitoring Parameters ............................. 42
0064-11 Secondary Engine Speed no pattern
Idle Parameters .................................................... 43
(34) ...................................................................... 98
Input Selections .................................................... 44
0070-05 Inlet Air Heater current low ..................... 98
Maintenance Parameters ...................................... 48
0070-06 Inlet Air Heater current high .................... 99
Output Selections ................................................. 49
0071-00 Idle Shutdown Override (01) ................... 99
Passwords ............................................................ 51
0071-01 Idle Shutdown (47) ............................... 100
Selected Engine Rating ........................................ 51
0071-14 PTO Shutdown (47) .............................. 100
Smart Idle Parameters .......................................... 51
0084-00 Vehicle Overspeed Warning (41) .......... 100
Timer Parameters ................................................. 52
0084-01 Vehicle Speed loss of signal (31) ......... 101
Trip Parameters .................................................... 53
0084-02 Vehicle Speed signal invalid (36) .......... 101
Truck Manufacture Parameters ............................ 54
0084-08 Vehicle Speed signal out of range (36) .. 102
Vehicle Speed Parameters ................................... 55
0084-10 Vehicle Speed signal rate of change
(36) .................................................................... 102
System Configuration Parameters
0091-08 Throttle Position Invalid (32) ................. 102
System Configuration Parameters ........................ 58
0091-13 Throttle Position out of calibration (28) .. 103
0096-03 Fuel Level voltage high ......................... 103
Troubleshooting without a Diagnostic Code
0096-04 Fuel Level voltage low .......................... 104
Can Not Reach Top Engine RPM ......................... 59
0100-03 Oil Pressure voltage high (24) .............. 104
Can Not Reach Vehicle Speed Limit ..................... 60
0100-04 Oil Pressure voltage low (24) ............... 104
Check Engine Lamp or Warning Lamp Is
0100-11 Very Low Oil Pressure (46) ................... 105
Malfunctioning ..................................................... 62
0102-03 Boost Pressure voltage high (25) ......... 108
Cruise Control, Idle, or PTO Can Not Be Set ....... 63
0102-04 Boost Pressure voltage low (25) ........... 108
Driver Questionnaire ............................................. 67
0102-07 Boost Pressure not responding ............ 108
Driver Questionnaire Response ............................ 68
0105-00 High Intake Manifold Air Temperature
ECM Will Not Accept Factory Passwords ............. 69
Warning (64) ..................................................... 109
Electronic Service Tool Will Not Communicate with
0105-03 Intake Manifold Air Temperature voltage
ECM .................................................................... 69
high (38) ............................................................. 110
Elevated Idle ......................................................... 70
0105-04 Intake Manifold Air Temperature voltage low
Engine Cranks but Will Not Start .......................... 71
(38) ..................................................................... 110
Engine Has Early Wear ........................................ 74
0105-11 Very High Intake Manifold Air Temperature
Engine Misfires, Runs Rough or Is Unstable ........ 75
(64) ..................................................................... 110
Engine Vibration ................................................... 76
0108-03 Barometric Pressure voltage high (26) .. 112
Engine Will Not Crank ........................................... 77
0108-04 Barometric Pressure voltage low (26) ... 113
4 RENR1367-11
Table of Contents
0110-00 High Coolant Temperature Warning Cruise Control Switch Circuit - Test .................... 202
(61) ..................................................................... 113 ECM Memory - Test ............................................ 216
0110-03 Coolant Temperature voltage high (27) .. 113 Electrical Connectors - Inspect ........................... 219
0110-04 Coolant Temperature voltage low (27) ... 114 Engine Pressure Sensor Open or Short Circuit -
0110-11 Very High Coolant Temperature (61) ...... 114 Test ................................................................... 224
0111-01 Low Coolant Level Warning (62) ............ 114 Engine Running Output Circuit - Test ................. 231
0111-02 Coolant Level signal invalid (12) ............ 115 Engine Speed/Timing Sensor Circuit - Test ........ 234
0111-03 Coolant Level voltage high (12) ............. 115 Engine Temperature Sensor Open or Short Circuit -
0111-04 Coolant Level voltage low (12) ............... 116 Test ................................................................... 239
0111-11 Very Low Coolant Level (62) .................. 116 Exhaust Brake Circuit - Test ............................... 245
0128-03 Secondary Fuel Level voltage high ....... 117 Exhaust Particulate Filter Circuit - Test ............... 251
0128-04 Secondary Fuel Level voltage low ......... 117 Fast Idle Enable Circuit - Test ............................. 253
0164-00 Excessive Injection Actuation Pressure Fast Idle Lamp Circuit - Test ............................... 257
(17) ..................................................................... 118 Fuel Level Sensor Circuit - Test .......................... 260
0164-02 Injection Actuation Pressure Signal Erratic Idle Shutdown Timer - Test ................................. 264
(15) ..................................................................... 118 Ignition Key Switch Circuit and Battery Supply Circuit
0164-03 Injection Actuation Pressure voltage high - Test ................................................................. 267
(15) ..................................................................... 118 Ignore Brake/Clutch Switch Circuit - Test ........... 273
0164-04 Injection Actuation Pressure voltage low Injection Actuation Pressure - Test ..................... 277
(15) ..................................................................... 119 Injection Actuation Pressure Control Valve Circuit -
0164-11 Injection Actuation Pressure system fault Test ................................................................... 282
(39) ..................................................................... 119 Injection Actuation Pressure Sensor - Test ......... 287
0168-02 ECM Battery Power Intermittent (51) .... 120 Injector Solenoid Circuit - Test ............................ 290
0186-14 PTO Engine Shutdown Switch Occurrence Input Selection Switch Circuit - Test ................... 298
(47) .................................................................... 120 Neutral Switch Circuit - Test ................................ 304
0190-00 Engine Overspeed Warning (35) .......... 120 Powertrain Data Link Circuit - Test ..................... 316
0190-02 Primary Engine Speed Loss of Signal PTO Engine Shutdown Switch Circuit - Test ....... 324
(34) .................................................................... 121 PTO Shutdown Timer - Test ................................ 328
0190-11 Primary Engine Speed no pattern (34) .. 121 PTO Switch Circuit - Test .................................... 330
0224-11 Theft Deterrent Active (00) ................... 121 PTO Switch ON Lamp Circuit - Test ................... 339
0224-14 Theft Deterrent Active with Engine Cranking Remote PTO Accelerator Position Sensor Circuit -
(00) .................................................................... 122 Test ................................................................... 343
0231-02 J1939 Data Incorrect (58) ..................... 122 Service Brake Pedal Position (Switch 1) Circuit -
0231-11 J1939 Data Link Fault (58) ................... 123 Test ................................................................... 350
0231-12 J1939 Device Not Responding ............. 123 Service Brake Pedal Position (Switch 2) Circuit -
0232-03 5 Volt Supply voltage high (21) ............. 123 Test ................................................................... 362
0232-04 5 Volt Supply voltage low (21) .............. 124 Starting Aid Output Circuit - Test ........................ 374
0246-11 Brake Pedal Switch #1 Fault ................. 124 Tachometer Circuit - Test .................................... 377
0247-11 Brake Pedal Switch #2 Fault ................. 125 Transmission (AT/MT/HT) Relay Circuit - Test .... 381
0252-11 Engine Software Incorrect (59) ............. 125 Vehicle Speed and Speedometer Circuit - Test .. 384
0253-02 Check Customer or System Parameters Wait To Start Lamp Circuit - Test ........................ 393
(56) .................................................................... 125 Warning Lamp Circuit - Test ................................ 397
0253-14 Truck Manufacturer Parameter Not
Programed ........................................................ 126 Calibration Procedures
Engine Speed/Timing Sensor - Calibrate ............ 401
Diagnostic Functional Tests Vehicle Speed Circuit - Calibrate ........................ 403
5 Volt Engine Pressure Sensor Supply Circuit -
Test ................................................................... 127 Index Section
Accelerator Pedal (Throttle) Position Sensor Circuit -
Test ................................................................... 132 Index ................................................................... 406
Air Inlet Heater Circuit - Test ............................... 139
ATA (SAE J1587 / J1708) Data Link Circuit -
Test ................................................................... 146
Change Oil Lamp Circuit - Test ........................... 153
Check Engine Lamp Circuit - Test ...................... 156
Clutch Pedal Position Switch Circuit - Test ......... 159
Coolant Level Sensor Circuit - Test .................... 171
Cooling Fan Circuit and A/C Compressor Clutch
Circuit - Test ...................................................... 179
Cooling Fan Circuit and A/C High Pressure Switch
Circuit - Test ...................................................... 187
RENR1367-11 5
Troubleshooting Section
Troubleshooting Section An accelerator pedal position sensor is used to

determine the desired engine speed. The ECM
compares the desired engine speed to the actual
engine speed. The actual engine speed is calculated
Electronic Troubleshooting from signals that are generated by the engine
speed/timing sensors. If the desired engine speed
is greater than the actual engine speed, the ECM
i02292388 adjusts the signal that is sent to the injectors and
the fuel system’s high pressure oil pump in order to
System Overview reduce the engine speed. The ECM continuously
monitors the engine for actual conditions in order to
SMCS Code: 1900 adjust for desired conditions.
System Operation
The fuel system for this engine uses Hydraulic
Electronic Unit Injectors (HEUI). The injection pump,
the fuel lines and the nozzles that are used in
mechanical engines have been replaced with an
hydraulic electronic unit injector in each cylinder. A
solenoid on each injector controls the amount of
fuel that is delivered by the injector. High pressure
engine oil is used to operate the injector. An Engine
Control Module (ECM) sends a signal to the injection
actuation pressure control valve in order to control
injection pressure. Another electrical signal is sent to
each injector solenoid in order to inject fuel into the
cylinders.
Electronic Controls
The engine’s electronic system consists of the ECM,
the engine sensors, the fuel injection system, and
the vehicle interface. The ECM is used to control the Illustration 1
g01120999
operation of the engine. The ECM flash file contains Typical example
the software that is used to program the ECM. The
flash file contains the operating maps that define the The desired engine speed is typically determined by
following characteristics of the engine: one of the following conditions:
• Horsepower • The position of the accelerator pedal
• Torque curves • The desired vehicle speed in cruise control
• Engine speed (rpm) • The desired engine rpm in PTO control
Engine Governor Timing Considerations
The ECM provides the functionality of the engine The ECM determines the fuel injection timing. In
governor. addition to desired engine speed and actual engine
speed, the following inputs are used by the ECM in
The ECM determines the timing, the duration and order to calculate the engine timing:
the pressure of injection. The amount of fuel that
is delivered to the cylinders is precisely controlled • Coolant temperature
by the ECM. This control is based on the actual
conditions and the desired conditions at any given • Intake manifold air temperature
time during starting and operation of the engine.
• Atmospheric pressure
• Boost pressure
6 RENR1367-11
The signal from the engine speed/timing sensor is Injection Actuation Pressure Control
used by the ECM to determine the orientation of System
the crankshaft. This signal is used by the ECM to
calculate an output for the injector solenoids relative The ECM controls injection actuation pressure by
to the top center position of each piston. The injection controlling the output current to the injection actuation
signal is adjusted for optimum engine performance, pressure control valve (IAPCV). The IAPCV utilizes
for fuel economy, and for the control of white smoke. the movement of spool valves that are inside the high
The injection signal is output to each injector solenoid pressure oil pump to control pump outlet pressure.
at the optimum time. By adjusting flow of control oil to the spool valves,
the IAPCV controls the injection actuation pressure
Fuel Injection that is provided to the injectors. This determines the
pressure of the fuel that is injected into the cylinder
The ECM controls the injection timing and injection by the injectors.
duration by varying the output signals to the injectors.
The injectors pump fuel into the cylinder only while The injection actuation pressure sensor provides
the injector solenoid is energized. The ECM outputs a signal to the ECM that represents the pressure
a high voltage signal to the injector solenoid in order of the oil that is in the high pressure oil manifold.
to energize the solenoid. Energizing the injector The injection actuation pressure sensor’s signal
solenoid actuates a seated pin inside the injector. is compared by the ECM to the desired injection
The pin is seated and the injection actuation pressure actuation pressure. The desired injection actuation
increases within the fuel injector body. The hydraulic pressure is a calculated value that is based on
force that is provided by the actuation pressure is sensor inputs, on control maps, and on power
used to move an intensifier piston in the body of the demands of the engine. The difference between
injector. The intensifier piston multiplies the hydraulic the actual pressure and the desired pressure is
force that is transfered to the fuel. As the force of the used by the ECM to calculate adjustments to the
pressurized fuel overcomes the spring tension that is control current that is output to the injection actuation
used to seat the nozzle check, fuel injection occurs. pressure control valve. The ECM provides continuous
monitoring and precise control of the pressure that is
Precise control of the injection actuation pressure in the high pressure oil manifold.
and of the injector solenoid allows the ECM to deliver
fuel over a varied rate during a single injection. High pressure oil is routed from the high pressure oil
This strategy provides the engine with optimum fuel pump to the high pressure manifold through a steel
economy and with strictly controlled emissions. tube. From the manifold, the oil is routed into each
injector. All injectors have a constant supply of oil
The software that is used to control the ECM provides while the engine is running. Disabling the electrical
instructions for the amount of fuel that can be injected signal to the injector solenoid does not interrupt the
into the cylinder. The “FRC Fuel Limit” is a limit that flow of high pressure oil that is available to the fuel
is based on the boost pressure. The “FRC Fuel Limit” injector.
is used to control the air/fuel ratio for the control of
emissions. When the ECM senses a higher boost “Basic” Systems and “Full Feature”
pressure, the ECM increases the “FRC Fuel Limit”.
A higher boost pressure indicates that the density of Systems
air that is entering the cylinder is being increased.
Some 3126B HEUI Truck Engines ((S/N: 7AS; 8SZ))
When the ECM increases the “FRC Fuel Limit”, the
ECM also adjusts the signals to the fuel system. This were manufactured with one of two different engine
control modules that were available. Each ECM must
adjusts the delivery of fuel to the cylinders.
use different ECM software. These systems are
The “Rated Fuel Limit” is a limit that is based on commonly referred to as “Basic” and “Full Feature”.
“Basic” systems are typically found in GM trucks
the power rating of the engine and of engine rpm.
and chassis, while “Full Feature” systems are found
The “Rated Fuel Limit” is similar to the rack stops
and the torque spring on a mechanically governed in other applications. The “Basic” system and the
“Full Feature” system use different default values for
engine. The “Rated Fuel Limit” defines the power
several of the customer parameters that are common
curves and the torque curves for a specific engine
family and for a specific engine rating. All of these to both of the systems. The ECM flash file for a
“Basic” system cannot be used with a “Full Feature”
limits are determined at the factory. These limits
system. The reverse is true as well. The “Full Feature”
are contained in the ECM software and these limits
cannot be changed. ECM provides some features that are not available
with the “Basic” ECM. Refer to Troubleshooting,
“Programming Parameters” for more details.
RENR1367-11 7
Other 3126B Truck Engines ((S/N: 8YL; 8SZ)) use Some of the engine monitoring parameters are
an ECM that defines the features of both systems intended to notify the driver of potential engine
through the use of unique software. A new ECM damage. Some parameters can be used in order
parameter is used in the ECM flash file that is used to enhance fuel economy (Vehicle Speed, Cruise
to define each system. The “Truck Manufacturer” Control, Engine/Gear Speed Limit Parameter and
parameter is used to define the functionality of the Idle Shutdown). Some of the parameters must be
“Basic” system versus the “Full Feature” system. used in order to accommodate the installation of the
This ECM parameter is configured at the factory engine into a vehicle. Other parameters are also
to select the correct defaults and options for any used to provide operating information about the
given application. If an ECM replacement is required, engine to the truck engine owner.
the “Truck Manufacturer” parameter must be
programmed for the specific vehicle. The software
will then configure the ECM with the correct settings
Engine Monitoring
for that application. This engine utilizes a factory installed engine
monitoring system. The engine monitoring system
Cold Mode monitors the following variables:
Cold mode is activated when the sum of coolant • Coolant temperature

temperature and the inlet manifold air temperature is
below 18 °C (64 °F). When cold mode is active, the • Inlet manifold air temperature
idle rpm speed ramps up to the default value of 1000
rpm unless another value has been programmed • Coolant level (option)
into the “Warm Up Mode Idle Speed” parameter.
Cold mode remains active until any of the following • Engine oil pressure (option)
conditions are met:
The engine monitoring system can be programmed
• The sum of coolant temperature and the inlet to four different modes. The four modes of
manifold air temperature warms to 18 °C (64 °F). programming are “OFF”, “WARNING”, “DERATE”,
and “SHUTDOWN”. The ECM will react to engine
• The engine has been started for 12 minutes. conditions according to the mode that is selected.
• The service brake is depressed. Functions of the Engine Monitoring

• The clutch pedal is depressed. System
• The automatic transmission is placed in gear. “OFF” Mode
This option is not applicable for OCT01 ECM

Customer Parameters and Engine Speed software.
Governing
If the engine monitoring system is programmed to
Unique features with electronic engines are customer “OFF”, the ECM will not flag high coolant temperature
specified parameters. These parameters allow the or high inlet manifold air temperature. The ECM will
vehicle owner to define characteristics of engine not initiate warnings, derates, or shutdowns. If an
operation to the specific needs of the application. The adverse engine condition warrants an action, the
configuration of these parameters allows the vehicle ECM will not take action.
owner to specify some aspects of engine operation
for the typical usage and for the power train of the The ECM continues to monitor the engine sensors
vehicle. for engine operation. Cold mode operation, control
of the air inlet heater, and control of the cooling fan
Many of the customer parameters provide control will remain functional.
of the actions that will be performed by the ECM in
response to the driver’s input. For example, the “PTO
Top Engine Limit” is a limit that is used to control
the maximum engine speed during PTO operation.
The “PTO Top Engine Limit” feature instructs the
ECM to suppress the signal to the fuel injectors at
engine speeds above an engine rpm that has been
predefined .
8 RENR1367-11
“WARNING” Mode The ECM will also respond to a low coolant level
by limiting the maximum vehicle speed. The engine
If the engine monitoring system is programmed to power rating is derated as well. Refer to Illustration 4.
“WARNING”, the ECM illuminates a warning lamp in
the case of an abnormal operating condition or active
diagnostic code. The ECM will also flash the check
engine lamp when a diagnostic code becomes active.
The lamps are used to communicate an abnormal
operating condition. The engine monitoring system
illuminates the lamps in order to warn the operator.
The ECM will log the diagnostic code, but no further
action will be initiated.
“DERATE” Mode
If the engine monitoring system is programmed to

“DERATE” the ECM begins to begin flashing the
check engine lamp and the warning lamp. . Again,
g01121033
this is done in order to communicate the problem to Illustration 4
the operator. The ECM logs the diagnostic code. For Graph for the coolant level
a high coolant temperature, the ECM will limit the Limited derate mode (10 percent per second)
maximum vehicle speed. The engine power rating is
also reduced. Refer to Illustration 2 and Illustration 3. The response to a very low oil pressure will also
affect the vehicle speed and the engine power rating.
Refer to Illustration 5.
g01121008
Illustration 2
Coolant temperature bargraph
g01121043
Limited derate mode (10 percent per second) Illustration 5
Graph for very low oil pressure
An engine derate is provided in order to protect the

engine and/or the vehicle from specific abnormal
conditions.
“SHUTDOWN” Operation
If the system is programmed to “SHUTDOWN”, the

ECM activates the actions of the “DERATE” mode.
If the conditions deteriorate to predetermined levels,
the ECM will initiate the engine shutdown.
The “SHUTDOWN” mode begins when any of the

following conditions exist:
g01121023
Illustration 3
• “Very low oil pressure”
Coolant temperature bargraph for emergency vehicles
Limited derate mode (10 percent per second) • “Very low coolant level”
RENR1367-11 9
• “Very high coolant temperature” Engine Snapshot Data

Note: The very low oil pressure is only available on When a diagnostic code becomes active, the ECM
“Full Feature” systems. records the time of the occurrence in ECM memory.
The ECM also records an engine snapshot prior to
After the ECM has completed an engine shutdown the occurrence and after the occurrence. The engine
for conditions that relate to engine monitoring, the snapshot is a record of specific operating parameters.
ECM allows the engine to be restarted. If adverse The ECM records data for ten seconds before
conditions persist, engine monitoring will repeat the the diagnostic code becomes active and for three
engine shutdown. seconds after the diagnostic code becomes active.
Other Functions of the Engine An engine snapshot can also be triggered from
the cruise control set/resume switch. In order to
Monitoring System trigger the engine snapshot from the cruise control
set/resume switch, quickly toggle the switch to the
The ECM also provides enhanced control of the SET position. Then, quickly toggle the switch to
engine for vehicle functions such as exhaust the RESUME position. Toggling the cruise control
brake and PTO controls. Refer to Troubleshooting, set/resume switch from the RESUME position to the
“Customer Specified Parameters” for supplemental SET position will also activate the feature.
information that is related to other functions of the
monitoring system. Caterpillar Electronic Technician (ET) can also be
used to activate an engine snapshot. The data from
Self-Diagnostics an engine snapshot can be retrieved with Cat ET
as well.
The ECM has the ability to diagnose problems that
relate to the engine’s and to the vehicle’s electronics. Effect Of Diagnostic Codes on
When an electrical problem is detected the ECM
activates a diagnostic code. The ECM communicates Engine Performance
this diagnostic information to the operator by
illuminating a check engine/diagnostic lamp. The Diagnostic Codes
ECM also stores the information in permanent
memory. An active diagnostic code indicates that an Diagnostic codes are activated by the ECM in order
electrical problem has been detected by the ECM. to indicate that an electrical problem or an electronic
The code will remain active while the problem is problem has been detected by the ECM. Some of the
detected by the ECM. problems that cause the codes may have an effect
on engine performance while other problems that are
Diagnostic codes that are stored in the ECM memory detected may not have an effect. More frequently,
are referred to as logged diagnostic codes. A logged the driver will not detect any difference in engine
diagnostic code that is read from ECM memory does performance.
not necessarily indicate that something needs to be
repaired. The problem may have been temporary, If the check engine lamp is flashing and a change in
or the problem may have been repaired since the engine performance is apparent, the cause of the
problem was logged. Logged diagnostic codes code may also be the cause of the change in engine
intended to provide historical information about performance. Troubleshoot active diagnostic codes
electrical problems that have been detected by prior to performing any other service on an engine. Be
the ECM. A common use for this information is sure to check for the occurrence of logged diagnostic
troubleshooting intermittent electrical problems. codes in ECM memory. This will provide information
on problems that are intermittent or problems that
Event codes are used to identify engine operating occur only during specific operating conditions.
conditions that are outside the normal operating
range. Event codes are not typically an indication Event Codes
of an electronic system problem. For example, an
event code is logged into ECM memory if engine Event codes are used to identify abnormal operating
overspeed condition occurs. conditions of the engine. Event codes seldom identify
electrical problems or electronic problems with the
Some of the logged codes require passwords to be engine. During the detection of an event, the ECM
cleared from ECM memory. Diagnostic codes that do logs the code into memory.
not require passwords to be cleared from memory
are automatically deleted after 50 hours of engine The following codes are available for this engine:
operation.
• 84-00 Vehicle Overspeed Warning (41)
10 RENR1367-11
• 100-11 Very Low Oil Pressure (46) Other Information That is Stored in
• 110-11 Very High Coolant Temperature (61)
the ECM Memory
The “Fleet Trip Data” allows information that is related
• 111-11 Very Low Coolant Level (62) to engine operation to be recorded over specified
intervals. These intervals are defined by the vehicle
• 190-00 Engine Overspeed Warning (35) owner (July 1999 and newer ECM software). This
data is stored in ECM memory. If power is removed
The ECM uses an internal clock to time stamp the
from the ECM, the data is retained in memory with an
occurrence of an event code. This information is also
internal battery backup.
stored in ECM memory.
Fleet Trip Data
ECM Lifetime Totals
The functionality for the fleet trip data includes a
The ECM records the total data in permanent “Fleet Trip Segment”, histograms, and custom data.
memory for the following parameters: The “Fleet Trip Segment” includes data for the
following parameters:
Total Time (Engine Hours) – The total time is
accumulated during the operational hours of the • Time (engine hours)
engine. The engine hours do not include the time
when the ECM is powered and the engine is not • Driving time
running.
• Distance
Total Distance – The distance data requires a
vehicle speed sensor or an electronic vehicle speed • Fuel
source to be connected to the ECM. The same
sensor must be used for the vehicle speed parameter. • Idle time
Distance can be displayed in miles or kilometers.
• Idle fuel
“PTO Time” and “PTO Fuel” – This is recorded
when the PTO on/off switch is in the ON position and • PTO time
vehicle speed is within the range of the “PTO Vehicle
Speed Limit” parameter. • PTO fuel
“Idle Time” and “Idle Fuel” – Idle information is • Average load factor
recorded only when the engine speed is set by using
the cruise switches and the vehicle speed is within • Average vehicle speed
the range of the “Idle Vehicle Speed Limit” parameter.
• Idle time (percent)
Average Load Factor – This provides relative
engine operating information. The average load • PTO time (percent)
factor is derived from the engine’s “Total Maximum
Fuel”, “Idle Fuel”, and “Fuel Consumption” data. • Overall fuel economy
Total Fuel – This is the maximum amount of fuel • Driving fuel economy
that is consumed by the engine during operation.
• Average driving speed
Total Maximum Fuel – This is the amount of fuel
that could have been consumed by the engine during • Maximum vehicle speed
operation.
• Maximum engine speed
Note: Fuel information can be displayed in US
gallons or in liters. • Start time
This information can be viewed with Cat ET. • End time
• Odometer (start)
• Odometer (end)
RENR1367-11 11
The “Fleet Trip Data” feature can be configured for The ECM also uses the engine oil capacity to
three different histograms: determine the maintenance interval. An engine
oil capacity that is larger provides oil change
• Engine operation versus engine speed intervals that are longer. The engine oil capacity is
programmed into the ECM in liters or in quarts. If
• Vehicle speed versus time the “PM1” is programmed to the “Manual” mode,
the owner can program the ECM with a unique
• Engine speed and vehicle speed versus time maintenance interval.
Cat ET can be used to calculate the averages of The maintenance interval can also be programmed
the parameters over time. Custom data is also to the owner’s specific interval that can be based on
available. Custom data allows the recording of engine mileage or on time.
parameters that are specified by the vehicle owner.
The interval for the “PM2” and the interval for the
Maintenance of the fleet trip data can be performed cooling system clean/flush are established by the
by using any of the following tools: factory.
• Cat ET Messenger
• Caterpillar Fleet Information Software (FIS) Caterpillar Messenger is available to provide engine
operating information to the driver. The “Fleet Trip
• Caterpillar Driver Information Display (CAT ID) Data”, and the “Maintenance Indicator” data can be
viewed. However, the fleet trip histograms and the
• Caterpillar Messenger custom data cannot be viewed from the display.
Maintenance Indicator Data Messenger provides the ability to enter an ID code

for a driver in order to divide the “Fleet Trip Data”
The ECM records the current totals when a reset for two drivers. If the driver enters the information
occurs for the following maintenance options: regarding the state of travel, the “Fleet Trip Data” can
be tagged by the state of travel.
• PM1
Messenger can be used in order to tag portions of the
• PM2 “Fleet Trip Data” into two ID codes. Messenger can
also be used in order to tag portions of the “Fleet Trip
• Cooling system clean/flush Data” into the state of travel. The ID code and the
information regarding the state of travel cannot be
The ECM uses the previous point of maintenance viewed from the display. Only the Caterpillar FIS can
in order to calculate the time of the next scheduled view this information. The ability to reset any of these
maintenance. parameters is dependent on customer parameters
in the ECM.
The “Maintenance Indicator Mode” can be
programmed to hours or to distance. Messenger will also display operating information
such as engine rpm, coolant temperature, boost
The “PM1” maintenance parameter can be pressure, PTO parameters, etc.
programmable to “Off”, to “Automatic Distance”,
to “Automatic Hours”, to “Manual Distance”, or to Diagnostic data can also be viewed with Messenger.
“Manual Hours”. Engine diagnostic codes that use the PID-FMI format
can be displayed. Messenger also displays a brief
If the “PM1” is programmed to the “Automatic” mode, text description of the diagnostic codes that are
the ECM calculates the next point of maintenance active.
by considering the history of the vehicle’s operation
from the previous maintenance interval. If the vehicle Another available feature on Messenger is the theft
has a history of poor fuel economy the “Maintenance deterrent. The theft deterrent allows the driver to input
Indicator” parameter will occur sooner than a vehicle a password prior to shutdown. The theft deterrent will
with better fuel economy. prevent the engine from restarting until the password
is successfully entered. Messenger must have the
version of software that is capable of supporting this
feature.
12 RENR1367-11
An “Auto-Enable” option is available for the theft Customer parameters are parameters that are
deterrent. If this option is selected, the theft deterrent available to the customer or to the vehicle
will automatically be activated when the engine manufacturer. Some of the customer parameters are
is shut down. The driver must input the correct configured to specifically define the application of the
password in order to start the engine. engine. Other customer passwords can be set by the
owner in order to tailor the engine to the specific use
“Secure Idle” is another theft deterrent. This allows by the customer. The following parameters are typical
the driver to bring the engine to an idle condition. parameters that can be configured by the customer:
The driver then enters the password. The engine will
remain at low idle until the password is re-entered. If • Parameters that define cruise control functions
the engine is shutdown, a password will be required
to go above low idle after start-up. • Vehicle speed limits
Fleet Information Software (FIS) (JUL99 • Parameters that define the progressive shifting
and Newer ECM Software)
• Engine rpm settings
The Caterpillar FIS is another method that can be
used to review the trip information. The entire “Fleet • Maintenance interval schedules
Trip Segment”, which includes the following elements
Customer passwords may be required to change
of data can be accessed with the Caterpillar FIS: customer specified parameters.
• Histograms Some of the parameters may affect engine operation
in an unusual way. A driver might not expect this
• Custom data type of effect. Without adequate training, these
parameters may lead to power complaints or
• Information that is tagged by the ID code performance complaints even though the engine’s
performance is to the specification.
• Information that is tagged by the state of travel
Refer to Troubleshooting, “Customer Specified
Maintenance Indicator information can also be
Parameters”.
accessed by using the Caterpillar FIS.
When the Caterpillar FIS downloads the information, Passwords

the Caterpillar FIS also resets the ECM in order to
prepare the ECM for the next trip. The information System configuration parameters specify the
can be downloaded to a computer with the Caterpillar power rating, the family, and the emissions of an
FIS, or the information can be downloaded to an engine. These parameters are protected by factory
Argo Mobile Data Tool. The Argo Mobile Data Tool is passwords. Changing these parameters requires the
then connected to a computer in order to download use of factory passwords. Factory passwords are
the information. available only through authorized Caterpillar dealers.
Cat ET must be used to change system configuration
parameters.
Programmable Parameters
Customer parameters are protected by customer
Certain parameters that affect the operation of
passwords. The customer passwords are
the HEUI engine may be changed using Cat ET.
programmed by the customer. Factory passwords
These parameters are stored in the ECM and can be used to change customer passwords if
most of the parameters are password protected.
customer passwords are lost.
These parameters are either system configuration
parameters or customer parameters. Refer to Troubleshooting, “Customer Passwords”
and Troubleshooting, “Factory Passwords”.
System configuration parameters are parameters
that define the engine operation or the engine
application. These parameters are set at the factory. i02303718
System configuration parameters define the power
rating and emissions levels. Factory passwords are Electronic Service Tools
required to change system configuration parameters.
Factory passwords are available only to authorized SMCS Code: 0785
Caterpillar Dealers.
Caterpillar Electronic Service Tools are designed to
help the service technician:
RENR1367-11 13
• Obtain retrieval. Table 2

Part Number Description
• Diagnose electrical problems.
190-8900 Connector Repair Kit (1)
• Read parameters. 7X-6370 Adapter Cable As (3-PIN
BREAKOUT)
• Program parameters.
8T-8726 Adapter Cable As (3-PIN
• Calibrate sensors. BREAKOUT)
7X-1710 Multimeter Probe
Required Service Tools 1U-5718 Vacuum Pump
Table 1 1U-8757 Tube (FLUID SAMPLING)
Required Service Tools 169-7372 Fluid Sampling Bottle
Part Number Description 9S-9082 Engine Turning Tool
N/A 4 mm Allen Wrench 198-4240
Digital Pressure Indicator
or
5P-7277 Voltage Tester Engine Pressure Group
1U-5470
9U-5103 Socket (SLOTTED) 4C-4911(1) Battery Load Tester
6V-2197 Transducer 6V-9130(2) Temperature Adapter (MULTIMETER)
7X-1171 Transducer Adapter 124-5643 Cable As (SERVICE TOOL
7X-1695 Cable As BREAKOUT)
1U-5804 Crimp Tool (12−AWG TO 18−AWG) 125-3662 Cable As (SENSOR BYPASS)
1U-5805 Wire Removal Tool 157-4829 Cable Adapter
151-6320 Wire Removal Tool 7X-1403 Adapter Cable As
167-9225 Harness (SERVICE TOOL 7X-1686 Cable Adapter

ADAPTER)
139-4166 Data Link Cable As (ATA OR CAT)
208-0059 Adapter Cable As (70-PIN
7X-1714 Data Link Cable As (ATA OR CAT)(2)
BREAKOUT)
(1) This kit includes a 1U-5804 Crimp Tool.
6V-7070 Digital Multimeter (HEAVY-DUTY) (1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911
Battery Load Tester for 6, 8, and 12 Volt Lead Acid Batteries”
9U-7330 Digital Multimeter
and Special Instructions, SEHS7633, “Battery Test Procedure”.
(2) Refer to Special Instructions, SEHS8382, “Use of the 6V-9130
146-4080 Digital Multimeter Gp (RS232)
Temperature Adapter Group”.
212-2160 Digital Multimeter Gp (2) “GM truck manufactures only”
Two short jumper wires are needed to check the Caterpillar Electronic Technician
continuity of some wiring harness circuits by shorting
two adjacent terminals together in a connector. A
(ET)
long extension wire may also be needed to check the
Cat ET can display the following information:
continuity of some wiring harness circuits.
• Programmable parameter settings
Optional Service Tools
• Active diagnostic codes and logged diagnostic
Table 2 lists the optional service tools that may help codes
you service the engine.
• Logged events
• Engine rating history
• Driver and fleet trip segments
• Histograms
• Custom data
14 RENR1367-11
• Date/time clock for the Engine Control Module Connecting Cat ET and the
(ECM) Communication Adapter Gp
• Maintenance intervals
Cat ET can also be used to perform the following
functions:
• Diagnostic tests
• Sensor calibrations
• Flash programming
• Parameter programming
• Copy configuration function for ECM replacement
• Data logging
• Graphs (real time)
• Snapshot recorder
Table 3 lists the service tools that are required in
order to use Cat ET.
Table 3
Service Tools for the Use of Cat ET

Part Description g01121866
Number Illustration 6
(1) Personal Computer (PC)
JERD2124 Single Use Program License (2) 196-0055 Adapter Cable As
(3) 171-4401 Communication Adapter Gp
JERD2125 Data Subscription (Truck Engine)
(4) 207-6845 Adapter Cable As
Data Subscription (Truck and Commercial
JERD2128
Engine) Note: Items (2), (3), and (4) are part of the 171-4400
Communication Adapter Gp.
Data Subscription for All Engines and
JERD2129
Machines
Use the following procedure in order to connect Cat
171-4400(1)
Communication Adapter (“CAT ET” TO ET and the Communication Adapter II.
ECM INTERFACE)
237-7547(2) Adapter Cable As 1. Turn the keyswitch to the OFF position. If the
keyswitch is not in the OFF position, the engine
(1) The 7X-1700 Communication Adapter Gp may also be used. may start.
(2) The 237-7547 Adapter Cable As is required to connect to the
USB port on computers that are not equipped with a RS232
serial port. 2. Connect cable (2) between the “COMPUTER”
end of communication adapter (3) and the RS232
Note: For more information regarding the use of serial port of PC (1).
Cat ET and the PC requirements for Cat ET, refer to
the documentation that accompanies your Cat ET Note: The 237-7547 Adapter Cable As is required
software. to connect to the USB port on computers that are not
equipped with a RS232 serial port.
3. Connect cable (4) between the “DATA LINK” end

of communication adapter (3) and the service tool
connector.
RENR1367-11 15
4. Place the keyswitch in the ON position. If a. Connect Cat ET to the service tool connector.
Cat ET and the communication adapter do Refer to Troubleshooting, “Electronic Service
not communicate with the Electronic Control Tools”.
Module (ECM), refer to the diagnostic procedure
Troubleshooting, “Electronic Service Tool Will Not b. Print the parameters from the “Configuration”
Communicate With ECM”. screen on Cat ET. If a printer is unavailable,
record all of the parameters.
i02408691
c. Obtain the customer passwords from
Replacing the ECM the vehicle owner. Access the customer
specified parameters with Cat ET. Use
SMCS Code: 1901-510 the Troubleshooting, “Customer Specified
Parameters Worksheet” to record the customer
parameters.
NOTICE
Care must be taken to ensure that fluids are contained Note: If the customer passwords are not available
during performance of inspection, maintenance, test- proceed to Troubleshooting, “Customer Passwords”
ing, adjusting and repair of the product. Be prepared to for details that are related to customer passwords.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- d. Record ECM lifetime totals. Use the
nent containing fluids. Troubleshooting, “Customer Specified
Parameters Worksheet (Current Totals
Refer to Special Publication, NENG2500, “Caterpillar Worksheet)” to record the ECM lifetime totals.
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar e. Record the mileage from the vehicle odometer.
products.
f. Record any logged diagnostic codes.
Dispose of all fluids according to local regulations and
mandates. g. Use the “Copy Configuration/ECM
Replacement” feature that is found under the
NOTICE “Service” menu on Cat ET. Select “Load from
Keep all parts clean from contaminants. ECM” in order to copy the configuration data
from the suspect ECM.
Contaminants may cause rapid wear and shortened
component life. Note: If the “Copy Configuration” process fails and
the parameters were not obtained in Step 1.b, the
parameters must be obtained elsewhere. Some of
The Engine Control Module (ECM) contains no the system configuration parameters are stamped on
moving parts. Replacement of the ECM can be the engine information plate. Most of the parameters
costly. Replacement can also be a time consuming must be obtained from the factory. Parameters that
task. Follow the troubleshooting procedures in this are related to customer specified parameters must
manual in order to ensure that replacing the ECM will be obtained from the customer or from the Original
correct the problem. Verify that the suspect ECM is Equipment Manufacturer (OEM).
the cause of the problem.
2. Remove the ECM:
Note: Ensure that the ECM is receiving power and
that the ECM is properly wired to the negative battery a. Turn the keyswitch to the OFF position.
circuit before a replacement of the ECM is attempted.
Refer to Troubleshooting, “Electrical Power Supply b. Disconnect the P1 and P2 connectors from
Circuit - Test”. the ECM.
A test ECM can be used to determine if the ECM is NOTICE

faulty. Refer to Troubleshooting, “Test ECM Mode”. Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
NOTICE
If the flash file and engine application are not matched,
engine damage may result. NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
Perform the following procedure in order to replace will be disconnected. Fit a suitable cover over discon-
the ECM: nected fuel system component.
1. Record the configuration data:
16 RENR1367-11
c. Remove the fuel lines (if equipped) from the i02293867

ECM.
Sensors and Electrical
d. Disconnect the ECM ground strap. Connectors
e. Remove the mounting bolts from the ECM. SMCS Code: 1900-NS; 7553-WW
3. Install the replacement ECM: Table 4
Connector Function
a. Use the old mounting hardware to install the
replacement ECM. J1/P1 ECM Connector
J2/P2 ECM Connector
b. Connect the fuel lines (if equipped).
J100/P100 Coolant Temperature Sensor
Note: Verify that the fuel lines are installed correctly.
J103/P103 Air Inlet Temperature Sensor
The fuel lines must not put tension on the ECM .
Rubber grommets are used to protect the ECM from J200/P200 Boost Pressure Sensor
excessive vibration. The ECM should move slightly in
the rubber grommets. If the ECM cannot be moved J201/P201 Engine Oil Pressure Sensor
slightly, check that the fuel lines are not pulling the J203/P203 Atmospheric Pressure Sensor
ECM against one side of the grommets.
J204/P204 Injection Actuation Pressure Sensor
c. Connect the ECM ground strap. J300/P300 Valve Cover Connector
d. Connect the P1 and P2 connectors. Tighten J400/P400 Engine Timing Calibration Probe
the ECM connector (allen head screw) to J401/P401 Primary Engine Speed/Timing
the proper torque. Refer to Troubleshooting, Sensor
“Electrical Connectors - Inspect” for the correct
torque value. J402/P402 Secondary Engine Speed/Timing
Sensor
4. Configure the replacement ECM: J500/P500 Injection Actuation Pressure Control
Valve
a. Flash program the latest available flash file J501/P501 Air Inlet Heater Relay
into the ECM. Refer to Troubleshooting, “Flash
Programming” for the correct procedure.
b. Use Cat ET to match the engine application

and the interlock code if the replacement ECM
was used for a different application.
c. If the “Copy Configuration” process from

Step 1.b was successful, return to the “Copy
Configuration/ECM Replacement” screen on
Cat ET and select “Program ECM”. Proceed to
Step 4.e when programming is complete.
d. If the “Copy Configuration” process from Step

1.b was unsuccessful, manually program the
ECM parameters. The parameters must match
the parameters from Step 1.b.
e. Program the engine monitoring system, if

necessary.
f. Calibrate the engine speed/timing if there is

a diagnostic code for speed/timing sensor
calibration. Refer to Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”.
RENR1367-11 17
g01148554
Illustration 7
Components for the 3126B and 3126E
18 RENR1367-11
g01148664
Illustration 8
Left side engine view
(1) Injection actuation pressure control valve (5) Atmospheric pressure sensor (9) Secondary engine speed/timing sensor
(2) Injection actuation pressure sensor (6) Boost pressure sensor (12) ECM
(3) Air inlet heater relay (7) Valve cover connector (13) J2/P2 ECM connectors
(4) Air inlet temperature sensor (8) Primary engine speed/timing sensor (14) J1 ECM connector
RENR1367-11 19
Programming Parameters 3. Obtain the factory passwords. The information

that is recorded on the “Factory Passwords
Worksheet” must be provided. When you obtain
i02305999 the factory passwords, a permanent record of your
access is generated at Caterpillar.
Programming Parameters
4. From the “Factory Password” screen, enter the
SMCS Code: 1901 factory passwords.
Programmable parameters affect the operation of the 5. When the “Read Customer Passwords” screen
engine. The parameters are stored in the Engine appears, record the customer passwords. The
Control Module (ECM). customer passwords may then be used to change
parameters that are customer programmable.
The parameters are divided into two different types:
Customer Specified Parameters – Customer i02306136

specified parameters allow the vehicle owner to
influence the operating technique of the driver. ECM Date/Time Stamped
Customer passwords may be required to change the Information
values of customer specified parameters. Refer to
Troubleshooting, “Customer Specified Parameters” SMCS Code: 0785
for additional information.
System Configuration Parameters – System ECM Date/Time Clock

configuration parameters affect the emissions of the
engine or the power of the engine. Factory passwords The Electronic Control Module (ECM) contains a
may be required to change the values of system Date/Time Clock. Typically, the Date/Time Clock
configuration parameters. Refer to Troubleshooting, indicates the time of day and the date. The clock is
“System Configuration Parameters” for additional used to time stamp the following diagnostic event
information. codes:
• 84-00 Vehicle Overspeed Warning

i02419716
• 84-14 Quick Stop Occurrence
Customer Passwords
• 94-01 Low Fuel Pressure
SMCS Code: 0785
• 100-11 Very Low Oil Pressure
Customer passwords may be used to protect
customer parameters from being changed. The • 110-11 Very High Coolant Temperature
passwords are programmed into the Electronic
Control Module (ECM) with the Caterpillar Electronic • 111-11 Very Low Coolant Level
Technician (ET). One password may be programmed
or both passwords may be programmed. If • 190-00 Engine Overspeed Warning
customer passwords are not programmed, customer
parameters may be changed by anyone. The ECM also attaches a time stamp to each
snapshot.
To obtain customer passwords, contact the owner of
the engine. If the owner has forgotten the customer
passwords, customer passwords may be read by
Adjustment of the ECM Date/Time Clock
using Cat ET. Factory passwords are required in
Do not replace an ECM because of an incorrect
order to read customer passwords.
time of day. Do not change the ECM Date/Time
Clock just because the date or the time is incorrect.
Use the following procedure in order to read customer
Remember that the vehicle may be based in a
passwords with Cat ET:
different time zone.
1. Select the “Information” menu. Then select
“Passwords”.
2. When the “Factory Password” screen appears,

record the information that is listed on the “Factory
Passwords Worksheet”. Refer to programming
parameters Troubleshooting, “Factory Passwords
Worksheet” for additional information.
20 RENR1367-11
Before adjusting the ECM Date/Time Clock, ask i02305595

the owner/operator if the time stamped information
should be recorded. After the time stamped ECM Snapshot
information is recorded, clear the information before
adjusting the ECM Date/Time Clock. This is a very SMCS Code: 0785
important step if the adjustment of the clock is a big
adjustment. This will prevent unnecessary confusion The Engine Control Module (ECM) can record a
if someone else views the information at a later date. snapshot of certain engine parameters and certain
vehicle parameters. The snapshot records the
Compare the current time of day on the ECM to the parameters for a period of 13 seconds that surround
time stamped information in the ECM in order to an event. The following events trigger snapshots:
determine the amount of time that has passed since
the occurrence of the time stamped event. Refer to • Certain diagnostic codes
the following example:
• Operator request
The Caterpillar Electronic Technician (ET) indicates
that a diagnostic code occurred. The 190-00 Engine • Quick Stop event
Overspeed Warning occurred on 19 November 1998
at 10:30:46. Cat ET also indicates that the current The ECM can store a maximum of two snapshots that
time of day in the ECM is 24 November 1998 at are triggered by a diagnostic code, two snapshots
11:20:58. This indicates that the problem occurred in that are triggered manually, and one Quick Stop
the past (approximately one week and 50 minutes). snapshot. The snapshots are stored in a circular
buffer. The newest snapshot will replace the oldest
The engine control module’s time of day may snapshot.
differ significantly from the current time of day. For
example, the month may be incorrect. In this case, The ECM stores the snapshots in memory. Snapshots
ensure that any important time stamped information are maintained by the internal battery in the ECM until
is recorded before the clock is adjusted. After the snapshots are cleared. The following conditions
recording the information, clear the code or the will clear a snapshot:
snapshot. Then adjust the clock.
• Operator request via the Caterpillar Electronic
Technician (ET)
Diagnostic Clock
• The snapshot has been stored for 100 hours.
Do not confuse the ECM Date/Time Clock with the
diagnostic clock. The diagnostic clock starts at zero
when battery power and the key switch input are first Snapshot That is Triggered by a
applied to the ECM. Then, the diagnostic clock will Diagnostic Code
increment while the key switch and battery power are
applied to the ECM. The diagnostic clock is used to When certain diagnostic codes occur the ECM
time stamp diagnostic codes and event codes. records many of the status parameters that
are available on Cat ET. The ECM records this
Logged diagnostic codes and logged event codes information for approximately nine seconds before
display the diagnostic clock hour of the first the code occurs and approximately four seconds
occurrence and the last occurrence and the total after the code occurs.
number of occurrences.
Snapshot That is Triggered by the
Total Time
Operator
The “Total Time” is the total cumulative time of engine
operation. The “Total Time” can be obtained from the A snapshot can be triggered by the operator by
“Current Totals” menu of Cat ET. using the Cruise Control Set/Resume Switch, or
by using Cat ET. Use the following procedure in
order to trigger the snapshot with the Cruise Control
Set/Resume Switch:
RENR1367-11 21
• Vehicle Speed
• Cruise Status
• Brake Switch
Use of Snapshot Data

Use snapshot data only to help determine
engine/vehicle operating conditions when an
intermittent problem occurs. If an intermittent
diagnostic code is causing problems, use the
snapshot data. Snapshot data can be used to
determine whether the problem occurs under specific
Illustration 9
g00627693 circumstances. The following list contains examples
(1) OFF position
of specific circumstances:
(2) SET position
(3) RESUME position • Engine rpm
1. Toggle the switch quickly from the OFF position • Range of vehicle speeds
(1) to the SET position (2).
• Range of coolant temperatures
2. Toggle the switch quickly from the SET position
(2) to the RESUME position (3). Use the snapshot data in order to determine the
operating conditions that were present during the
3. Toggle the switch quickly from the RESUME event. Attempt to duplicate the conditions in order
position (3) back to the OFF position (1). to get the code to recur.
Note: All three steps must occur within a one second Replacement of electronic components should
time period in order to take a snapshot. Performing not be based on snapshot data alone. If too much
the steps in the reverse order also triggers a emphasis is put on snapshot data, the result could
snapshot. be a misdiagnosed root cause. Also when snapshot
data that is triggered by a diagnostic code is being
On Cat ET, the snapshot can be triggered from the viewed, the ECM sets a sensor value with an active
Snapshot Recorder Tool. Refer to the instructions on diagnostic code to a default value when the code
the screen or the system’s documentation for help. is active. This is the reason that the sensor value
suddenly jumps to a specific value at the trigger point
and the sensor value remains at the specific value for
Snapshot That is Triggered by a the rest of the snapshot frames.
Quick Stop
i02297862
A snapshot can also be recorded for a Quick Stop
event if the customer parameter is programmed. The
ECM stores the number of occurrences of the Quick
Factory Passwords
Stop event and a snapshot of the latest occurrence. SMCS Code: 0785
One data record is kept for the most recent Quick
Stop event. The previous record is replaced by the NOTICE
most recent record. Operating the engine with a flash file not designed for
that engine will damage the engine. Be sure the flash
Each Quick Stop record contains 60 frames of file is correct for your engine.
information. Frame 45 is the Quick Stop event. The
record contains 44 frames before the Quick Stop Note: Factory passwords are provided only to
event and 15 frames after the Quick Stop event. Caterpillar dealers.
Each frame is separated by one second. Each frame
of the Quick Stop record stores the following data: Factory passwords are required to perform each of
the following functions:
• Engine RPM
• Throttle Position
• Clutch Switch
22 RENR1367-11
• Program a new Electronic Control Module (ECM). i02170328
When an ECM is replaced, the system Factory Passwords Worksheet

configuration parameters must be programmed
into the new ECM. A new ECM will allow these SMCS Code: 0785
parameters to be programmed once without factory
passwords. After the initial programming, some Note: A mistake in recording these parameters will
parameters are protected by factory passwords. result in incorrect passwords.
Table 5
• Rerate the engine.
Factory Passwords Worksheet
This may require changing the interlock code,
Dealer Code
which is protected by factory passwords. This
includes the rerate of the multitorque parameter Customer’s Name
for the engine.
Address
• Clear engine events and certain diagnostic codes.
Most engine events require factory passwords in
order to clear the code from ECM memory. Clear Telephone Number
these codes only when you are certain that the Information From the Engine Information Plate
problem has been corrected. For example, the
190-00 Engine Overspeed Warning requires the Engine Serial Number
use of factory passwords in order to clear the code Full Load Setting
from ECM memory. Factory passwords must also
be obtained in order to clear a 252-11 Incorrect Full Torque Setting
Engine Software (59) from memory. Information From the Vehicle Odometer
• Read customer passwords. Engine’s Miles (km)

Information From the “Factory Password Entry
If the customer passwords are lost, the customer Screen” on the Caterpillar Electronic Technician (ET)
will not be able to change customer parameters.
The factory passwords must be obtained in order to Electronic Service Tool
read the customer passwords from ECM memory. Serial Number
Engine Serial Number
• Unlock parameters.
ECM Serial Number
Factory passwords are required in order to unlock Total Tattletale
certain system configuration parameters and
customer parameters. If this occasion arises, Reason Code
Cat ET will request factory passwords before From Interlock(1)
the changes are allowed.
To Interlock(1)
Note: The “Customer Parameter Lockout” may Factory Passwords
restrict changing some customer parameters unless
factory passwords are obtained. If changing a Factory Password (No. 1)
customer parameter indicates that the factory Factory Password (No. 2)
passwords are required, the parameter has been
(1) This parameter is required when the engine is being rerated.
locked out. Refer to Troubleshooting, “Customer
This parameter is displayed only when the engine is being
Specified Parameters” for additional information. rerated.
Since factory passwords contain alphabetic

characters, the Caterpillar Electronic Technician (ET) i02419726
must be used to perform these functions. In order to
obtain factory passwords, proceed as if you already Flash Programming
have the password. If factory passwords are needed,
Cat ET will request the factory passwords and SMCS Code: 1901-591
Cat ET will display the information that is required
to obtain the passwords. For the worksheet that Flash Programming – This is a method of
is used for acquiring factory passwords, refer to programming or updating the flash file in an engine’s
Troubleshooting, “Factory Passwords Worksheet”. Electronic Control Module (ECM).
RENR1367-11 23
Caterpillar Electronic Technician (ET) is used to flash i02278907

program a file into the memory of the engine’s ECM.
Service Information Report
If you do not have the flash file, use the “Flash File
Search” tool on the Service Technician Workbench SMCS Code: 0336
(STW) to obtain the flash file for your engine.
Alternatively, use the “Service Software Files” feature After verifying the correct repair has been performed
on SIS Web to obtain the flash file for your engine. on the engine, it is critical to provide brief, detailed
You must have the engine serial number in order to information. This information helps Caterpillar better
search for the flash file. After locating the correct serve you and the customer.
flash file, download the flash file to your PC. Write
down the name of the flash file for future reference. Recommendations
Programming a Flash File Customer’s Complaint
1. Establish communication between Cat ET and the Obtain as much information from the customer
engine’s ECM. as possible. Investigate any written information
that is available and document any information
2. Select “WinFlash” from the “Utilities” menu on Cat that is gathered from the customer. The following
ET. information is of particular importance:
Note: If “WinFlash” will not communicate with the • Indicate if the diagnostic lamp was flashing.
ECM, refer to troubleshooting without a diagnostic
code Troubleshooting, “Electronic Service Tool Will • Indicate if the warning lamp was flashing, or if the
Not Communicate with ECM”. lamp was on continuously.
3. Program the flash file into the ECM. • Indicate the symptoms of engine operation that are
present.
a. Select the engine ECM under the “Detected
ECMs”. Be as specific as possible.
b. Press the “Browse” button in order to select the Cause of Failure

name of the flash file that will be programmed
into the ECM. Comments on the cause of failure should include
the number of diagnostic codes that were logged.
c. When the correct flash file is selected, press Comments should also indicate if the code was an
the “Open” button. active code. Indicate the source of the problem. Also
indicate the method that was used to discover the
d. Verify that the “File Values” match the problem. Examples of the methods that were used to
application. If the “File Values” do not match discover the problem could be one of the following
the application, obtain the correct flash file. methods:
e. When the correct flash file is selected, press • A specific procedure in the manual was followed.
the “Begin Flash” button.
• A visual inspection indicated that wire abrasion on
f. Cat ET will indicate when flash programming the engine harness existed.
has been successfully completed.
• An engine dynamometer test indicated that the
4. Start the engine and check for proper operation. power was below the specification at 1700 rpm
Repair any active diagnostic or event codes. due to the loss of the no. 4 injector and an engine
dynamometer test indicated that the power was
“WinFlash” Error Messages below the specification at all engine speeds above
1700 rpm due to the loss of the no. 4 injector.
If you receive any error messages during flash
programming, click on the “Cancel” button in order Be as specific as possible.
to stop the process. Access the information about
the “ECM Summary” under the “Information” menu. Repair Procedure
Make sure that you are flashing the correct file for
your engine. Comments on the repair procedure should include
the following types of information:
• The wiring harness was repaired.

24 RENR1367-11
• The Full Load Setting (FLS) was changed per the

factory’s instructions.
Be as specific as possible.
RENR1367-11 25
Customer Specified If a lockable parameter is not locked out, factory

passwords are not required. A locked out parameter
Parameters restricts the parameter from being changed directly
by the customer. This helps vehicle owners that
are encountering problems with operators that are
i01726562 obtaining customer passwords and altering some of
Customer Specified these parameters.
Parameters A locked out parameter also provides an audit trail.

The audit trail can be used to determine the following
SMCS Code: 1901 information:
Customer Specified Parameters allow the vehicle • Time of change

owner to influence the operating technique of a driver.
Some parameters may affect engine operation in a • Operator during change
way that would not be expected by an inadequately
trained driver. These parameters may lead to power The following customer parameters are available for
or performance complaints even though the engine’s lockout:
performance is within the engine’s specification.
• “A/C Pressure Switch Fan-On Time” (Full feature)
Customer parameters may be changed repeatedly
as a customer’s operation changes or as new drivers • “Battery Monitor and Engine Control Voltage ”
are assigned to a truck. Customer passwords may be (OCT01 and newer Personality Modules)
required to change these parameters.
• “Battery Monitor and Low Idle Engine Control”
The following information is a brief description of (OCT01 and newer Personality Modules)
the Customer Specified Parameters. The following
parameter values are included with the descriptions: • “High Cruise Control Speed Set Limit”
• Minimum • “High Speed Range Axle Ratio”
• Maximum • “Input #6” (MAR99 Personality Modules through
JUL01 Personality Modules)
• Default
• “Low Speed Range Axle Ratio”(MAR98 and newer
Note: Parameter values that are shown in bold text Personality Modules)
are programmed settings that disable the feature.
• “Max PTO Vehicle Speed” (OCT01 and newer
The tables show values in an approximate range for Personality Modules)
metric units that is followed by the metric conversion
to English units. The exact range of the parameter in • “Soft Vehicle Speed Limit”
metric units depends on the service tool that is being
used. Each tool may use slightly different conversion • “Top Engine Limit”
factors.
• “Transmission Style”
Customer Parameter Lockout
• “Two Speed Axle Switch” (OCT01 and newer
Personality Modules)
The Customer Parameter Lockout is available in
order to restrict access to changing some of the
available parameters. Locking out a parameter • “Vehicle ID”
requires customer passwords (if used). Once a
parameter is locked out, factory passwords are • “Vehicle Speed Cal J1939-ABS)” (OCT01 and
newer Personality Modules)
required to change the parameter. Also, once a
parameter is locked out, factory passwords are
required to unlock the parameter. • “Vehicle Speed Cal (J1939-Trans)”
• “Vehicle Speed Calibration”
• “Vehicle Speed Limit”
• “VSL Protection”
26 RENR1367-11
When an attempt to change a locked out parameter

occurs, the “Factory Password” screen will come
up. If changing the parameter is required, follow the
instructions on the service tool display.
Factory passwords are also required to change a

parameter from a locked parameter to an unlocked
parameter. If more than one parameter is locked out,
and each one needs to be unlocked, one factory
password is required.
i01592289
Customer Specified
Parameters Table
SMCS Code: 1901
Table 6
Customer Specified Parameter Table

Parameter Available Range or Options Default
Selected Engine Rating Dependent on engine power
Vehicle ID
Vehicle ID 17 Digits
Available characters are dependent all zeroes
on the service tools.
Truck Manufacturer Parameters
Truck Manufacturer GM, Other Not Programmed
Truck Model Type GMT-560 GM 530/540
Vehicle Speed Parameters
Vehicle Speed Calibration GM: 2485 to 238080 PPKM
(4000 to 384000 PPM) GM: 19884 PPKM (32000 PPM)
Other: 2485 to 93226 PPKM Other (Not Programmed)
(4000 to 15000 PPM)
Vehicle Speed CAL (J1939-Trans) 0 rev per km (0 rev per mile) to 43000
(Not Programmed)
rev per km (65000 rev per mile)
Vehicle Speed CAL (J1939-ABS) 0 to 6.550 (Not Programmed)
Vehicle Speed Limit (VSL) GM: 48 to 121 km/h (30 to 75 mph) GM: 121 km/h (75 mph)
Other: 48 to 204 km/h (30 to 127 mph) Other: 204 km/h (127 mph)
VSL Protection GM: 1700 rpm GM: 1700 rpm
Other: 1700 to TEL rpm Other: TEL rpm
Tachometer Calibration GM: 17.5 ppr
2.0 to 500.0 ppr
Other: 134.0 ppr
Soft Vehicle Speed Limit NO YES
Low Speed Range Axle Ratio 0.00 to 19.99 0.00
High Speed Range Axle Ratio 0.0 to 9.99 0.00
Cruise Control Parameters
Low Cruise Control Speed Set Limit GM: 48 to 121 km/h (30 to 75 mph) GM: 48 km/h (30 mph)
(continued)
RENR1367-11 27
(Table 6, contd)
High Cruise Control Speed Set Limit GM: 48 to 121 km/h (30 to 75 mph) GM: 121 km/h (75 mph)
Engine Brake Mode Coast, Latch or Manual Manual
Cruise/Idle/PTO Switch Configuration GM: Set/Decel
Set/Decel-Set/Accel
Other: Set/Accel
Soft Cruise Control GM: NO
YES or NO
Other: YES
Idle Parameters
Idle Vehicle Speed Limit 2 to 24 km/h (1 to 15 mph) 2 km/h (1 mph)
Idle RPM Limit 700 rpm to TEL rpm TEL rpm
Idle/PTO RPM Ramp Rate 5 to 1000 rpm/sec 50 rpm/sec
Idle/PTO Bump RPM 5 to 500 rpm 20 rpm
Fast Idle RPM 1 700 rpm to TEL 1000 rpm
Fast Idle RPM 2 700 rpm to TEL 0 rpm
Dedicated PTO Parameters
PTO Configuration OFF
Cab Switches
OFF
Remote Switches
Remote Throttle
PTO Top Engine Limit 700 to TEL rpm TEL rpm
PTO Engine RPM Set Speed Low idle rpm to PTO TEL rpm 0
PTO Engine RPM Set Speed A
Low Idle rpm, PTO TEL rpm 0
PTO Engine RPM Set Speed B
PTO to Set Speed YES or NO NO
PTO Cab Controls RPM Limit Low idle rpm, TEL rpm, or PTO TEL rpm TEL rpm
PTO Vehicle Speed Limit 2 to 204 km/h (1 to 127 mph) 2 km/h (1 mph)
Torque Limit 135 N·m (100 lb ft) to Rated Torque 2712 N·m (2000 lb ft)
PTO Shutdown Time 3 to 1440 minutes 0
PTO Activates Cooling Fan Normal, Continuous Normal
Maximum PTO Enable Speed 700 rpm to TEL rpm TEL rpm
Maximum PTO Vehicle Speed 24 to 204 km/h (15 to 127 mph) 204 km/h (127 mph)
PTO Active Output J1/P1:19 None
Engine/Gear Parameters
Lower Gears Engine RPM Limit 1500 to TEL rpm TEL rpm
Lower Gears Turn Off Speed 2 to 24 km/h (1 to 15 mph) 2 km/h (1 mph)
Intermediate Gears Engine RPM Limit 1500 to TEL rpm TEL rpm
Intermediate Gears Turn Off Speed 16 to 80 km/h (10 to 50 mph) 16 km/h (10 mph)
Gear Down Protection RPM Limit 1700 to TEL rpm TEL rpm
Gear Down Protection Turn On Speed GM: 48 to 121 km/h (30 to 75 mph) GM: 121 km/h (75 mph)
Top Engine Limit (TEL) Dependent on the engine and the rating Dependent on the engine rating
(continued)
28 RENR1367-11
(Table 6, contd)
Low Idle Engine RPM 700 to 800 rpm 700 rpm
Idle Quality Calibration Decrease 1, 2, 3, or 4
Nominal
Increase 1, 2, 3, or 4, Nominal
Transmission Style GM: Universal
Manual Option 1
Manual Option 2
Automatic Option 1
Automatic Option 2 GM 30/540: Universal
Automatic Option 3 GMT-560: Manual Option 2
Automatic Option 4 Other: ManualOption 1
AT/MT/HT Option 1
AT/MT/HT Option 2
AT/MT/HT Option 3
AT/MT/HT Option 4
AT/MT/HT Part Throttle Shift Speed Low and Medium High
Fan Pulley Ratio 7.375 1.25
Governor Type Min/Max Full Range
Timer Parameters
Idle Shutdown Time 3 to 1440 minutes 0 minutes
Allow Idle Shutdown Override YES
YES
NO
A/C Switch Fan-On Time
0 to 600 seconds 0 seconds
Full Feature Only
Fan with Engine Brake On
YES or NO NO
Full Feature Only
Exhaust Brake Configuration GM 530/540: Exhaust Brake Only
None, Warm Up Only, Exhaust
GMT-560: None
Brake & Warm Up
Other: Exhaust Brake Only
Warm Up Mode Idle Speed 700 rpm to 1400 rpm 1000 rpm
Smart Idle Parameters
Battery Monitor & Engine Control GM 530/540: 0 Volts
Voltage 0 Volts to 25.5 Volts GMT-560: 11.5 Volts
Other: 0 Volts
Battery Monitor Low Idle Speed Monitor 700 rpm to TEL 1000 rpm
Engine Monitoring Parameters
Engine Monitoring Mode GM: OFF,DERATE
Other: OFF,DERATE, WARNING
SHUTDOWN
Engine Monitoring Mode GM 530/540: WARNING,DERATE
GM: WARNING
OCT01 and newer Personality Modules GMT- 560 & Other: WARNING,DERATE
Other: DERATE
SHUTDOWN
Engine Monitoring Lamps (GM only) High Coolant Temp Warning Lamp
Warning Lamp
or Warning Lamp
Coolant Level Sensor GM: NA
4-pin
Other: NO
(continued)
RENR1367-11 29
(Table 6, contd)
Coolant Level Sensor GM 530/540: 4-pin
GM 530/540 & Other: NO
OCT01 and newer Personality Modules GMT- 560: NO
GMT- 560: 2-pin
Other: 2-wire Float Sensor
Oil Pressure Sensor Installed or Not Installed Not Installed
Oil Pressure Sensor GM 530/540 & Other: Installed GM 530/540 & Other: Not Installed
OCT01 and newer Personality Modules GMT- 560: Not Installed GMT- 560: Installed
Oil Level Switch Installation Status
Not Installed Installed
GMT-560 Only
Primary Fuel Tank Size None
GMT-560 Only 25 gallons 50 gallons
35 gallons
Secondary Fuel Tank Size 25 gallons
GMT-560 Only 35 gallons None
50 gallons
Maintenance Parameters
Maintenance Indicator Mode OFF
Manual Distance
Manual Hours OFF
Automatic Distance
Automatic Hours
PM 1 Interval (Manual Maintenance 8050 to 56325 km (5000 to 35000 miles) 24140 km (15000 miles)
Indicator Mode) 100 to 750 hours 250 hours
Engine Oil Capacity (Automatic GM: 21 L (22 qt)
19 to 57 L (20 to 60 qt)
Maintenance Indicator Mode) Other: 31 L (33 qt)
Trip Parameters
Dash - PM 1 Reset YES or NO NO
Dash - Customer Parameters YES or NO NO
Theft Deterrent System Control YES, NO or AUTO-Enable NO
Theft Deterrent Password Four Characters
A thru Z 0000
0 thru 9
Quick Stop Rate 0 km/h per second ( 0 mph per
second) to 205 km/h per second 0 km/h per second (0 mph per second)
(128 mph per second)
Input Selections
Transmission Neutral Switch None,
J1/P1:62
J1939
Exhaust Brake Switch Installed or Not Installed Installed
Exhaust Brake Switch J1/P1:16
OCT01 and newer Personality Modules J1939 Body Controller
None
J1939 Cab Controller
J1939 Instrument Cluster
Input #4
MAR98 through JUN01 Personality Torque Limit Switch None
Modules
Torque Limit Switch J1/P1:17
None
OCT01 and newer Personality Modules J1/P1:23
(continued)
30 RENR1367-11
(Table 6, contd)
Input #5
None,
MAR99 through JUN01 Personality None
Ignore Brake/Clutch Switch
Modules
J1/P1:47 None
OCT01 and newer Personality Modules
Input #6
None,
MAR99 through JUN01 Personality None
2-Speed Axle On/Off Switch
Modules
2-Speed Axle Switch
J1/P1:6 None
Input #7 None,
JUL99 through JUN01 Personality Diagnostic Enable None
Modules PTO Engine RPM Set Speed Input A
Diagnostic Enable J1/P1:46
OCT01 and newer Personality Modules J1939 Body Controller
None
J1939 Cab Controller
PTO Engine RPM Set Speed Input A
J1/P1:46 None
Input #19
None,
JUL99 through JUN01 Personality None
PTO Engine RPM Set Speed Input B
Modules
PTO Engine RPM Set Speed Input B J1/P1:7
None
PTO Engine Shutdown Switch J1/P1:7
None
Cruise Control On/Off Switch J1939 Body Controller
OCT01 and newer Personality Modules J1939 Cab Controller J1/P1:59
Cruise Control Set/Resume Switch J1939 Body Controller
OCT01 and newer Personality Modules J1939 Cab Controller J1/P1:35 & 44
Cruise Pause Switch J1939 Body Controller
OCT01 and newer Personality Modules J1939 Cab Controller None
A/C High Pressure Switch
None J1/P1:41
A/C Fan Request Switch
J1/P1:41 J1/P1:2
Vehicle Speed Input J1939-ABS
J1/P1:32 & 33
J1939-Trans
Fan Override Switch J1939 Body Controller
OCT01 and newer Personality Modules J1939 Cab Controller None
Service Brake Pedal Position Switch #1 J1939 Body Controller
(continued)
RENR1367-11 31
(Table 6, contd)
Clutch Pedal Position Switch J1939 Body Controller
Output Selections
Output #9
Wait to Start Lamp GM: Unavailable
OCT98 through JUN01 Personality
Fast Idle Lamp Other: Fast Idle Lamp
Modules
Fast Idle Enable Lamp Other: J1/P1:31
None
OCT01 and newer Personality Modules GMT-560: J1/P1:21
Wait To Start Lamp
This feature is only available when
J1/P1:31 None
“Truck Manufacturer” is programmed
to “Other”.
Change Oil Lamp
None J1/P1:30
Fan Control Type
(Full Feature Only) On/Off None
Personality Modules prior to JUN01
Fan Control Type GM: On/Off, Variable Speed Option S
OCT01 and newer Personality Modules GMT-560: On/Off, Variable Speed
Option B, Variable Speed Option B25, None
Variable Speed Option B27
Other: On/Off, Variable Speed Option S
Engine Running Output
J1/P1:31 None
Starting Aid Output
Automatic OFF
Customer Passwords
Customer Password (1) 8 Digits
Available characters are dependent
Customer Password (2) on the service tools.
Data Link Parameters
Power train Data Link GM: J1939
None, J1939
Other: None
i01596107 Table 9
Customer Specified Truck Manufacturer Parameters
Parameters Worksheet Truck Manufacturer

Truck Model Type
SMCS Code: 1901
Table 7
Selected Engine Rating
Rating Number
Table 8
ECM Identification Parameters

Vehicle ID
32 RENR1367-11
Table 10 Table 13
Vehicle Speed Parameters Dedicated PTO Parameters
Vehicle Speed Calibration PTO Configuration
(PPM)
PTO Top Engine Limit
Vehicle Speed CAL
(J1939-Trans) PTO Engine RPM Set
Speed
Vehicle Speed CAL
(J1939-ABS) PTO Engine RPM Set
Speed Input A
Vehicle Speed Limit (VSL)
PTO Engine RPM Set
VSL Protection (rpm) Speed Input B
Tachometer Calibration PTO to Set Speed
(PPR)
PTO Cab Throttle RPM
Soft Vehicle Speed Limit Limit
Low Speed Range Axle PTO Vehicle Speed Limit
Ratio
Torque Limit
High Speed Range Axle
Ratio PTO Shutdown Time
PTO Activates Cooling Fan
Table 11
Maximum PTO Enable
Cruise Control Parameters Speed
Low Cruise Control Speed Maximum PTO Vehicle
Set Limit Speed
High Cruise Control Speed PTO Active Output
Set Limit
Engine Brake Mode Table 14
Cruise/Idle/PTO Switch Engine/Gear Parameters

Configuration Lower Gears Engine RPM
Soft Cruise Control Limit
Lower Gears Turn Off
Table 12 Speed
Idle Parameters Intermediate Gears Engine
RPM Limit
Idle Vehicle Speed Limit
Intermediate Gears Turn
Idle RPM Limit Off Speed
Idle/PTO RPM Ramp Rate Gear Down Protection
(rpm/sec) RPM Limit
Idle/PTO Bump RPM Gear Down Protection
Fast Idle RPM (1) Turn On Speed
Fast Idle RPM (2) Top Engine Limit (TEL)

Low Idle Engine rpm
Idle Quality Calibration
Transmission Style
AT/MT/HT Part Throttle
Shift Speed
Fan Pulley Ratio
Governor Type
RENR1367-11 33
Table 15 Table 19
Timer Parameters Input Selections
Idle Shutdown Time Transmission Neutral
(minutes) Switch
Allow Idle Shutdown Exhaust Brake Switch
Override
Input No. 4
A/C Switch Fan-On Time Torque Limit Switch
OCT01 and newer
Fan with Engine Brake On
Personality Modules
Exhaust Brake
Configuration Input No. 5
Warm Up Mode Idle Speed Ignore Brake/Clutch Switch

OCT01 and newer
Personality Modules
Table 16
Input No. 6
Engine Monitoring Parameters
2-Speed Axle Switch
Engine Monitoring Mode OCT01 and newer
Personality Modules
Engine Monitoring Lamps
(GM only) Input No. 7
Coolant Level Sensor Diagnostic Enable
OCT01 and newer
Oil Pressure Sensor
Personality Modules
Oil Level Switch Installation
Input No. 19
Status
GMT-560 Only PTO Engine RPM Set
Speed Input B
Primary Fuel Tank Size
OCT01 and newer
GMT-560 Only
Personality Modules
Secondary Fuel Tank Size
PTO Engine Shutdown
GMT-560 Only
Switch
OCT01 and newer
Table 17 Personality Modules
Maintenance Parameters Cruise Control On/Off
Switch
Maintenance Indicator OCT01 and newer
Mode Personality Modules
PM 1 Interval Cruise Control
(Distance/Hrs.) Set/Resume Switch
Engine Oil Capacity OCT01 and newer
(Quarts/Liters) Personality Modules
Cruise Pause Switch
Table 18 OCT01 and newer
Personality Modules
Trip Parameters
A/C High Pressure Switch
Dash - PM 1 Reset OCT01 and newer
Dash - Customer Personality Modules
Parameters A/C Fan Request Switch
Theft Deterrent Control OCT01 and newer
System Personality Modules
Theft Deterrent Password Vehicle Speed Input
Quick Stop Rate Fan Override Switch

OCT01 and newer
Personality Modules
(continued)
34 RENR1367-11
(Table 19, contd) Current Totals Worksheet

Input Selections
Table 23
Service Brake Pedal
Lifetime Totals
Position Switch #1
OCT01 and newer Total Time
Personality Modules
Total PTO Time
Clutch Pedal Position
Switch Total Idle Time
OCT01 and newer Total Distance
Personality Modules
Total Fuel
Table 20 Total PTO Fuel
Output Selections Total Idle Fuel
Output No. 9
Fast Idle Enable Lamp i01727005
OCT01 and newer
Personality Modules Cruise Control Parameters
Wait To Start Lamp
This feature is only SMCS Code: 1901
available when “Truck
Manufacturer” is
programmed to “Other”. “Low Cruise Control Speed Set
Change Oil Lamp
Limit”
OCT01 and newer
Personality Modules The “Low Cruise Control Speed Set Limit” sets
the lowest vehicle speed that will allow the cruise
Fan Control Type control to be set. Programming this parameter to the
Engine Running Output maximum value disables cruise control.
OCT01 and newer
Personality Modules Table 24
Manufacturer Minimum Maximum Default

Starting Aid Output
OCT01 and newer GM 48 km/h 121 km/h 48 km/h
Personality Modules (30 mph) (75 mph) (30 mph)
Other 24 km/h 204 km/h 204 km/h
Table 21 (15 mph) (127 mph) (127 mph)
Customer Passwords
Customer Password (1) “High Cruise Control Speed Set
Customer Password (2) Limit”
Table 22 The “High Cruise Control Speed Set Limit” sets the
Data Link Parameters
highest vehicle speed that will allow the cruise control
to be set. If a driver attempts to set a vehicle speed
Power train Data Link higher than this limit, the “High Cruise Control Speed
Set Limit” will be the cruise set speed. If the “High
Cruise Control Speed Set Limit” is programmed to a
value that is greater than the “Vehicle Speed Limit”,
the cruise control switches can be used to exceed
the programmed “Vehicle Speed Limit”.
RENR1367-11 35
Table 25 Table 27
Manufacturer Minimum Maximum Default Manufacturer Alternative Default
48 km/h 121 km/h 121 km/h “Set/Accel-Res/ “Set/Decel-
GM GM
(30 mph) (75 mph) (75 mph) Decel” Res/Accel”
204 km/h “Set/Decel-Res/ “Set/Accel-
32 km/h 204 km/h Other
Other (127 Accel” Res/Decel”
(20 mph) (127 mph)
mph)
“Soft Cruise Control”

“Engine Brake Mode”
“Soft Cruise Control” provides a 8 km/h (5 mph)
“Engine Brake Mode” determines the operation of the operating range around the cruise control set speed
engine brake while the cruise control on/off switch in order to provide a smoother cruise control. “Soft
is in the ON position but the engine is not in cruise Cruise Control” controls the cruise speed within the
control. This does not determine the operation of the following range:
engine brake while the engine is in cruise control.
Also, this does not allow operation of the engine • 4 km/h (2.5 mph) below the set vehicle speed at
brake while the engine is in cruise control. full load
The following modes are allowable options: • 4 km/h (2.5 mph) above the set vehicle speed at
no load
• Coast
• Latch
• Manual
When the “Engine Brake Mode” is programmed to
the Coast Mode, the engine brake is enabled only
while the service brakes are being applied. When the
ECM is programmed to the Latch Mode, the engine
brake stays enabled after the service brakes are
released. A direct, immediate pressure on the brake
pedal latches the engine brake in the ON position
and the engine brake will remain in the ON position
until the accelerator pedal is depressed.
When the “Engine Brake Mode” is programmed

to the Manual Mode, the engine brake operates
independently of the cruise control status.
The engine brake operates with the application and

the release of the service brake in the Coast Mode. Illustration 10
g00670797
Soft Cruise control and soft vehicle speed limit

The engine brake turns on with the application of the
service brakes in the Latch Mode. The engine brake Table 28
stays on even when the service brakes are released.
Manufacturer Alternative Default
Table 26
GM “YES” “NO”
Alternative Default
Other “NO” “YES”
“Coast” “Latch” “Manual”
i01728860
“Cruise/Idle/PTO Switch
Configuration” Data Link Parameters
“Cruise/Idle/PTO Switch Configuration” defines the SMCS Code: 1901
function of the set/resume switch for “ACCEL” mode
and “DECEL” mode. This parameter affects cruise “Powertrain Data Link”
control mode, idle mode and PTO mode.
36 RENR1367-11
This parameter must be programmed to “J1939” in Note: When an exhaust particulate filter is installed,
order to receive any switch inputs from the “J1939” the parameter “PTO Configuration” is automatically
data link. This parameter determines if the ECM will programmed to “Cab Switches”. This parameter
communicate to a power train component by using cannot be reprogrammed.
the J1939 data link. If the vehicle is not using the data
link for communication to the power train systems, If the parameter “PTO Configuration” is programmed
this parameter should be programmed to “NONE”. to “Remote Switches”, the ECM will monitor
The following systems are examples of power train programmed signals such as the remote set switch
systems: and remote resume switch. Signals from the cab
controls will be ignored when the PTO on/off circuit is
• Traction control systems on. The following components are cab controls:
• Anti-lock brake systems • Brake switch

• Electronically controlled transmissions • Clutch switch
Note: A 231-11 J1939 Data Link Fault(58) will occur • Accelerator
if the parameter for the power train data link is set
to J1939 without a J1939 power train ECM on the • Cruise control switches
vehicle. The J1939 power train ECM is used to
communicate with the engine ECM. If the parameter “PTO Configuration” is programmed
to “Remote Throttle”, the ECM will monitor input 8
Table 29 (J1/P1:68) for the remote accelerator pedal. The
Manufacturer Alternative Default ECM will monitor programmed signals and the ECM
will ignore all cab controls when the PTO on/off circuit
GM “NONE” “J1939” is on.
Other “J1939” “NONE”
Table 30
Alternative Default
i01727043
“Cab Switches”, “Remote
Dedicated PTO Parameters Switches”, and “Remote
Throttle”
“OFF”
SMCS Code: 1901

“PTO Top Engine Limit”
“PTO Configuration”
The “PTO Top Engine Limit” is the top engine limit
The “PTO Configuration” determines the features that is available by using a PTO on/off circuit that is
that are available for dedicated PTO applications connected to input 1 of ECM connector (J1/P1:56).
and the input signals that are used for dedicated
PTO applications. When the “PTO Configuration” Note: The “PTO Configuration” must be programmed
is programmed to “OFF”, the application does to “Cab Switches”, “Remote Switches”, or “Remote
not use the settings for the PTO. The remaining Throttle” before this parameter can be programmed.
programmable options for the PTO require a PTO
on/off circuit that is connected to ECM input 1 (ECM Table 31
connector J1/P1:56). A PTO switch on lamp can also Minimum Maximum Default
be connected to output 1 (ECM J1/P1 terminal 30).
700 TEL rpm TEL rpm
If the parameter “PTO Configuration” is programmed
to the “Cab Switches”, the ECM will use the signals
from the following two switches for PTO control and “PTO Engine RPM Set Speed”
cruise control:
The “PTO Engine RPM Set Speed” is the engine
rpm that is allowed by the ECM when the PTO on/off
• Cab set switch (J1/P1:35) circuit is on and the set switch is actuated.
• Resume switch (J1/P1:44) If the “PTO to Set Speed” parameter is programmed
to “YES”, the engine will proceed to this speed
whenever the PTO on/off circuit is turned on.
RENR1367-11 37
Note: “PTO Configuration” must be programmed If the “PTO Engine RPM Set Speed B” parameter is
to “Cab Switches” or “Remote Switches” for this programmed to the corresponding switch input option,
parameter to function. the switch is used in order to control engine speed
during PTO operation. The “PTO Configuration”
This parameter must be programmed higher than the parameter must be programmed to “Cab Switches”,
programmed low idle. If the “PTO to Set Speed” is “Remote Switches”, or “Remote Throttle” and the
programmed to a higher value than the “PTO Top “PTO Engine RPM Set Speed B” parameter must be
Engine Limit”, the set speed will be limited by the programmed to a valid speed.
lower “PTO Top Engine Limit”.
For one rpm set speed above low idle, program the
“PTO to Set Speed”
“PTO Top Engine Limit” to the same rpm as the “PTO
This parameter causes the ECM to proceed to the
Engine RPM Set Speed”.
programmed “PTO Engine RPM Set Speed” when
the PTO on/off switch is on. “PTO Configuration”
For two rpm set speeds above low idle, program this
must be programmed to “Cab Switches” or “Remote
parameter to some intermediate value between the
Switches” before this parameter can be programmed.
low idle and the “PTO Top Engine Limit”.
Note: This parameter is not available when “PTO
Move the PTO on/off switch to the ON position.
Configuration” is programmed to “Remote Throttle”.
Toggle the set switch once in order to cause the rpm
to advance to the “PTO Engine RPM Set Speed”. Table 35
Toggle the set switch again in order to increase the
engine rpm to the “PTO Top Engine Limit”. Toggling Alternative Default
the resume switch decreases the engine rpm to the “YES” “NO”
previous set speed.
Table 32 “PTO Cab Throttle RPM Limit”

Minimum Maximum Default
This determines the engine rpm limit of the pedal
Low Idle rpm PTO TEL rpm 0 rpm position sensor for the cab accelerator and the cab
set/resume switch when “PTO Configuration” is
programmed to “Cab Switches” and the PTO on/off
“PTO Engine RPM Set Speed Input circuit is on. This parameter is intended to prevent
A” engine overspeed when the dedicated PTO is used.
JUL99 and newer Personality Modules. • If the parameter is programmed to “Low Idle”, the
cab controls are ignored.
If the “PTO Engine RPM Set Speed A” parameter is
programmed to the corresponding switch input option, • If the parameter is programmed to “Top Engine
the switch is used in order to control engine speed Limit” (TEL), the engine will operate to the
during PTO operation. The “PTO Configuration” programmed “Top Engine Limit”.
parameter must be programmed to “Cab Switches”,
“Remote Switches”, or “Remote Throttle” and the • If the parameter is programmed to “PTO Top
“PTO Engine RPM Set Speed A” parameter must be Engine Limit”, the engine will operate to the
programmed to a valid speed. programmed “PTO Top Engine Limit”.
Table 33 Note: “PTO Configuration” must be programmed

Minimum Maximum Default to “Cab Switches” for this parameter to take effect.
If “PTO Configuration” is programmed to “Remote
Low Idle rpm PTO TEL rpm 0 rpm Switches” or “Remote Throttle”, the ECM will always
ignore the cab controls when the PTO on/off circuit
Table 34 is on.
Minimum Maximum Default Table 36
Low Idle rpm PTO TEL rpm 0 rpm Alternative Default
“Low Idle”, “TEL” and
“TEL”
“PTO Engine RPM Set Speed Input “PTO TEL”
B”
JUL99 and newer Personality Modules.
38 RENR1367-11
“PTO Kickout Vehicle Speed Limit ” “PTO Shutdown Time”

This is the maximum vehicle speed for setting or The “PTO Shutdown Time” is the time (minutes) of
maintaining a set engine rpm in PTO mode. PTO engine operation with the PTO on/off circuit ON and
Mode is entered if the PTO on/off switch is on. (This no vehicle speed before shutting down. The timer will
uses input 1.) If the vehicle speed signal exceeds this only count with no vehicle speed and the PTO on/off
value, the engine will not maintain the set engine rpm. circuit turned on. The PTO shutdown timer will not
begin counting if the engine is in Cold Mode. This
Table 37 parameter requires the “PTO Configuration” to be
Minimum Maximum Default programmed to “Cab Switches”, “Remote Switches”,
or “Remote Throttle” for the timer to function.
204 km/h
2 km/h (1 mph) 2 km/h (1 mph)
(127 mph) Note: This feature does not shut down the vehicle’s
power. The ECM and the vehicle remain powered.
“Torque Limit” Table 39
Manufacturer
Range Default
/ Model
GM 530/540 1440 minutes
3 minutes
GMT-560 to
1440 minutes 0 minutes
Other
“PTO Activates Cooling Fan”

This parameter requires the use of the ECM cooling
fan circuit. When this parameter is programmed to
“Continuous”, the ECM will signal the cooling fan to
run continuously when the PTO on/off circuit is on.
g00628600
Illustration 11 The cooling fan runs continuously in order to reduce
Operation of torque limit changes in the load while the engine is being used for
(1) Programmed torque limit dedicated PTO applications. When this parameter is
programmed to “Normal”, the PTO on/off circuit does
The parameter for the “Torque Limit” defines the not affect the cooling fan. In this mode, the operation
maximum torque output of the engine during of the fan is based on coolant temperature, inlet air
dedicated PTO operation. This parameter provides temperature or air conditioning high head pressure.
temporary protection of equipment. The “Torque The “PTO Configuration” must be programmed to
Limit” of the engine is active when the circuit for the “Cab Switches”, “Remote Switches”, or “Remote
torque limit switch is on. The maximum value is the Throttle” before this parameter can be programmed.
rated torque of the engine. The “Torque Limit” is The “Fan Control Type” must be programmed to
programmable to N·m (lb ft) of torque. Programming “On/Off”.
a value higher than the rated torque is limited by the
Table 40
ECM to rated torque. The torque limit is indicated by
the dashed line in Illustration 11. Alternate Default
Table 38
“Continuous” “Normal”

135 N·m 2712 N·m 2712 N·m “Maximum PTO Enable Speed”
(100 lb ft) (2000 lb ft) (2000 lb ft)
This parameter specifies the maximum engine speed
for the engagement of the PTO mode. The PTO
mode will engage when the engine rpm is equal to the
programmed limit or less than the programmed limit.
Table 41

700 rpm TEL rpm TEL rpm
RENR1367-11 39
“PTO Active Output ” Table 45

OCT01 and newer Personality Modules.
The output driver is capable of providing 1.0 Amp
when the PTO mode is active. The output is on if the “Intermediate Gears Turn Off Speed”
following conditions are met:
This parameter is similar to the “Lower Gears Turn
• The PTO switch is on. Off Speed”. This parameter is typically programmed
to a slightly higher vehicle speed than the “Lower
• PTO Mode is active. Gears Turn Off Speed”.
• The engine speed is within the programmed limits. Table 46
• The vehicle speed is within the programmed limits.
16 km/h (10 mph) 80 km/h (50 mph) 16 km/h (10 mph)
Table 42
Alternate Default “Gear Down Protection RPM Limit”
“J1/P1:19” “None”
This parameter is the engine rpm limit when the
vehicle speed is above the “Gear Down Protection
i01727137 Turn On Speed”. This is a hard limit. The ECM will
not allow fuel to the engine above this limit. This
Engine/Gear Parameters parameter is used to encourage the driver to shift
into overdrive or top gear.
SMCS Code: 1901
Table 47
“Lower Gears Engine RPM Limit”
The engine will accelerate at a slower rate when this
limit is exceeded under normal driving conditions. 1700 rpm TEL rpm TEL rpm
This parameter is used to encourage the driver to
shift to the next highest gear.
Table 43
“Gear Down Protection Turn On Speed”
Minimum Maximum Default This parameter is the vehicle speed when the “Gear
1500 rpm TEL rpm TEL rpm Down Protection RPM Limit” is turned on. This
must be matched to the specific drive train for best
performance. Above this “Vehicle Speed Limit”,
“Lower Gears Turn Off Speed” the engine rpm will be limited by the “Gear Down
Protection RPM Limit”.
The “Lower Gears Turn Off Speed” parameter is
the vehicle speed when the “Lower Gears Engine Table 48
RPM Limit” is shut off. This must be matched with the
“Lower Gears Engine RPM Limit” to the specific drive
train for best performance. 121
48 km/h 121 km/h km/h
GM
Table 44 (30 mph) (75 mph) (75
mph)
204
2 km/h (1 mph) 24 km/h (15 mph) 2 km/h (1 mph) 48 km/h 204 km/h km/h
Other
(30 mph) (127 mph) (127
“Intermediate Gears Engine RPM Limit” mph)
This parameter is similar to the “Lower Gears Engine “Top Engine Limit (TEL)”
RPM Limit”. The engine will accelerate at a slower
rate when this limit is exceeded under normal driving This parameter is the maximum engine rpm when
conditions. This parameter is typically programmed the engine is under load. The engine will still achieve
to a slightly higher rpm than the “Lower Gears Engine rated rpm under no load conditions.
RPM Limit”.
40 RENR1367-11
Table 49 If any other automatic transmission is installed, this

parameter should be programmed to one of the
following options:
2640 rpm 2640 rpm 2640 rpm
• Automatic Option 1
Note: Select ratings have a different “Top Engine
Limit”. • Automatic Option 2
“Low Idle Engine RPM” • Automatic Option 3
The “Low Idle Engine RPM” is the minimum engine • Automatic Option 4
rpm.
If one of the manual options is selected, terminal
Table 50 J1/P1:24 must receive a signal from a clutch pedal
position switch or a message from a clutch switch
Minimum Maximum Default from one of the supported J1939 sources. If one of
700 rpm 800 rpm 700 rpm the transmissions with a neutral switch is selected,
terminal J1/P1:62 must receive a signal from a
transmission neutral switch or a message from a
“Idle Quality Calibration” neutral switch from one of the supported J1939
sources. If one of the transmissions with two brake
This parameter should not be adjusted without first switches is selected, the second brake switch must
consulting a Caterpillar representative. be connected to terminal J1/P1:64.
Table 51
Table 52
Alternative Default
Switch Usage.
Decrease 1, 2, 3, or 4, Nominal Setting For
Transmission Service Service
Increase 1, 2, 3, or 4
Style Brake Brake
Clutch Neutral
Parameter Switch Switch
“Transmission Style” 1 2
“Manual
(Full Feature Only) X X
Option 1”
This parameter is used to tell the ECM the type of “Manual

X X X
transmission that is installed in the vehicle. This Option 2”
parameter is used by the ECM to read the signals “Automatic
X
from the following devices: Option 1”
“Automatic
• Brake switch (No. 2) Option 2”
X X
• Clutch switch “Automatic

X X X
Option 3”
• Neutral switch “Automatic
X X
Option 4”
• Output (No. 7)
“AT/MT/HT
X
The ECM must be programmed to one of the following Option 1”
options if an Allison Wt Automatic Transmission “AT/MT/HT
transmission is installed: X X
Option 2”
“AT/MT/HT
• AT/MT/HT option 1 Option 3”
X X X
• AT/MT/HT option 2 “AT/MT/HT

X X
Option 4”
• AT/MT/HT option 3 “Universal
X X X X
Option”
• AT/MT/HT option 4
RENR1367-11 41
Table 53 This variable is used to calculate the actual fan speed

Manufacturer
for control of the fan.
Alternative Default
/ Model
Table 55
GM “Automatic Option 1”, Universal Minimum Maximum Default
“Automatic Option 2”,
“Automatic Option 3”, 0 7.375 1.25
“Automatic Option 4”,
“AT/MT/HT Option 1”,
“AT/MT/HT Option 2”, “Manual “Governor Type”
GMT-560
“AT/MT/HT Option 3”, Option 2”
“AT/MT/HT Option 4” OCT01 and newer Personality Modules.
“Manual Option 1”
“Manual Option 2” This parameter determines the type of governor that
“Automatic Option 1”, controls the engine. The Full Range governor tries
“Automatic Option 2”, to maintain a constant engine speed for a throttle
“Automatic Option 3”, position. The Min/Max Governor only governs engine
“Automatic Option 4”, “Manual speed when the engine speed is at the minimum
Other
“AT/MT/HT Option 1”, Option 1” allowable engine speed or at the maximum allowable
“AT/MT/HT Option 2”, engine speed. When the engine is operating between
“AT/MT/HT Option 3”, the engine speed limits, the Min/Max Governor tries
“AT/MT/HT Option 4” to keep power constant across the engine speed
range.
“AT/MT/HT Part Throttle Shift Speed”
JUL99 and newer Personality Modules.
Allison Wt Automatic Transmissions require an input

from the ECM to regulate the transmission shifting.
The ECM monitors the accelerator pedal position,
engine speed, vehicle speed, load, cruise control
status and neutral switch status in order to determine
if the transmission should use closed throttle or full
throttle shift modulation. The “AT/MT/HT Part Throttle
Shift Speed” parameter provides three different
settings for shift modulation.
Table 54
Alternative Default
“Low” (80% Enable / “High” (60% Enable /
65% Disable) 45% Disable)
“Medium” (70% Enable
/ 55% Disable)
g00837953
Illustration 12
Programming the “Transmission Style” to “AT/MT/HT
Graph for the Min/Max Governor
Option 1”, “AT/MT/HT Option 2”, “AT/MT/HT Option
3”, or “AT/MT/HT Option 4” activates ECM output 7.
This output controls a shift relay that is connected to Select “Full Range” for manual transmissions and for
a modulator in the Allison transmission. electronically shifted manual transmissions. Select
“Min/Max” for automatic transmissions.
The high setting will cause the transmission to remain Table 56
in a lower gear longer before upshifting to the next
gear. The medium setting is a compromise between Alternative Default
the default setting and the high setting. “Min/Max” “Full Range”
“Fan Pulley Ratio”
Note: This feature is only available when “Truck

Manufacturer” is programmed to “GMT-560”.

42 RENR1367-11
i01858290 OCT01 and newer Personality Modules.

Engine Monitoring Parameters Table 60
Manufacturer
SMCS Code: 1901 or Model
Alternative Default
“Engine Monitoring Mode” GM 530/540

“High Coolant Temp “Warning
Warning Lamp” Lamp”
This parameter determines the level of action that will GMT-560
be taken by the ECM in response to a condition that “Warning
“Warning Lamp”
Other Lamp”
has the capability to damage the engine. The ECM
reads the Caterpillar coolant temperature sensor
and the coolant level sensor, if equipped. If the ECM “Coolant Level Sensor”
has been programmed to monitor the OEM installed
coolant level sensor, the ECM will read that sensor. This parameter determines if the ECM monitors
the input signal of the coolant level sensor. This
Table 57
feature requires the “Engine Monitoring Mode” to be
Manufacturer Alternative Default programmed to “Warning”, “Derate”, or “Shutdown”.
“OFF”,
An OEM installed coolant level sensor must be
GM “WARNING” connected to the ECM in order to use this parameter.
“DERATE”
“OFF”, Table 61
Other “DERATE” and “WARNING”
“SHUTDOWN”
GM N/A N/A
OCT01 and newer Personality Modules. Other “4-pin connector” “NO”
Table 58
Manufacturer
Alternative Default
or Model Table 62
“WARNING”, Manufacturer
GM 530/540 Alternative Default
“DERATE” “WARNING” or Model
GMT-560 “WARNING”, GM 530/540 “4-pin” “NO”
“DERATE”, and
Other “SHUTDOWN” “DERATE” “2-pin
GMT-560 “NO”
switch”
“Engine Monitoring Lamps” Other “2-wire float sensor” “NO”
The “Engine Monitoring Lamps” parameter is “Engine Oil Pressure Sensor”

only available for the GM Truck Manufacturer
configuration. The “Warning Lamp” option configures JUN98 and newer Personality Module.
“Output #9” to be used for the connection of a
warning lamp for use with the Caterpillar Engine An optional engine oil pressure sensor is sometimes
Monitoring System. The optional “High Coolant Temp installed on applications with an instrument cluster
Warning Lamp” setting configures the ECM to provide that requires an engine oil pressure gauge. The
an indication when engine coolant temperature is 3126B engine and the 3126E engine does not require
abnormally high. This circuit is used to interface the an engine oil pressure indicator for engine protection.
GM Vehicle Shutdown System. When output 9 is The HEUI fuel system will not allow the engine to run
programmed to “High Coolant Temp Warning Lamp”, if no engine oil pressure is present.
you can not use the output for a warning lamp for the
Caterpillar Monitoring System. If the engine oil pressure sensor is installed in the
engine, the “Engine Oil Pressure Sensor” parameter
Table 59
must be set to “Installed”. The engine oil pressure
Manufacturer Alternative Default signal will be communicated over the ATA Data link.
“High Coolant Temp “Warning
GM
Warning Lamp” Lamp”
Other N/A N/A
RENR1367-11 43
Table 63 Table 67
Alternatives Default Alternatives Default
“Installed” “Not Installed” “25 gallons” “None”
“35 gallons”
“50 gallons”
Table 64
i02200171
Manufacturer Alternatives Default
or Model Idle Parameters
GM 530/540 “Installed” “Not Installed”
SMCS Code: 1901
GMT-560 “Not Installed” “Installed”
Other “Installed” “Not Installed” “Idle Vehicle Speed Limit”
The “Idle Vehicle Speed Limit” is the maximum
“Oil Level Switch Installation Status”
vehicle speed for setting or maintaining a set engine
rpm in the idle mode. In order to enter the idle mode,
the engine rpm must be set by the set/resume switch
while the cruise control on/off switch is in the ON
position. If the vehicle speed signal exceeds this
value, the engine will not maintain the set engine rpm.
This parameter is used to tell the ECM that an oil Table 68
level sensor is installed.
Table 65
2 km/h (1 mph) 24 km/h (15 mph) 2 km/h (1 mph)
Alternatives Default
“Not Installed” “Installed” “Idle RPM Limit”
“Primary Fuel Tank Size” The “Idle RPM Limit” is the maximum engine rpm in
idle mode. The idle mode occurs if the engine rpm
Note: This feature is only available when “Truck is set by using the cruise control on/off switch and
Manufacturer” is programmed to “GMT-560”. the set/resume switch. Refer to “Idle Vehicle Speed
Limit”. The actual high limit of this parameter is
OCT01 and newer Personality Modules. determined by the programmed “Top Engine Limit”.
The lower limit is determined by the programmed
This parameter is used to identify the size of the “Low Idle Engine RPM”.
primary fuel tank in gallons.
Programming this parameter to 600 rpm will prevent
Table 66 the engine from idling at a constant rpm above the
Alternatives Default programmed “Low Idle Engine RPM”.
“None” “50 gallons” Table 69

“25 gallons”
“35 gallons” Minimum Maximum Default
“Secondary Fuel Tank Size”
Note: This feature is only available when “Truck “Idle/PTO RPM Ramp Rate”
The “Idle/PTO RPM Ramp Rate” determines the
OCT01 and newer Personality Modules. rate of increase or decrease of engine rpm. This
parameter determines rates of increase or decrease
This parameter is used to identify the size of the in engine rpm for the following functions:
secondary fuel tank in gallons.
• Accel
• Decel
• Resume idle
44 RENR1367-11
• PTO “Fast Idle RPM 2”

The parameter can be set to a value between 5 rpm “Fast Idle RPM 2” determines the second fast idle
and 1000 rpm in increments of one rpm. engine rpm that is controlled by the fast idle enable
switch. The “Fast Idle RPM 2” is disabled by changing
Note: This parameter affects both idle control and the parameter to 0.
PTO control. The idle mode occurs if the engine rpm
is set by using the cruise control on/off switch and If the engine is operating at the “Fast Idle RPM
the set/resume switch. The PTO mode occurs if the 1” setting, actuating the “Fast Idle Enable” switch
engine rpm is set by using the PTO on/off switch and will increase the engine idle speed to the engine
the set/resume switch. speed that is programmed at the “Fast Idle RPM 2”
parameter. Actuating the fast idle enable switch for a
Table 70 third time will cause the engine rpm to return to low
Minimum Maximum Default idle. The engine rpm changes to “Fast Idle RPM 1”,
“Fast Idle RPM 2”, and low idle rpm at a rate that is
5 rpm/sec 1000 rpm/sec 50 rpm/sec independent of the value that is programmed as the
“Idle/PTO RPM Ramp Rate” parameter.
“Idle/PTO Bump RPM” Table 73
The “Idle/PTO Bump RPM” determines the increment
or the decrement in engine rpm when the “Accel” 700 rpm TEL rpm 0 rpm
switch or the “Decel” switch is briefly toggled. The
“Idle/PTO Bump RPM” also pertains to the dedicated
PTO and to engine idle. If the “PTO Engine RPM i01728467
Set Speed” has been set then the “Idle/PTO Bump
RPM” pertains only to the engine speed control Input Selections
that is initiated with the cruise control on/off switch.
When the “PTO Engine RPM Set Speed” has been SMCS Code: 1901
programmed, the “Idle/PTO Bump RPM” does not
pertain to the control of the engine rpm that is initiated “Transmission Neutral Switch”
by utilizing the PTO on/off circuit.
This parameter is used to specify the input that will
Table 71 be used by the ECM to receive the status information
Minimum Maximum Default from the Neutral Switch. The default J1/P1:62
configures the ECM to monitor pin 62 of the vehicle
5 rpm 500 rpm 20 rpm harness connector for a connection for the neutral
switch circuit.
“Fast Idle RPM 1” The ECM can also be configured to receive the
status of the neutral switch via the J1939 data link.
“Fast Idle RPM 1” determines the fast idle engine The transmission ECU must be capable of supporting
rpm that is controlled by the fast idle enable switch. the required protocol of the broadcast announcement
Actuating the fast idle switch will cause the engine message.
speed to increase to the programmed value. This rpm
can be overridden by the operator. To override the Table 74
“Fast Idle RPM 1” setting, depress the accelerator
Alternative Default
pedal until the desired rpm is reached. Once the
desired engine rpm is reached, depress the “Fast “J1939”,“ None” “J1/P1:62”
Idle Enable” switch. The ECM retains this value as
the “Fast Idle RPM 1” parameter until the ECM is
powered down.
Table 75
Table 72
Manufacturer Alternatives Default
Minimum Maximum Default / Model
700 rpm TEL rpm 1000 rpm GM 530/540 “J1939”, “None” “J1/P1:62”
GMT-560 “J1/P1:62”, “J1939”
“None”
Other “J1939”, “None” “J1/P1:62”
RENR1367-11 45
“Exhaust Brake Switch” OCT01 and newer Personality Modules.
The exhaust brake can be controlled by connecting This parameter configures an input for a torque limit
an on/off switch into the ECM circuit for the output switch. The torque limit switch is used to limit the
of the exhaust brake. The “Exhaust Brake Switch” engine torque. This feature should only be used for
parameter must be programmed to “Not Installed” if a temporary protection of equipment. This parameter
switch is installed in the output circuit. A switch that is must be programmed to J1/P1:7 or J1/P1:23 in order
installed in the output circuit will disable the brake by to enable this feature.
opening the output circuit.
Table 79
The exhaust brake can also be controlled by Alternative Default
connecting a switch circuit to the ECM switch input.
This parameter must be programmed to “Installed” if “J1/P1:7”, “J1/P1:23” “NONE”
a switch is connected to the ECM at the dedicated
input for the exhaust brake. “Input #5”
Table 76
MAR99 through JUN01 Personality Modules.
Alternative Default
The “Input #5” to the ECM can be used to connect an
“Installed” “Not Installed”
brake/clutch disable switch. The brake/clutch disable
switch is used for applications that require the mobile
OCT01 and newer Personality Modules. use of the vehicle with a set engine rpm that does
not require the brake or the clutch to disengage
The exhaust brake can be controlled by connecting the engine rpm set speed. This parameter must be
an on/off switch into the ECM circuit for the output programmed to “Ignore Brake/Clutch Switch” for this
of the exhaust brake. The “Exhaust Brake Switch” feature to be enabled.
parameter must be programmed to “NONE” if a
switch is installed in the output circuit. A switch that is Table 80
installed in the output circuit will disable the brake by Alternative Default
opening the output circuit.
“Ignore Brake/Clutch
“NONE”
The exhaust brake can also be controlled by Switch”
connecting a switch circuit to the ECM switch input.
This parameter must be programmed to “J1/P1:16”, “Ignore Brake/Clutch Switch”
“J1939 Body Controller”, “J1939 Cab Controller”, or
“J1939 Instrument Cluster” if a switch is connected to OCT01 and newer Personality Modules.
the ECM at the dedicated input for the exhaust brake.
This parameter configures an input for a brake/clutch
Table 77 disable switch. The “Ignore Brake/Clutch Switch” is
Alternative Default used for applications that require the mobile use of
the vehicle with a set engine rpm that does not require
“J1/P1:16” “NONE” the brake or the clutch to disengage the engine rpm
“J1939 Body Controller”
“J1939 Cab Controller”
set speed. This parameter must be programmed to
“J1939 Instrument Cluster” “J1/P1:47” for this feature to be enabled.
Table 81
“Input #4” Alternative Default
MAR98 through JUN01 Personality Modules. “J1/P1:47” “NONE”
The “Input #4” to the ECM can be used to connect a “Input #6”
torque limit switch in order to limit the engine torque.
This feature should only be used for temporary MAR99 through JUN01 Personality Modules.
protection of equipment. This parameter must be
programmed to “Torque Limit Switch” in order to
enable this feature.
Table 78
Alternative Default
“Torque Limit Switch” “NONE”
“Torque Limit Switch”

46 RENR1367-11
The “Input #6” to the ECM is used to connect the “Diagnostic Enable”
two-speed axle switch. When a two-speed axle
is used, the change in gear ratios from the main OCT01 and newer Personality Modules.
drive axle ratio to the two-speed axle ratio alters
the calibration of the vehicle speed signal. When This parameter configures an input for a diagnostic
the parameter is programmed to “Two Speed Axle enable switch. The diagnostic enable switch is used
Switch” and the switch is in the ON position the ECM to retrieve diagnostic flash codes. Set this parameter
automatically adjusts the vehicle speed calibration. to “J1/P1:46” if a switch is wired to this input. Set this
This will ensure that the ECM driven speedometer parameter to “J1939 Body Controller”, “J1939 Cab
and the information that is stored in the ECM correctly Controller”, or “J1939 Instrument Cluster” if a J1939
reflect the actual vehicle speed. message is used.
Table 82 Table 85
Alternative Default Alternative Default
“Two Speed Axle Switch” “NONE” J1/P1:46 “NONE”
“J1939 Body Controller”
“Two-Speed Axle Switch” “J1939 Instrument Cluster”

“PTO Engine RPM Set Speed Input A”
This parameter configures an input for a two-speed
axle switch. When a two-speed axle is used, the OCT01 and newer Personality Modules.
change in gear ratios from the main drive axle ratio
to the two-speed axle ratio alters the calibration of This parameter configures an input for a PTO engine
the vehicle speed signal. When the parameter is rpm set speed A switch. This switch is used to
programmed to “J1/P1:6” and the switch is in the ON control engine speed during PTO operation. The
position the ECM automatically adjusts the vehicle “PTO Configuration” parameter must be programmed
speed calibration. This will ensure that the ECM to “Cab Switches”, “Remote Switches” or “Remote
driven speedometer and the information that is stored Throttle” and the “PTO Engine RPM Set Speed A”
in the ECM correctly reflect the actual vehicle speed. parameter must be programmed to a valid speed.
Table 83 Table 86
Alternative Default Alternative Default
“J1P1:6” “NONE” “J1P1:46” “NONE”
“Input #7” “Input #19”
JUL99 through JUN01 Personality Modules. JUL99 through JUN01 Personality Modules.
A PTO engine rpm set speed A switch or a diagnostic The PTO engine rpm set speed B switch can be
enable switch can be connected to “Input #7”. If the connected to “Input #19”. If the “Input #19” parameter
parameter is programmed to “Diagnostic Enable”, is programmed to “PTO Engine RPM Set Speed
the switch is used to prompt diagnostic flash codes. Input B”, the switch is used to control engine speed
If the parameter is programmed to “PTO Engine during PTO operation. The “PTO Configuration”
RPM Set Speed Input A”, the switch is used to parameter must be programmed to “Cab Switches”,
control engine speed during PTO operation. The “Remote Switches” or “Remote Throttle” and the
“PTO Configuration” parameter must be programmed “PTO Engine RPM Speed Input B” parameter must
to “Cab Switches”, “Remote Switches” or “Remote be programmed to a valid speed.
Throttle” and the “PTO Engine RPM Speed Input A”
Table 87
parameter must be programmed to a valid speed.
Table 84
“PTO Engine RPM Set
Alternatives Default “None”
Speed Input B”
“Diagnostic Enable”,
“PTO Engine RPM Set “NONE” “PTO Engine RPM Speed Input B”
Speed Input A”
RENR1367-11 47
This parameter configures an input for a PTO engine “Cruise Control Pause Switch”
rpm set speed B switch. This switch is used to
control engine speed during PTO operation. The OCT01 and newer Personality Modules.
“PTO Configuration” parameter must be programmed
to “Cab Switches”, “Remote Switches” or “Remote This parameter configures an input for use as a
Throttle” and the “PTO Engine RPM Set Speed B” cruise control pause switch. This functionality is
parameter must be programmed to a valid speed. only available for use over a J1939 data link. This
feature affects cruise control, elevated idle, and PTO
Table 88 operation.
Table 92
“J1/P1:7”, “J1P1:23” “None”
Alternative Default
“J1939 Body Controller” “NONE”
“PTO Engine Shutdown Switch” “J1939 Cab Controller”
“J1939 Instrument Cluster”
This parameter configures an input to use for a “A/C High Pressure Switch”
engine shutdown switch. The switch will shut down
the engine when the engine is in PTO mode and OCT01 and newer Personality Modules.
there is no vehicle speed.
This parameter determines if the high pressure
Table 89 switch for the air conditioning system will control the
output for the cooling fan. When this parameter is
programmed to “J1/P1:41”, the ECM will turn on the
“J1/P1:7”, “J1P1:23” “None” cooling fan when the high pressure switch opens.
Table 93
“Cruise Control On/Off Switch”
OCT01 and newer Personality Modules. “None” “J1/P1:41”
This parameter configures an input for a cruise
control on/off switch. Set this parameter to “J1/P1:59” “A/C Fan Request Switch”
if a switch is wired to this input. Set this parameter
to “J1939 Body Controller”, “J1939 Cab Controller”, Note: This feature is only available when “Truck
or “J1939 Instrument Cluster” if a J1939 message Manufacturer” is programmed to “GMT-560”.
is used.
Table 90
Alternative Default
This parameter configures the cooling fan to start
when the clutch for the air conditioning compressor
“J1939 Body Controller” “J1/P1:59” is engaged.
“J1939 Instrument Cluster” Table 94
“Cruise Control Set/Resume Switch”
“J1/P1:41” “J1/P1:62”
“Vehicle Speed Input”
This parameter configures an input for a cruise
control set/resume switch. Set this parameter to The ECM has an input circuit that can be used to
“J1/P1:35 & 44” if a switch is wired to this input. Set receive vehicle speed information. The ECM input
this parameter to “J1939 Body Controller”, “J1939 can receive the vehicle speed information in either of
Cab Controller”, or “J1939 Instrument Cluster” if a the following ways:
J1939 message is used.
• A vehicle speed sensor can be connected to the
Table 91 input.
Alternative Default
• A signal wire from an electronic control can be
“J1939 Body Controller” “J1/P1:35 & 44” connected to the input.
48 RENR1367-11
The “Vehicle Speed Input” parameter must be This switch input is required for some transmission
programmed to “J1/P1:32 & 33” to use this option. styles. A switch can be wired to this input or a J1939
message may be used as an input.
The ECM can also be configured to receive vehicle
speed information from an Electronic Transmission
Control Unit via the J1939 data link. The transmission
must be capable of supporting the “J1939 ETC1 Table 98
Broadcast Message”. The “Vehicle Speed Input” Alternative Default
must be programmed to “J1939-Trans”.
“J1939 Body Controller” “J1/P1:22”
The ECM can also be configured to receive vehicle “J1939 Cab Controller”
speed information from the ABS system via the
J1939 data link. The ABS system must be capable
of supporting the “J1939 High Resolution Wheel
i01727522
Speed Broadcast Message”. The “Vehicle Speed
Input” must be programmed to “J1939-ABS”. The
“J1939-ABS” option is only available with OCT01 and
Maintenance Parameters
newer Personality Modules . SMCS Code: 1901
Table 95
“Maintenance Indicator Mode”
Alternative Default
“J1939-Trans” “J1/P1:32 & 33” The ECM records data that is related to the
“J1939-ABS” vehicle’s maintenance. If “Distance” is selected,
all maintenance indications on the service tool
will be displayed in distance. Typical maintenance
“Fan Override Switch” indications are “PM 1”, “PM 2” and the “Coolant
Flush/Fill”.
If “Hour” is selected, all maintenance indications
This parameter selects the J1939 source that will on the service tool will be displayed in Hours.
broadcast a switch position in order to override the Typical maintenance indications are “PM 1”, “PM
fan control. When the fan override switch is activated, 2” and the “Coolant Flush/Fill”. The ECM provides
the ECM will receive a J1939 message. The ECM will “PM 1” maintenance interval and last maintenance
disregard all other parameters for fan control and the information.
ECM will turn on the fan.
Table 99
Table 96
Alternative Default
Alternative Default
Manual Distance
“J1939 Body Controller” “NONE” Manual Hours
“J1939 Cab Controller” OFF
Automatic Distance
“J1939 Instrument Cluster” Automatic Hours
“Service Brake Pedal Position Switch #1” Note: When the “Truck Manufacturer” parameter is
programmed to “GMT-560”, “Automatic Distance” is
OCT01 and newer Personality Modules. the default setting.
This switch input is required. A switch can be wired “PM 1 Interval (Manual Maintenance Indicator
to this input or a J1939 message may be used as Mode”
an input.
The “PM 1 Interval” allows a maintenance interval
Table 97
(“PM 1”) to be specified by the user. This parameter
Alternative Default (“PM 1 Interval”) must be programmed only when
the Maintenance Indicator Mode is programmed to a
“J1939 Body Controller” “J1/P1:45”
Manual Mode (Distance or Hours).
“Clutch Pedal Position Switch”

RENR1367-11 49
Table 100 If “Output #9” is programmed to “Fast Idle Lamp”, the

Manual Distance output will turn on when fast idle operation is active.
This requires the “Fast Idle RPM #1” parameter to
Minimum Maximum Default be programmed to a value above low idle and a
8047 km 56327 km 24140 km
momentary switch to be installed on input 18.
(5000 miles) (35000 miles) (15000 miles)
If the “Output #9” parameter is programmed to “Wait
to Start Lamp”, the output will turn on when the air
Table 101
inlet heater is on and the engine is not running.
Manual Hours
Table 104
100 750 250
GM N/A N/A
“PM1 Engine Oil Capacity (Automatic Other “Wait to Start “Fast Idle Lamp”
Maintenance Indicator Mode)” Lamp”
The “PM 1 Interval” can be determined by the When the “Truck Manufacturer” parameter is
ECM. The ECM bases the “PM 1 Interval” on fuel programmed to “GM” the “Output #9” (Warning
usage. This parameter (“PM 1 Interval”) must be Lamp) is used with the standard Caterpillar
programmed only when the Maintenance Indicator Engine Monitoring system. With SEP00 and newer
Mode is programmed to an Automatic Mode Personality Modules, “Output #9” can be configured
(Distance or Hours). Capacity of the sump influences to only activate when the ECM detects high engine
the maintenance interval. coolant temperature. The “Engine Monitoring Lamps”
parameter can be programmed to “Warning Lamp” for
Table 102 normal operation with the Engine Monitoring system.
Manufacturer Minimum Maximum Default This is the default option. The “Engine Monitoring
Lamps” parameter can also be programmed to the
21 L “High Coolant Temp Warning Lamp” option. In this
GM 19 L (20 qt) 57 L (60 qt)
(22 qt)
configuration, the ECM will only provide an indication
31 L of high coolant temperature. This setting allows the
Other 19 L (20 qt) 57 L (60 qt)
(33 qt) ECM to interface with the Vehicle Shutdown System.
When this setting is used, the warning lamp will
OCT01 and newer Personality Modules. not be available for normal use with the Caterpillar
Engine Monitoring System.
Table 103
When the ECM is configured for the “High Coolant
Manufacturer Minimum Maximum Default Temp Warning Lamp” option, the output for the
/ Model
warning lamp (terminal 29) will be connected to the
21 L vehicle shutdown module. The ECM will provide
GM 530/540 19 L (20 qt) 57 L (60 qt)
(22 qt) a ground path at terminal 29, if a high coolant
temperature is detected. If a ground path is present
GMT-560 19 L (20 qt) 57 L (60 qt) 28 L
(30 qt) at the ECM output for the warning lamp (terminal 29),
the vehicle shutdown module will disrupt keyswitch
31 L power to the ECM. This will cause the engine to shut
Other 19 L (20 qt) 57 L (60 qt)
(33 qt) down. The ECM will only pull terminal 29 to ground
when all of the following conditions are present:
i01728725 • “Truck Manufacturer” parameter is programmed

to “GM”.
Output Selections
SMCS Code: 1901
• “Engine Monitoring Mode” parameter is not
programmed to “OFF”.
“Output #9”
• “Engine Monitoring Lamps” parameter is
programmed to “High Coolant Temp Warning
OCT98 through JUN01 Personality Modules. Lamp”.
“Output #9” can be used to connect a fast idle lamp
or a wait to start lamp.
• The engine has been running for a minimum of 30
seconds.
50 RENR1367-11
• The coolant temperature sensor circuit has no Table 106

open circuit faults that are active. Alternatives Default
• The coolant temperature sensor circuit has no “J1/P1:31” “NONE”

short circuit faults that are active.
“PTO Switch On Lamp”
• The coolant temperature is at 113 °C (235 °F) or
above 113 °C (235 °F) for four seconds. OCT01 and newer Personality Modules.
Note: If the circuit for terminal 29 is shorted to ground This parameter configures the ECM to turn on a lamp
in the wiring harness, the vehicle shutdown module that is connected to output J1/P1:30 when the engine
will shut down the engine. is in PTO mode.
After a ground has been detected for two seconds, Table 107
the vehicle shutdown module will alert the driver of an
impending shutdown. A “Check Gauges” message Alternatives Default
and an audible tone will be present for approximately “NONE” “J1/P1:30”
25 seconds. A second tone will then sound when the
vehicle shutdown module removes keyswitch power
from the ECM input. When the keyswitch power is “Change Oil Lamp”
removed from the ECM input, the engine will shut
down. OCT01 and newer Personality Modules.
Note: When the “High Coolant Temp Warning This parameter configures the ECM to turn on a
Lamp” feature is utilized, the other Caterpillar engine lamp that is connected to output J1/P1:30 when the
monitoring features are not available to shut down the programmed maintenance parameters indicate that
engine. The vehicle shutdown module may provide an oil change is needed.
similar functions. Table 108
“Fast Idle Enabled Lamp” Alternatives Default

“NONE” “J1/P1:30”
This parameter configures the ECM to turn on a lamp “Fan Control Type”
that is connected to output J1/P1:31 or to output
J1/P1:21 when fast idle operation is active. To use Personality Modules prior to JUN01.
this feature, a momentary switch must be connected
to input #18 (J1/P1:40) and the parameter “Fast Idle If the ECM is used to operate the cooling fan, this
RPM #1” must be programmed to a valid speed that parameter must be programmed to the “On/Off”. This
is above low idle. parameter should be programmed to “NONE” if the
ECM is not connected to the cooling fan relay or the
Table 105 cooling fan solenoid. Also, this parameter should be
Manufacturer
programmed to “NONE” if the ECM is not operating
Alternatives Default the cooling fan relay or the cooling fan solenoid.
/ Model
When this parameter is programmed to “NONE”, the
“J1/P1:21” service technician can use Cat ET to determine that
Other “J1/P1:31”
“NONE” the ECM is not connected to the fan circuit.
“J1/P1:31”
GMT-560 “J1/P1:21” Table 109
“NONE”
Alternative Default
“Wait To Start Lamp” “On/Off” “NONE”

Manufacturer” is programmed to “Other”. “Fan Control Type”
This parameter configures the ECM to turn on a OCT01 and newer Personality Modules.
lamp that is connected to output J1/P1:31 when the
air inlet heater is on and the engine is not running.
“Fast Idle Enabled Lamp” must be programmed to
“J1/P1:21” for this feature to be used.
RENR1367-11 51
If the ECM is used to operate the cooling fan, this i02374245

parameter must be programmed to the “On/Off”
or one of the optional parameters. This parameter Passwords
should be programmed to “NONE” if the ECM is not
connected to the cooling fan relay or the cooling fan SMCS Code: 1901
solenoid. Also, this parameter should be programmed
to “NONE” if the ECM is not operating the cooling Customer Passwords
fan relay or the cooling fan solenoid. When this
parameter is programmed to “NONE”, the service
“Customer Password #1”
technician can use Cat ET to determine that the ECM
is not connected to the fan circuit. This parameter is optional. This parameter is
Table 110
a password that is created by the customer.
This parameter can be up to eight alphanumeric
Manufacturer characters in length. If this parameter is programmed,
Alternative Default
/ Model Password 1 is required in order to change any of the
“On/Off” customer specified parameters.
GM
“Variable Speed Option S”
“On/Off” “Customer Password #2”
“On/Off Option B”
“Variable Speed Option This parameter is optional. This parameter is
GMT-560 B25” “NONE” a password that is created by the customer.
“Variable Speed Option This parameter can be up to eight alphanumeric
B27” characters in length. If this parameter is programmed,
(1)
Password 2 is required in order to change any of the
“On/Off” customer specified parameters.
Other
“Variable Speed Option S”
(1) All of the “B options” are not available with the OCT01 software i02126985
release.
Selected Engine Rating
“Engine Running Output”
SMCS Code: 1901
Manufacturer” is programmed to “GMT-560”. “Rating Number”
OCT01 and newer Personality Modules. The rating number is the selected rating within a
power rating family. The personality module defines
This parameter configures the ECM to control a the power rating family (224 kW (300 hp)) and the
solenoid or a relay in order to prevent the starter personality module may contain only one or several
motor from being engaged after the engine has ratings. The rating number defines the power rating
started. that is used within the power rating family.
Table 111
Alternative Default ECM Identification Parameters
“J1/P1:31” “NONE” “Vehicle ID”
“Starting Aid Output” “Vehicle Identification” is the identification of the
vehicle that is assigned by the customer. “Vehicle
OCT01 and newer Personality Modules. Identification” is used only for the customer’s
reference. “Vehicle Identification” is not required by
This parameter is used to allow the ECM to determine the Engine Control Module (ECM).
if conditions are correct for the use of a starting aid
(ether).
i01727431
Table 112
Smart Idle Parameters
Alternative Default
SMCS Code: 1901
“Automatic” “OFF”
“Battery Monitor & Engine Control Voltage”

52 RENR1367-11
This parameter sets a voltage trip point. When This parameter determines if the clutch or the service
the voltage falls below the trip point the ECM will brake can be used to override the idle shutdown
automatically elevate the engine speed to the rpm timer during the driver alert. The driver alert is the
that is specified in the “Battery Monitor & Low Idle last 90 seconds when the check engine lamp begins
Engine Speed” parameter. flashing. This parameter requires the “Idle Shutdown
Time” to be programmed to a 3 or more minutes
Table 113 for the parameter to be enabled. When the “Idle
Manufacturer Shutdown Time” is programmed to 0, the parameter
Minimum Maximum Default is turned off.
/ Model
GM 530/540 0 Volts Table 116
GMT-560 0 Volts 25.5 Volts 11.5 Volts Alternative Default
Other 0 Volts “NO” “YES”
“Battery Monitor Low Idle Engine Speed” “A/C Switch Fan-On Time”
OCT01 and newer Personality Modules. Input 11 to the ECM can be used for the connection
of a normally closed high pressure A/C switch.
This parameter sets the engine speed if the battery The ECM has a built-in timer. The timer is used
voltage falls below the trip point that is specified to prevent excessive cycling of the cooling fan
in the “Battery Monitor & Engine Control Voltage” clutch due to successive cycling of the A/C switch.
parameter. Programming this parameter to 0 disables the
function. Programming depends on the refrigerant,
Table 114 and the design of the air conditioning system as
Minimum Maximum Default well as the use of the signal input. Program the
timer to 1 second for the connection of this input to
700 rpm TEL 1000 rpm another system. Programming the timer to 1 second
also provides a time delay. This feature requires the
“Fan Control Type” parameter to be programmed to
“On/Off” or to “Variable Speed Fan Option S”. Also,
i01727228 the “A/C High Pressure Switch” parameter must
be programmed to “J1/P1:41”or to “J1/P1:62” for
Timer Parameters GMT-560.
SMCS Code: 1901 Table 117
“Idle Shutdown Time”
GM N/A N/A N/A
The “Idle Shutdown Time” is the time (minutes) of
600
engine idle before shutting down. The engine will Other 0 seconds
seconds
0 seconds
only shut down if the ECM senses low engine load
and no vehicle speed. The “Idle Shutdown Time” will
not begin counting if the engine is in Cold Mode. If OCT01 and newer Personality Modules.
this parameter is programmed to zero, this feature is
disabled and the engine will idle until the keyswitch Table 118
for the ignition is in the OFF position. Minimum Maximum Default
Note: This feature does not shut down the vehicle’s 0 second 600 seconds 0 seconds
power. The ECM and the vehicle remain powered.
“Fan with Engine Brake On”
Table 115
Minimum Maximum Default This parameter determines whether the cooling fan
will turn on when the engine brake has been active
3 minutes 1440 minutes 0 minutes for at least two seconds. This feature requires the
“Fan Control Type” parameter to be programmed to
“Allow Idle Shutdown Override” “On/Off”. An on/off fan must also be installed in order
for this option to be functional.
RENR1367-11 53
Table 119 Table 123

Manufacturer Alternatives Default Alternative Default
GM N/A N/A “YES” “NO”
Other “YES” “NO”
OCT01 and newer Personality Modules. Table 124
Table 120 Manufacturer / Model Alternatives Default

Alternatives Default GM 530/540 “YES” “NO”
“YES” “NO” GMT-560 “NO” “YES”
Other “YES” “NO”
“Exhaust Brake Configuration”
“Dash - Customer Parameters”
Four parameters can be accessed when this
This parameter determines the functionality of
parameter is programmed to “YES”. The Cat ID is
the exhaust brake. The exhaust brake can be
used to change the “Dash - Customer” parameters.
programmed only as an exhaust brake to aid in
The following four parameters can be accessed:
slowing the vehicle or the exhaust brake can be
programmed to put a load on the engine in order to
warm up the engine faster. • “SoftCruise Control”
Table 121 • “Fast Idle RPM #1”

Manufacturer/ • “Fast Idle RPM #2”
Model
GM 530/540 “None” “Exhaust Brake • “Low Idle Engine RPM”

“Exhaust Brake Only”
Only” Each parameter that is listed has a “YES/NO” option
GMT-560 “None”
“Warm Up” with “NO” as the default. The Cat ID must have the
“Exhaust Brake “Exhaust Brake EEPROM chip that is capable of communicating with
Other & Warm Up” Only” the 3126B HEUI engine software. Version 1.3 and
later versions meet this requirement.
“Warm Up Mode Idle Speed” Table 125
OCT01 and newer Personality Modules. Alternative Default

“YES” “NO”
This parameter determines the idle speed of
the engine until the engine reaches operating
temperature. “Theft Deterrent System Control”
Table 122 When this parameter is used with a “Theft Deterrent

Password”, this parameter prevents the engine from
starting unless the password has been entered via
700 rpm 1400 rpm 1000 rpm the dash display of the CAT ID. Before the operator
can use the feature of theft deterrent of the CAT
ID, the system must be turned on. In order to turn
i01727555 on the theft deterrent, a service tool must be used
to program the parameter for the theft deterrent to
Trip Parameters YES. The operator must first enter the password
before the engine is shut off. This will enable the
SMCS Code: 1901 system. Enabling the system prevents the engine
from starting without re-entering the password
“Dash - PM 1 Reset” on the next attempted start. If this parameter is
programmed to the “Auto-Enable” option, the system
This parameter determines if the Caterpillar Driver will automatically be armed when the keyswitch is
Information Display (Cat ID) can be used to reset turned off.
the PM 1 Maintenance Interval. The “Maintenance
Indicator Mode” cannot be programmed to “OFF” for
the PM 1 reset parameter to take effect.
54 RENR1367-11
Note: The “Auto-Enable” feature requires a JUL99 Table 129

or more recent Personality Module with a Cat ID Alternative Default
(version number 2.1 or higher).
0 kilometers per hour
Table 126 per second ( 0 miles per
0 kilometers per hour
hour per second) to 205
Alternative Default second (0 miles per
kilometers per hour per
hour per second)
“YES”, “Auto-Enable” “NO” second (128 miles per
hour per second)
“Theft Deterrent Password”

Note: Programming the “Quick Stop Rate” too low
The “Theft Deterrent Password” is the password will cause an excessive number of Quick Stop Event
that is required by the ECM before the feature of Codes. A vehicle without a load or a trailer will be
theft deterrent is enabled. After the theft deterrent able to stop much more quickly than a vehicle with
is enabled, the “Theft Deterrent Password” is the a heavy load. If too many Quick Stop Event Codes
password that is required to restart the engine. All of are being logged, the “Quick Stop Rate” should be
the characters must be uppercase. Four characters increased. This will improve the detection of the
are available for the password. If the password is lost, exceptions when the exceptions occur.
a service tool and a factory password are required in
order to start the engine. i01726787
Table 127 Truck Manufacture Parameters

Alternative Default
SMCS Code: 1901
Four Characters
A through Z 0000
0 through 9 “Truck Manufacturer”
“Quick Stop Rate”
This parameter is used to configure the correct set of
This parameter determines the rate of vehicle
options and/or ranges for the default parameter for
speed change that is used by the ECM to record a
the application. The 3126B truck engine with serial
Quick Stop Event Code and a quick stop snapshot.
number prefix 7AS is equipped with a Basic ECM
Programming this parameter to 0 will disable this
or the 3126B truck engine is equipped with a Full
feature and no quick stop events will be logged.
Feature ECM. The Personality Module software will
Each quick stop snapshot contains 60 frames of
depend on the vehicle application. The option for the
information. Frame 45 is the quick stop event. The
“Truck Manufacturer” parameter is set at the factory
quick stop snapshot also contains 44 frames before
to provide the same functionality with one ECM and
the quick stop event and 15 frames after the quick
one set of Personality Module software. If an ECM
stop event. Each frame is separated by 1.0 second.
replacement is required, the “Truck Manufacturer”
Table 128 parameter must be programmed before programming
other customer parameters in order to configure the
ECM Snapshot Frame Data proper set of defaults/ranges. When a Basic ECM is
“Engine rpm” “Vehicle Speed” replaced in a General Motors chassis, program the
“Throttle Position” “Cruise Status” “Truck Manufacturer” parameter to the GM option.
“Clutch Switch” “Brake Switch” When a Full Feature ECM is replaced on a engine in
any other chassis, program the “Truck Manufacturer”
parameters to “Other”.
The most recent quick stop snapshot is stored in
the ECM memory. When a quick stop event occurs Table 130
the ECM replaces the old quick stop snapshot with
the new quick stop snapshot. The ECM also logs a Alternative Default
diagnostic event code for each quick stop event. The “GM”, “Other” “Not Programmed”
ECM stores a maximum of 255 occurrences.
“Truck Model Type”

RENR1367-11 55
This parameter is used to configure the correct set “Vehicle Speed Cal (J1939-Trans)”
of options and/or ranges for the default parameter
for the application. The option for the “Truck Model The “Vehicle Speed Cal (J1939-Trans)” is used
Type” parameter is set at the factory. If an ECM when the ECM is configured to use the speed of the
replacement is required, the “Truck Model Type” transmission output shaft in order to calculate vehicle
parameter must be programmed before programming speed. The “Vehicle Speed Input” parameter must be
other customer parameters in order to configure the programmed to “J1939-Trans”. This value represents
proper set of defaults/ranges. When the software is the revolution of the transmission output shaft as
flashed into the Personality Module, this parameter revolutions per kilometer (revolutions per mile). This
will default to “GM 530/540”. parameter must be programmed. If this parameter is
not programmed, 253-02 Check Customer or System
Table 131 Parameters (56) will become active. This parameter
Alternative Default affects the cruise control and the ECM speedometer
signal. Also, this parameter can affect the PTO
“GMT-560” “GM530/540” operation, extended idle and trip totals.
Table 133
i01726906
Vehicle Speed Parameters 0 revolutions 43000 “Not Programmed”
per km (0 revolutions
SMCS Code: 1901 revolutions per km (65000
per mile) revolutions per
mile)
“Vehicle Speed Calibration”
This calibration is used when the ECM is configured “Vehicle Speed Cal (J1939 ABS)”
to use a vehicle speed sensor that is connected to
the ECM vehicle harness connector J1/P1:32 & 33. OCT01 and newer Personality Modules.
The “Vehicle Speed Calibration” is the value that is The “Vehicle Speed Cal (J1939-ABS)” is used to
used by the ECM in order to translate the vehicle calculate vehicle speed by using the input from the
speed signal into kilometers per hour (miles per wheel speed. The data from the wheel speed is
hour). When a vehicle speed sensor is connected transmitted via the J1939 data link. The “Vehicle
to an ECM input, the “Vehicle Speed Input” must be Speed Input” parameter must be programmed to
programmed to “J1/P1:32 & 33”. This parameter “Vehicle Speed Cal J1939-ABS”. The manufacturer
is programmed in pulses per kilometer (PPKM) or of the ABS system must transmit tire revolutions per
pulses per mile (PPM). This parameter must be mile that is based on the tire size. If the tire size is
programmed. If this parameter is not programmed, changed from tire size that is programmed in the
253-02 Check Customer or System Parameters (56) ABS system, the “Vehicle Speed Cal (J1939-ABS)”
will become active. This parameter affects the cruise must be changed. The value that is contained in
control and the ECM speedometer signal. Also, this the “Vehicle Speed Cal (J1939-ABS)” parameter is
parameter can affect the PTO operation, extended a ratio. If the actual tire size is equal to the tire size
idle and trip totals. that is programmed in the ABS system, the “Vehicle
Speed Cal (J1939-ABS)” parameter will be “1”. The
Table 132
ratio can be found by dividing the tire revolutions
Manufacturer Minimum Maximum Default per mile that is transmitted by the ABS system by
the actual tire revolutions per mile. Contact the
GM 2485 238080 19884 PPKM
PPKM PPKM (32000 PPM) manufacturer of the ABS system in order to verify
(4000 (384000 that this message is supported.
PPM) PPM)
If the “Vehicle Speed Input” parameter is programmed
Other 2485 238080 “Not to “Vehicle Speed Cal J1939-ABS”, this parameter
PPKM PPKM Programmed” must be programmed. If this parameter is not
(4000 (384000
PPM) PPM)
programmed, 253-02 Check Customer or System
Parameters (56) will become active. This parameter
affects the cruise control and the ECM speedometer
signal. Also, this parameter can affect the PTO
operation, extended idle and trip totals.
56 RENR1367-11
Table 134 “Tachometer Calibration”

The “Tachometer Calibration” is used by the ECM
0 6.550 “Not Programmed” to translate the engine speed signal into revolutions
per minute for a tachometer. The “Tachometer
Calibration” is programmed in pulses per revolution
“Vehicle Speed Limit (VSL)” (PPR). The programmable range is from 2.0 to 500.0
in increments of 0.1 PPR.
The “Vehicle Speed Limit” (VSL) is the maximum
vehicle speed that is allowed by the ECM. The ECM Table 137
will shut off fuel above this speed. An inexperienced Manufacturer Minimum Maximum Default
driver may think that something is wrong with the
engine because the ECM will not fuel the engine GM 2.0 PPR 500.0 PPR 17.5
above this vehicle speed limit. Vehicle speed limiting PPR
allows the implementation of a gear fast/run slow Other 2.0 PPR 500.0 PPR 134.0
specification for the truck. The gear fast/run slow PPR
specification for the truck improves fuel economy
while the parameter for the vehicle speed limit limits
the maximum vehicle speed of the truck. “Soft Vehicle Speed Limit”
Table 135 The “Soft Vehicle Speed Limit” operates in
Manufacturer Minimum Maximum Default conjunction with the “Vehicle Speed Limit”. The “Soft
Vehicle Speed Limit” limits the vehicle speed within
GM 48 km/h 121 km/h 121 km/h
the following range:
(30 mph) (75 mph) (75 mph)
Other 48 km/h 204 km/h 204 km/h • The minimum value is 4 km/h (2.5 mph) below the
(30 mph) (127 mph) (127 programmed “Vehicle Speed Limit” at full load.
mph)
• The maximum value is 4 km/h (2.5 mph) above the
selected “Vehicle Speed Limit” at no load.
“VSL Protection”
Table 138
The “VSL Protection” is the maximum engine rpm
when there is a problem with the vehicle speed signal
that is detected by the ECM. The ECM limits the All Applications “NO” “YES”
engine to this engine rpm when the ECM senses
no vehicle speed signal, and a load on the engine.
This is a feature that is used to prevent tampering by “Low Speed Range Axle Ratio”
running without a Vehicle Speed input to the ECM.
MAR98 and newer Personality Modules.
Note: When this parameter is programmed to the
TEL rpm, the ECM disables 84-01 Loss Of Vehicle The “Low Speed Range Axle Ratio” parameter
Speed Signal (31) and 84-10 Vehicle Speed Rate must be programmed when an on/off switch for
of Change (36) and the “VSL Protection” may be the two-speed axle is used by the ECM to adjust
exceeded by disconnecting the vehicle speed sensor. the vehicle speed calibration. When a two-speed
axle is used, the change in gear ratios from the
Table 136 high speed range to the low speed range alters the
Manufacturer Minimum Maximum Default calibration of the vehicle speed signal. Since the
vehicle speed signal has been altered, a calibration
GM “1700 rpm” “1700 rpm” “1700 adjustment is required to ensure that the ECM driven
rpm” speedometer and the information that is stored in the
Other 1700 rpm TEL rpm TEL rpm ECM correctly reflect the actual vehicle speed. This
parameter should be programmed to the “Low Speed
Range Axle Ratio”. This parameter only requires
programming when the “Two-Speed Axle Switch”
parameter is enabled.
Table 139
0.00 19.99 0.00
RENR1367-11 57
“High Speed Range Axle Ratio”

This parameter only requires programming when the
“Two-Speed Axle Switch” parameter is enabled. The
“High Speed Range Axle Ratio” must be programmed
when an on/off switch for the two-speed axle is used
by the ECM to adjust the vehicle speed calibration.
When a two-speed axle is used, the change in
gear ratios from the high speed range to the low
speed range alters the calibration of the vehicle
speed signal. Since the vehicle speed signal has
been altered, a calibration adjustment is required to
ensure that the ECM driven speedometer and the
information that is stored in the ECM correctly reflect
the actual vehicle speed. This parameter should be
programmed to the “High Speed Range Axle Ratio”.
Table 140

0.00 9.99 “0.00”
58 RENR1367-11
System Configuration • A 253-02 Check Customer Or System Parameters

(56) will be generated.
Parameters
When the engine is being rerated, programming this
code to 0 will prompt the ECM to read the interlock
i02297846 code that is stored in memory. The stored interlock
System Configuration code will be used by the ECM for the engine. This
code does not need to be programmed when the
Parameters flash file is installed under both of the following
conditions:
SMCS Code: 1901
• The new flash file is for the same family.
System configuration parameters affect the
emissions of the engine or the power of the engine. • The new flash file is for an engine with the same
System configuration parameters are programmed rating for emissions.
at the factory. Normally, the system configuration
parameters would never need to be changed If the flash file is from a different family, the following
through the life of the engine. System configuration components may need to be changed: pistons,
parameters must be reprogrammed if an Engine injectors, and other components. The engine
Control Module (ECM) is replaced. Unless the engine information plate must also be changed in order to
rating has changed, system configuration parameters reflect the new rating.
do not need to be reprogrammed when the ECM flash
file is updated. The system configuration parameters Some vehicle systems such as the cooling system
are stamped on the engine information plate. Factory or the transmission may also require changes when
passwords are required to change these parameters. the engine is rerated. Please contact the system’s
The following information is a description of the Original Equipment Manufacturer (OEM) for further
system configuration parameters. information.
“Full Load Setting” “Engine Serial Number”

“Full Load Setting” is a number that represents the Program the “Engine Serial Number” to match the
adjustment to the fuel system that was made at the engine serial number that is stamped on the engine
factory in order to fine tune the fuel system. The information plate. When a new ECM is delivered, the
correct value for this parameter is stamped on the engine serial number in the ECM is not programmed.
engine information plate. A new ECM requires this
parameter to be programmed to avoid generating a “Personality Module Release Date”
253-02 Check Customer Or System Parameters (56).
This parameter is defined by the Personality Module
“Full Torque Setting” and this parameter is not programmable. The
“Personality Module Release Date” is used to provide
“Full Torque Setting” is similar to “Full Load Setting”. the version of the software. The customer parameters
This parameter must be programmed to avoid and the software change levels can be monitored by
generating a 253-02 Check Customer Or System this date. The date is provided in the month and the
Parameters (56). year (NOV99). NOV is the month (November). 99
is the year (1999).
Interlock Code
The interlock code is a code that prevents the use
of incorrect ECM software for this engine. Each
horsepower family and each emission certification
has a different code that is associated with the
horsepower family or the emission certification.
When a flash file is replaced this code must match

the code that is stored in the ECM. If the interlock
code does not match the code that is stored in the
ECM, both of the following situations will exist:
• The engine will only run at low idle.

RENR1367-11 59
Troubleshooting without a • “Lower Gears Engine RPM Limit”

Diagnostic Code • “Intermediate Gears Engine RPM Limit”
• “Gear Down Protection Engine RPM Limit”
i02183349
Can Not Reach Top Engine • “Top Engine Limit” Engines with software
prior to DEC 02
RPM
SMCS Code: 1915-035
• “PTO Top Engine Limit” with the PTO On/Off
Switch turned ON.
Probable Causes
Note: If this problem occurs under load, refer to
• “PTO Vehicle Speed Limit” with the PTO
On/Off Switch turned ON.
Troubleshooting, “Low Power/Poor or No Response
to Throttle”. d. Set each parameter to the parameter’s
maximum value one at a time and determine
The probable root causes are listed in order below: whether the problem is corrected.
• Diagnostic codes 3. Check Cold Mode operation.
• Customer specified parameters (normal operation) Note: This is normal operation if the problem occurs
only after start-up in cold weather.
• Cold mode
a. Monitor Cat ET in order to verify that the engine
• Accelerator pedal position sensor has progressed from Cold Mode.
• Vehicle speed signal “Cold Mode” is indicated in the upper corner
of any status screen.
• Fuel supply
4. Check the accelerator pedal position sensor.
• Power train data link
a. Use the Cruise/Idle On/Off Switch to put the
• Air intake and exhaust system engine in idle mode.
Recommended Actions b. Vary the engine rpm with the Set/Resume

switches.
1. Check for diagnostic codes.
If both of the following conditions are met,
a. Connect the Caterpillar Electronic Technician monitor the status of the accelerator pedal
(ET) to the data link connector. position sensor.
b. Check for active diagnostic codes and/or • The engine is stable by using idle mode to
logged diagnostic codes. control the engine rpm.
Certain diagnostic codes will limit the engine • The engine is unstable by using the
speed. accelerator pedal position sensor.
c. Troubleshoot all active diagnostic codes before If the status of the accelerator pedal position
continuing with this procedure. sensor is unstable, refer to Troubleshooting,
“Accelerator Pedal (Throttle) Position Sensor
2. Check customer specified parameters. Circuit - Test”.
a. Verify that the complaint is not normal operation 5. Monitor the vehicle speed signal. Ensure the
(programmed parameter). accuracy of the vehicle speed signal by comparing
the vehicle speed signal to the actual vehicle
b. Access the “Configuration” screen on Cat ET. speed.
c. Check the following parameters:

60 RENR1367-11
If the vehicle speed is greater than the VSL, i02183361

the engine rpm is limited to the programmed
“VSL Protection”. If a problem is discovered, Can Not Reach Vehicle Speed
refer to Troubleshooting, “Vehicle Speed and Limit
Speedometer Circuit - Test”.
SMCS Code: 7463-035
6. Check the fuel supply.
a. Monitor the exhaust for smoke while the engine Probable Causes
is being cranked.
The probable root causes are listed in order below:
If no smoke is present, there may be a problem
with the fuel quality or there may be a problem • Diagnostic codes
with the fuel supply.
• Customer specified parameters (normal operation)
b. Check the fuel quality.
• Cold mode
c. Check the fuel pressure.
• Electronic system problem
d. Ensure that the fuel system has been primed.
• Fuel supply
e. Check for air in the fuel system.
• Air intake system or exhaust system
f. Check for fuel supply lines that are restricted.
• Leakage in air-to-air aftercooler core
g. Check the fuel filters . Refer to Testing and
Adjusting for more information on the fuel Recommended Actions
system. Also refer to Truck Application and
Installation Guide, LEBT5109. 1. Check for diagnostic codes.
h. If the temperature is below 0 °C (32 °F), check a. Connect the Caterpillar Electronic Technician
for solidified fuel (wax). (ET) to the data link connector.
7. Check the “Powertrain Data Link”. Ensure that the b. Turn the key switch to the ON position.
power train data link is not limiting the power.
c. Check for active diagnostic codes and logged
a. Monitor the “Powertrain Data Link” status diagnostic codes.
screen while the vehicle is experiencing
problems. Certain diagnostic codes will limit the vehicle
speed to 45 mph.
If the “Powertrain Data Link” status screen
indicates that the “Powertrain Data Link” is d. Troubleshoot all diagnostic codes before
limiting the power or the rpm, verify that this continuing with this procedure.
is not normal operation. If this is not normal
operation, refer to the vehicle OEM for repairs. 2. Check customer specified parameters.
8. Air intake and exhaust system a. Verify that the complaint is not due to normal
operation (programmed parameter).
a. Clean plugged air filters or replace plugged air
filters. Refer to the Operation and Maintenance b. Access the “Configuration” screen on Cat ET.
Manual.
c. Check the following parameters:
b. Check the air intake and the exhaust system
for restrictions and/or leaks. Refer to Testing • “Vehicle Speed Limit”
and Adjusting for more information.
• “Soft Vehicle Speed Limit”
• “Lower Gears Engine RPM Limit”
• “Intermediate Gears Engine RPM Limit”
RENR1367-11 61
• “Gear Down Protection Engine RPM Limit” When the engine is OFF, the boost pressure
should be 0 kPa (0 psi).
b. Monitor the status of the accelerator pedal
• “Top Engine Limit” position sensor. Operate the engine at high idle
with the vehicle in Neutral.
• Incorrect programming of the Vehicle Speed
calibration (ppm). If the engine can not reach the programmed
“Top Engine Limit”, check the duty cycle for the
• “PTO Top Engine Limit” with the PTO On/Off accelerator pedal position sensor in order to
Switch turned ON. ensure that the duty cycle is within calibration
(75 to 90 Percent at high idle).
• “Maximum PTO Vehicle Speed” with the
PTO On/Off Switch turned ON. If the accelerator pedal position is unstable,
check the duty cycle of the accelerator pedal
d. Set each parameter to the parameter’s position sensor. Check the duty cycle by slowly
maximum value one at a time and determine operating the accelerator pedal in order to
whether the problem is corrected. verify that the duty cycle is within calibration.
The accelerator pedal position sensor is
Note: The “Soft Vehicle Speed Limit” will not allow within calibration when both of the following
the vehicle to achieve the programmed VSL under conditions are met:
all engine load conditions. Programming the “Soft
Vehicle Speed Limit” to NO may be required to • 10 to 22 percent at low idle
eliminate the complaint.
• 75 to 90 percent at high idle
3. Check cold mode operation.
Also, ensure that the duty cycle changes as the
Note: This is normal operation if the problem occurs pedal position changes.
If a problem with the accelerator pedal position
a. Check the status screen on Cat ET. sensor is suspected, refer to Troubleshooting,
“Accelerator Pedal (Throttle) Position Sensor
“Cold Mode” is indicated in the upper corner of Circuit - Test”.
any status screen when cold mode is active.
Note: If the engine exceeds the “Top Engine Limit”,
4. Check for an electronic system problem. the “Top Engine Limit with Droop” is programmed to
YES.
a. Monitor the fuel position, the “Rated Fuel Limit”,
and the “FRC Fuel Limit”. 6. Monitor the vehicle speed signal. Ensure the
accuracy of the vehicle speed signal by comparing
While the vehicle is operating under full load, the vehicle speed signal to the actual vehicle
the parameters should meet the following speed.
conditions:
If the vehicle speed is greater than the VSL,
• The fuel position is equal to the “Rated Fuel the Power is limited. If a problem is discovered,
Limit”. refer to Troubleshooting, “Vehicle Speed and
Speedometer Circuit - Test”.
• The fuel position is less than the “FRC Fuel
Limit”. 7. Check the “Powertrain Data Link”. Ensure that the
SAE J1939 Powertrain Data Link is not limiting
If the fuel position is equal to the “Rated Fuel the power.
Limit” and the fuel position is less than the
“FRC fuel Limit”, the electronics are operating a. Monitor the “Powertrain Data Link” status
correctly. Go to Step 6. screen while the vehicle is experiencing
problems.
5. If the fuel position is not equal to the “Rated Fuel
Limit” and/or the fuel position is not less than the If the “Powertrain Data Link” status screen
“FRC Fuel Limit”, perform the following tests in indicates that the “Powertrain Data Link” is
order: limiting the power or the rpm, verify that this
is not normal operation. If this is not normal
a. When the engine is OFF, turn the key switch operation, refer to the vehicle OEM for repairs.
to the ON position. Check the boost pressure
on Cat ET. 8. Check the fuel supply.
62 RENR1367-11
a. Monitor the exhaust for smoke while the engine Recommended Actions
is being cranked.
Note: GM vehicles refer to the Check Engine Lamp
If no smoke is present, there may be a problem as the Service Engine Soon Lamp.
with the fuel quality or there may be a problem
with the fuel supply. Perform the following diagnostic procedures in order:
b. Check the fuel quality.

Intermittent Diagnostic Codes
c. Check the fuel pressure.
Use Caterpillar Electronic Technician (ET) to check
for any diagnostic codes that may be logged or
d. Ensure that the fuel system has been primed.
active. Check for any intermittent diagnostic codes.
e. Check for fuel supply lines that are restricted.
Check Engine Lamp
f. Check the fuel filters.
1. In order to check the check engine lamp, place
g. Check for air in the fuel system. Refer to the ignition key switch in the ON position while the
Testing and Adjusting for more information on engine is off.
the fuel system. Also refer to Truck Application
and Installation Guide, LEBT5109. The check engine lamp should turn on. Then,
the check engine lamp should turn off. The
h. If the temperature is below 0 °C (32 °F), check check engine lamp will flash if there is an active
for solidified fuel (wax). diagnostic code.
9. Check the air intake system for restrictions or a. Place the ignition key switch in the OFF
leakage. Check the exhaust system for restrictions position.
or leakage. Refer to Testing and Adjusting, “Air
Inlet and Exhaust System - Inspect”. b. If the check engine lamp did not operate
correctly remove the terminal for the check
10. Check for leakage in the Air-to-Air Aftercooler engine lamp (terminal 28) from the 70-pin
Core . Refer to Testing and Adjusting, “Aftercooler connector at the Engine Control Module (ECM).
- Test”.
c. Connect the check engine lamp (terminal 28) to
the ground stud. Place the ignition key switch
i02204546 in the ON position.
Check Engine Lamp d. Observe the check engine lamp.
or Warning Lamp Is
If the check engine lamp comes on there may
Malfunctioning be a problem with the circuit. Place the ignition
key switch in the OFF position. Check the
SMCS Code: 7431-035
power connection and the ground connection
of the ECM. Refer to Troubleshooting, “Check
Probable Causes Engine Lamp Circuit - Test” for additional
information.
• Intermittent diagnostic codes
If the lamp does not come on there may be a
• Check engine lamp problem with the lamp. Place the ignition key
switch in the OFF position. Check the lamp in
• Warning lamp order to ensure that the lamp is not burned out.
Also, check the wiring in order to ensure that
• Cruise control set/resume switch there is not an open circuit or a short circuit.
• Short in vehicle harness Warning Lamp

• Service engine soon lamp (GM) 1. In order to check the warning lamp, start the
engine.
RENR1367-11 63
The warning lamp should come on for at least two Warning Lamp
seconds. Then, the warning lamp should turn off.
The warning lamp will remain on or flash if there is Monitor the warning lamp while the terminal for
a problem with the engine. the warning lamp (terminal 29) is removed from
the P2 ECM connector. Also, the technician could
a. Place the ignition key switch in the OFF monitor the warning lamp while the ECM connector
position. The engine should be off. is disconnected.
b. If the warning lamp did not operate correctly If the lamp remains on and the terminal has been
remove the terminal for the warning lamp removed from the ECM there is a short circuit to
(terminal 29) from the 70-pin connector at the ground in the vehicle harness.
ECM.
c. Connect the warning lamp (terminal 29) to the

Service Engine Soon Lamp (GM)
ground stud. Place the ignition key switch in
Check the ALDL connector in order to ensure that
the ON position.
there is not a short circuit between terminal 4 and
terminal 6. Also, check for a short between terminal 5
d. Observe the warning lamp.
and terminal 6.
If the warning lamp comes on there may be a
problem with the circuit. Place the ignition key
switch in the OFF position. Check the power
connection and the ground connection of the
ECM. Refer to Troubleshooting, “Warning
Lamp Circuit - Test” for additional information.
If the lamp does not come on there may be a

problem with the lamp. Place the ignition key
switch in the OFF position. Check the lamp in
order to ensure that the lamp is not burned out.
Also, check the wiring in order to ensure that
there is not an open circuit.
g01113297
Cruise Control Set/Resume Switch Illustration 13
GM ALDL cab connector.
Connect Cat ET to the cab data link connector. Place (4) -Battery
the ignition key switch in the ON position. Observe (5) -Battery
the status screen for the cruise control set/resume (6) Diagnostic enable
(7) J1587 Data Link +
switch. (15) J1587 Data Link -
(16) +Battery
If the status screen indicates that the switch is on
and the switch is not in the ON position, the switch
is shorted out. Refer to Troubleshooting, “Cruise i02318966
Control Switch Circuit - Test”.
Cruise Control, Idle, or PTO
Short in Vehicle Harness Can Not Be Set
SMCS Code: 1915-035
Check Engine Lamp
Monitor the check engine lamp while the terminal Probable Causes
for the check engine lamp (terminal 28) is removed
from the P2 ECM connector. Also, the technician • Programmable parameters
could monitor the check engine lamp while the ECM
connector is disconnected. • Problem with a switch
If the lamp remains on and the terminal has been • Clutch switch or clutch spring
removed from the ECM, there is a short circuit to
ground in the vehicle harness.
64 RENR1367-11
Recommended Actions
Note: If a kickout occurred, the Engine Control
Module (ECM) stores the most recent cause of
the kickout. However, the ECM will not store the
information if the ECM is powered down. The ECM is
powered down when the keyswitch is placed in the
OFF position. It may be necessary to operate the
vehicle in order to duplicate the problem. Then, check
the value of the “Cruise Kickout”, the “Idle Kickout”,
or the “PTO Kickout” status parameter before the
ECM is powered down.
Perform the actions that relate to the feature that has

the complaint.
Check the Programmable Parameters

Refer to Table 141. Use the Caterpillar Electronic
Technician (ET) to verify that configuration
parameters for the feature with the complaint are
programmed correctly:
RENR1367-11 65
Table 141
Parameters for the Features
Feature Configuration Parameters Notes
Cruise Control Low Cruise Control Set Speed Limit If the vehicle speed is below the “Low Cruise Control
Set Speed Limit”, the cruise control can not be set or
resumed.
High Cruise Control Set Speed Limit If the vehicle speed exceeds the “High Cruise Control
Set Speed Limit” and the driver attempts to set a cruise
control speed, the cruise set speed will be the “High
Cruise Control Set Speed Limit”.
Transmission Neutral Switch
Cruise Control On/Off Switch
Cruise Control Set/Resume/Accel/Decel Switch
Cruise Control Pause Switch
Extended Idle Idle Vehicle Speed Limit If the driver attempts to set an idle engine rpm and the
vehicle speed exceeds the “Idle Vehicle Speed Limit”,
the idle will not activate.
Idle RPM Limit If the engine rpm is above the “Idle RPM Limit” and
the driver attempts to set an idle engine rpm, the idle
engine rpm will be the idle rpm limit.
PTO PTO Top Engine Limit
PTO Kickout Vehicle Speed Limit If the vehicle speed exceeds the programmed “PTO
Kickout Vehicle Speed Limit”, the ECM will not maintain
the set speed.
PTO On/Off Switch
Remote PTO Set Switch
Remote PTO Resume Switch
Check the Switches If the cause of the kick out is “Brake”, the ECM has
detected an open circuit in the circuit for a service
Typically, the operation of the PTO requires an brake switch. Verify that the operator did not operate
interlock switch such as a parking brake switch. the service brake. Use Cat ET to check the status of
Ensure that all interlocks are set to allow PTO the service brake switches while the service brake is
operation. operated. Refer to Troubleshooting, “Service Brake
Pedal Position (Switch 1) Circuit - Test” or , “Service
Cat ET uses the following status parameters to Brake Pedal Position (Switch 2) Circuit - Test”, if
display the most recent cause of the kick out for each necessary.
feature: “Cruise Kickout”, “Idle Kickout”, and “PTO
Kickout”. If the cause of the kick out is “Clutch”, the ECM
has detected an open circuit in the circuit for the
If the cause of the kick out is “Switch Turned Off”, clutch switch. Verify that the operator did not operate
the ECM has detected an open circuit in the circuit the clutch. Use Cat ET to check the status of the
for the cruise switch or the PTO switch. Verify that clutch switch while the clutch is operated. Refer
the operator did not turn off the switch. Use Cat ET to Troubleshooting, “Clutch Pedal Position Switch
to check the status of the on/off switch while the Circuit - Test”, if necessary.
switch is operated. Refer to Troubleshooting, “Cruise
Control Switch Circuit - Test” or Troubleshooting,
“PTO Switch Circuit - Test”, if necessary.
66 RENR1367-11
If the cause of the kick out is “Neutral”, the ECM

transmission neutral switch. Verify that the operator
did not shift the transmission into neutral. Use Cat
ET to check the status of the transmission neutral
switch while the transmission is shifted into neutral.
Refer to Troubleshooting, “Neutral Switch Circuit -
Test”, if necessary.
If the cause of the kick out is “Set SW Timeout”, then

the cruise control set/resume switch was placed to
the “Set” position by the operator for more than 15
seconds or there is a short circuit in the circuit for the
“Set” position of the switch. Determine the condition
that caused the kickout. Refer to Troubleshooting,
“Cruise Control Switch Circuit - Test”, if necessary.
Turn off the cruise control switch and turn on the
cruise control switch in order to get the cruise control
to work again.
If the cause of the kick out is “Res SW Timeout”, then

the “Resume” position by the operator for more than
15 seconds or there is a short circuit in the circuit
for the “Resume” position of the switch. Determine
the condition that caused the kickout. Refer to
Troubleshooting, “Cruise Control Switch Circuit -
Test”, if necessary. Turn off the cruise control switch
and turn on the cruise control switch in order to get
the cruise control to work again.
If the cause of the kick out is “Vehicle Speed < Limit”,

the vehicle speed signal exceeded the programmed
Idle/PTO vehicle speed limit or the vehicle speed
signal is missing or erratic. Perform the following
steps:
1. Inspect the vehicle speed sensor for debris.
2. Carefully inspect the vehicle’s electrical

connectors for the speed circuit. Look for
corrosion, for debris, and for loose terminals.
3. Check the P1 connector for corrosion, for debris,

and for loose terminals.
4. Use Cat ET to check the vehicle speed while

the vehicle is parked. Also check the vehicle
speed while the vehicle is being driven in order
to determine that the vehicle speed that is
indicated by Cat ET does not vary significantly
from the vehicle speed that is indicated by the
speedometer. Refer to Troubleshooting, “Vehicle
Speed and Speedometer Circuit - Test”.
Check the Clutch Switch and the Clutch

Spring
Check the clutch switch adjustment and the clutch
spring. Make repairs, if necessary.
RENR1367-11 67
i02127473
Driver Questionnaire
SMCS Code: 0336
Table 142
Ask the driver to answer the following questions before attempting to repair an intermittent problem, or a problem with
symptoms but no diagnostic codes. Use this and the response guideline to these questions on the next page.
Questions Yes Comments
1. Ask the driver if the check engine lamp turned on during the problem or
if the check engine lamp turned on after the problem.
The check engine lamp stays on for the following time period:
2. Ask the driver for the number of occurrences for this problem.
Ask the driver to duplicate the problem if the problem can be duplicated in
less than one hour.
3. Ask the driver if other shops have worked on the same problem.
If the answer is yes, ask the names of the shops. Also ask for the time
period for the work that was performed.
4. Ask the driver if the engine completely shut down. Ask the driver if the
restart required the use of the key switch.
Ask the driver for the waiting period before the driver could restart the
engine after the shutdown.
5. Ask the driver if the engine had a hesitation, a speed burp or a misfire
without a complete shutdown.
6. Ask the driver if the radio, dash gauges or lights momentarily turn off
during an occurrence of the problem.
Ask the driver if there are any other observations about the truck’s
components.
7. Ask the driver if the problem occurs only at specific engine loads.
Ask the driver for additional details.
8. Ask the driver if the problem occurs at a specific engine operating
temperature.
If the problem occurs at a specific engine operating temperature, record
the engine temperature.
9. Ask the driver if the problem occurs only at specific outside
temperatures or temperature ranges.
If the problem occurs only at specific outside temperatures or temperature
ranges, record the outside temperature or temperature range.
10. Ask the driver if the problem occurs during any other specific
conditions.
11. Ask the driver if the problem occurs at a specific vehicle speed.
If the problem occurs at a specific vehicle speed, record the vehicle
speed.
12. Ask the driver if the vehicle kicked out of cruise control mode, idle
mode or PTO mode.
13. Ask the driver if the problem occurs during the use of the accelerator.
During this time, the engine is not in cruise control mode or PTO mode.
14. Ask the driver if the problem occurs at a specific engine rpm.
If the problem occurs at a specific engine rpm record the engine rpm.
68 RENR1367-11
i01641542
Driver Questionnaire
Response
SMCS Code: 0336
Table 143
1. If the Check Engine Lamp turned on there will be a logged diagnostic code. Refer to Troubleshooting, “Possible
Performance Effect of Active Diagnostic Codes” in order to determine if the driver’s indicated symptoms agree with
the symptoms that are associated with the diagnostic code. If the driver’s symptoms do not match the symptoms of the
diagnostic code, troubleshooting the diagnostic code will not correct the problem. Review the snapshots that are associated
with each diagnostic code in order to determine the operating conditions of the engine during the occurrence of the problem.
Try to duplicate these conditions. If there are not any logged diagnostic codes, check the ECM battery connections. Refer to
Troubleshooting, “Ignition Key Switch Circuit and Battery Supply Circuit - Test”.
2. If the problem is easily repeatable, take the vehicle for a test drive while ET is connected to the cab data link connector. Note
the conditions when the problem occurs. The operator should be prepared to take snapshot data by using ET or the Cruise
Control Set/Resume switches. Ensure that you operate the vehicle after correcting the problem. During vehicle operation,
duplicate the operating conditions before releasing the vehicle in order to verify that the problem has been corrected.
3. If the vehicle has been to other shops for the same problem, call the other shops in order to determine the type of work that
has been done. Avoid replacing the same components again, unless you are absolutely sure that the components are the
problem. If a component has recently been changed, it is unlikely that the component will fail again.
4. Troubleshoot the reason that the engine will not start. Repair the reason that the engine does not start. When you
repair the reason that the engine did not start you should repair the reason that the engine shut down. If the engine shut
down completely, check the ECM battery connections, the ground connections, the fuel system, the fuel, the crankshaft
position sensor and the camshaft position sensor. If the engine will not restart, refer to Troubleshooting, “Engine Cranks
but Will Not Start”.
5. If the problem is easily repeatable, refer to Troubleshooting, “Engine Misfires, Runs Rough or Is Unstable”.
If the problem is not easily repeatable, refer to Troubleshooting, “Intermittent Low Power or Power Cutout”.
6. If other devices on the vehicle are affected, something is wrong with the vehicle wiring. Refer to Troubleshooting, “Ignition
Key Switch Circuit and Battery Supply Circuit Test” for information on inspecting the ECM battery connections.
7. Operate the engine under similar load conditions. Check the low pressure fuel lines for restrictions. Also check the
fuel/water separator and the fuel tanks for foreign objects that are blocking the fuel supply.
8. Operate the engine at this temperature. Attempt to duplicate the problem.
9. When possible, troubleshoot the problem in this temperature range.
10. If the problem seems to occur during the rain or a washing, thoroughly inspect the connectors for moisture. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
11. If the problem occurs at a specific vehicle speed, check the parameters that affect vehicle speed in order to verify that the
parameters are programmed close to the vehicle speed of the occurrence of the problem. Check the following parameters:
“Vehicle Speed Limit”
“VSL Protection”
“Low Cruise Control Speed Set Limit”
“High Cruise Control Speed Set Limit”
“Idle Vehicle Speed Limit”
“PTO Vehicle Speed Limit”
“Engine/Gear Speed Limit”
Set each parameter to the maximum value one at a time and verify that the problem is corrected.
12. If the vehicle kicks out of cruise control mode, idle mode or PTO mode and it can be duplicated, check the ET status
screen. Check the status of the Cruise Kickout, the Idle Kickout or the PTO Kickout. If the problem can not be duplicated,
inspect the vehicle speed circuit, the service brake circuit and the clutch switch circuit and switch adjustment, the circuit for
the neutral switch and the circuits for the cruise/idle/pto switches, as required.
13. Check for logged diagnostic codes that are associated with the accelerator pedal position sensor. Refer to
Troubleshooting, “Accelerator Pedal (Throttle) Position Sensor Circuit - Test”.
14. If the problem occurs at a specific engine rpm, check the “VSL Protection”, the “Idle rpm Limit”, the “Top Engine Limit”, the
“PTO Top Engine Limit” and the Progressive Shift Parameters. These parameters are programmable. Set each parameter
to the maximum value one at a time and verify that the problem is corrected.
RENR1367-11 69
i02319575 i02429502
ECM Will Not Accept Factory Electronic Service Tool Will

Passwords Not Communicate with ECM
SMCS Code: 1901-035 SMCS Code: 0785-035; 1901-035
Probable Causes Probable Causes

• Incorrect information for the password request • Configuration for the communications adapter
• Incorrect passwords • J1/P1 connectors
Recommended Actions • Communication adapter and/or cables

• Electrical power supply to the service tool
Check the Information for the Password connector
Request
• Caterpillar Electronic Technician (ET) and related
The information for the password request must be hardware
obtained from the Engine Control Module (ECM) that
is being programmed. Do not use information from • Electrical power supply to the Engine Control
an old ECM in order to program factory passwords Module (ECM)
on a replacement ECM.
• Override switches
Verify that the information that is used to request
the passwords is identical to the information that is • ATA data link
displayed on the Caterpillar Electronic Technician
(ET). • J1939 data link
Engine Serial Number – The engine serial number Recommended Actions
must be from the Cat ET screen rather than the
engine information plate.
Start the engine. If the engine starts, but the ECM
will not communicate with the Cat ET, continue with
Reason Code – Use the reason code from the
this procedure. If the engine will not start, refer to
factory password screen. Reason codes are assigned
Troubleshooting, “Engine Cranks but Will Not Start”.
for specific purposes and reason codes are not If the engine will not crank, refer to Troubleshooting,
interchangeable.
“Engine Will Not Crank”.
Turn the key switch to the OFF position. Then, turn
the keyswitch to the ON position. Try to enter the Configuration for the Communications
passwords again. Adapter
Incorrect Passwords 1. Access “Preferences” under the “Utilities” menu

on Cat ET.
Verify that the correct passwords were entered.
Check each character in each password. 2. Verify that the correct “Communications Interface
Device” is selected.
If rechecking the passwords does not correct the
problem, change a customer parameter from the 3. Verify that the correct “Port” is selected for use by
current value to another value and then change the the communication adapter. The most commonly
customer parameter back to the original value. This used port is “COM 1”.
will change the total tattletale. The new total tattletale
will require obtaining new factory passwords. Obtain 4. Check for any hardware that is utilizing the
new factory passwords and enter the passwords. same port as the communications adapter. If any
devices are configured to use the same port, exit
or close the software programs for that device.
J1/P1 Connector
Check the J1/P1 connectors for the following
problems:
70 RENR1367-11
• Proper torque Perform the following procedure:
• Cleanliness of the terminals 1. Turn the key switch OFF.
• Wires and terminals are properly installed into the 2. Disconnect Cat ET.
connector.
3. Turn the key switch ON.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for additional information. 4. Connect Cat ET.
Communication Adapter and/or Cables This may solve the communication problem.
Verify that the correct cable is being used between ATA Data Link
the communication adapter and the service tool
connector. Refer to Troubleshooting, “Electronic Troubleshoot the ATA data link for possible problems.
Service Tools”. Refer to Troubleshooting, “ATA (SAE J1587 / J1708)
Data Link Circuit - Test”.
If you are using a 171-4401 Communication Adapter
Gp, ensure that the firmware and software files for J1939 Data Link
the communication adapter are the most current
files that are available. If the firmware and software Troubleshoot the J1939 data link for possible
do not match, the communication adapter will not problems. Refer to Troubleshooting, “Powertrain
communicate with Cat ET. Data Link Circuit - Test”.
Electrical Power Supply to the Service

i02319720
Tool Connector
Elevated Idle
Verify that battery voltage is present between
terminals A and B of the service tool connector. If the SMCS Code: 1915-035
communication adapter is not receiving power, the
communication adapter’s display will be blank.
Probable Causes
Cat ET and Related Hardware This condition may be normal operation. One of the
following features may be causing the elevated idle:
In order to eliminate Cat ET and the related hardware
as the problem, connect Cat ET to a different engine. • Low Battery Elevated Idle
If the same problem occurs on a different engine,
check Cat ET and the related hardware in order to • Cold Mode Elevated Idle
determine the cause of the problem.
• PTO operation
Electrical Power Supply to the ECM
• Exhaust Brake
If the ECM is not receiving battery voltage, the ECM
will not communicate. Check the electrical power to Use the Caterpillar Electronic Technician (ET) to
the ECM. Refer to Troubleshooting, “Ignition Key verify that the engine is not in elevated idle. Elevated
Switch Circuit and Battery Supply Circuit - Test”. idle is indicated in the upper part of any status screen.
Override Switches Conditions

Verify that there are no aftermarket devices that are Low Battery Elevated Idle
preventing battery voltage from reaching the ECM.
The engine idle speed will be elevated to the value
Some type of override switch is interrupting the power that is programmed into the “Battery Monitor Low Idle
to the ECM if the following conditions are true:
Engine Speed” parameter when all of the following
conditions occur:
• Communication occurs when the engine is running.
• The vehicle is stopped.
• No communication occurs when the engine is not
running and the keyswitch is ON.
• The transmission is not in gear.
RENR1367-11 71
• The brake pedal is not depressed. • Personality module

• The clutch pedal is not depressed. • ECM
• System battery voltage is less than the value that • Hydraulic electronic unit injectors
is programmed into the “Battery Monitor & Engine
Control Voltage” parameter for 30 seconds. • Engine speed/timing signal
Cold Mode Elevated Idle • Injection actuation pressure control system
The engine idle speed will be elevated to the value • Engine software
that is programmed into the “Warm Up Mode Idle
Speed” parameter when all of the following conditions • Theft deterrent
occur:
• Fuel supply
• The transmission is not in gear.
• Combustion problem
• The brake pedal is not depressed.
Recommended Actions
• The clutch pedal is not depressed.
Perform the following diagnostic procedures in order:
• Cold mode is active.
PTO Operation
Ignition Key Switch
1. Connect an electronic service tool to the cab data
The engine speed may be elevated during PTO link connector.
operation. Check the value of the “PTO Engine RPM
Set Speed” parameter. 2. Access the status of the ignition key switch.
The Exhaust Brake Is Being Used as a 3. Slowly cycle the ignition key switch on and off
Warm Up Device while the status of the ignition key switch is being
monitored. The status should indicate the state
Check the value of the “Exhaust Brake/Warm Up of the switch.
Enable” parameter. If the parameter is programmed
to “Warm Up” or “Exhaust Brake and Warm Up”, the If the ECM will not communicate and the ignition
engine idle speed may be elevated during idle. key switch is in the ON position, refer to the next
step.
Refer to , “Exhaust Brake Circuit - Test” for additional
information about this feature. Note: If the idle shutdown is used or if the PTO
shutdown time is used, the status of the ignition key
switch may indicate that the switch is ON even though
i02063676 the ignition key switch is turned to the OFF position.
Engine Cranks but Will Not
Engine Oil Pressure
Start
1. Check the engine oil level. Engine oil is used to
SMCS Code: 1000-035 activate the high pressure hydraulic pump.
Probable Causes 2. Ensure that the engine oil meets the

recommendations of the Operation and
The probable root causes are listed in order below: Maintenance Manual.
• Ignition key switch 3. Check for air in the high pressure oil system.
• Engine oil pressure Note: Crank the engine for 30 seconds. Allow time
for the starter motor to cool. Crank the engine up
• Electronic Control Module (ECM) communications to five times in order to purge the air from the high
pressure oil system.
• Engine protection devices
• ECM power supply
72 RENR1367-11
Check Communications 5. Connect a bypass circuit for the ECM. Refer to

Illustration 14.
1. Connect the electronic service tool to the cab data
link connector.
2. Check the communications between the ECM and

the electronic service tool.
3. Ensure that the ignition key switch is in the ON

position. Attempt to access one of the electronic
service tool status screens.
If the electronic service tool indicates that the

ECM will not communicate go to the next step. If
the ECM communicates go to “Engine Software”.
Note: A new ECM has a personality module that is

not programmed. A personality module that is not
programmed will cause this symptom. Accessing the
ECM status in the electronic service tool WinFlash
program without programming the personality module
will cause the engine not to start or accessing the
ECM status in the electronic service tool WinFlash
Program without programming the personality
module will cause the engine not to communicate.
Cycling the ignition key switch from the OFF to the
ON position will correct this problem.
Engine Protection Devices

1. Check aftermarket engine protection devices.
These devices usually interrupt power to the
ECM and the ECM will not communicate with the
electronic service tool.
2. Check for the correct installation of the aftermarket

engine protection device.
3. Check for the correct operation of the aftermarket

Note: It may be necessary to disable the aftermarket

engine protection device before you continue.
4. Verify the voltage supply at the ECM.
ECM Power Supply

1. Verify that the ECM is receiving battery voltage.
2. Check the electrical power supply to the ECM.
3. Check the power connection of the ECM and the

ground connection of the ECM.
4. Verify that the ECM is receiving battery voltage

when the ignition key switch is turned on. Refer to
Troubleshooting, “Ignition Key Switch Circuit and
Battery Supply Circuit - Test”.
RENR1367-11 73
g01057556
Illustration 14
Personality Module 3. Check for logged diagnostic codes that are related
to the cylinder. Refer to Troubleshooting, “Injector
A new ECM has a personality module that is not Solenoid Circuit - Test” if diagnostic codes that are
programmed. The engine will not start until the related to the cylinder are present.
personality module has been flashed. Also, the
engine will not communicate until the personality
module has been flashed.
Engine Speed/Timing Signal
1. Check the engine speed/timing signal.
ECM
2. Observe the engine rpm with the electronic service
Before replacing the ECM, try to flash program tool while the engine is being cranked.
the existing ECM. Refer to Troubleshooting, “Flash
Programming”. This may require the electronic service tool to
be powered directly by the vehicle batteries or
If the ECM is suspected of being the problem, this may require the electronic service tool to be
temporarily connect a test ECM. This will show powered directly by a separate power source (12
whether the problem has been resolved or the VDC). Refer to Illustration 14.
problem has not been resolved.
There is a problem in the circuit of the speed/timing
sensor if the electronic service tool display reads
Hydraulic Electronic Unit Injectors 0 rpm during cranking. Refer to Troubleshooting,
“Engine Speed/Timing Sensor Circuit - Test”.
1. Check the electrical connections to the hydraulic
electronic unit injectors.
If an engine rpm is present, check the sensor
installation. If the sensor is not properly installed,
2. Ensure that the hydraulic electronic unit injector
the sensor may read RPM but the sensor may not
connector (J300/P300) is fully connected and
ensure that the hydraulic electronic unit injector be able to sense the tooth pattern. The ability to
sense the tooth pattern is necessary to determine
connector (J300/P300) is free of corrosion.
the cylinder position. Engine rpm is present when
the engine rpm is 50 rpm or more.
74 RENR1367-11
Injection Actuation Pressure 5. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, “Fuel System -
System Prime”.
1. Crank the engine and monitor the injection
6. Check for fuel supply lines that are restricted.
actuation pressure and the output of the injection
actuation pressure control valve. The high
7. Check the fuel filters.
pressure oil system is operating properly if the
pressure output is a minimum of 6 MPa (870 psi).
8. If the temperature is below 0 °C (32 °F), check
for solidified fuel (wax).
2. Connect the electronic service tool and check for
event code 164-11. If an 164-11 event code has
been logged recently, refer to Troubleshooting, Combustion Problem
“Injection Actuation Pressure -Test”.
Check for combustion problems.
3. If higher than actual pressure is being indicated,
then disconnect the injection actuation pressure Examples of combustion problems are shown in the
sensor and try to start the engine. If the engine following list:
starts, refer to Troubleshooting, “Injection
Actuation Pressure Sensor -Test”. • Outside temperatures are too cold.
Engine Software • Mechanical problem
Connect the electronic service tool and check for the i01434232
correct engine software. Ensure that there is not an
active 252-11 diagnostic code. Engine Has Early Wear
If the diagnostic code is present, refer to SMCS Code: 1000-035
Troubleshooting, “ECM Memory - Test”.
Probable Causes
Theft Deterrent
• Dirt in the engine oil
Ensure that the theft deterrent (if equipped) is not
active. Turn the ignition switch to the ON position. • Air inlet leaks
Observe the display screen on the CAT ID.
• Fuel leakage into engine oil
If the display screen on the CAT ID indicates that
the theft deterrent is enabled, the theft deterrent • Incorrect engine oil
passwords must be entered before the engine will
start. • Incorrect maintenance interval for the application
Fuel Supply Recommended Repairs

1. Check the fuel supply. Dirt in the Engine Oil
2. Monitor the exhaust for smoke while the engine Remove dirty engine oil. Install new filter elements.
is being cranked. Put clean oil in the engine. Check the oil filter bypass
valve for a weak spring or a broken spring. Look for
If no smoke is present, there may be a problem the source of the contamination.
with the fuel supply. Air Inlet Leaks
3. Check the fuel quality. Refer to Truck Performance
Inspect the air filter for leaks. Inspect all gaskets and
and Driveability Diagnostic Guide, LEBT3477. connections. Make repairs if leaks are found.
4. Check the fuel pressure. Refer to Testing and
Adjusting, “Fuel System Pressure - Test”.
RENR1367-11 75
Fuel Leakage into the Engine Oil Individual Cylinder Malfunction

Fuel leakage into the engine oil will cause high 1. Check for an individual cylinder malfunction.
fuel consumption and low engine oil pressure. This
condition may also increase the oil level in the 2. Ensure that the hydraulic electronic unit injector
crankcase. Make repairs if leaks are found. Install connector (J300/P300) is fully connected and
new parts, as required. ensure that the hydraulic electronic unit injector
connector (J300/P300) is free of corrosion.
Incorrect Engine Oil
3. Ensure that the ECM engine harness connector
Check oil recommendations for the proper oil (J2/P2) is fully connected and ensure that the
specifications for the engine operating conditions. engine harness connector (J2/P2) is free of
corrosion.
Incorrect Maintenance Interval 4. Connect Caterpillar Electronic Technician (ET)
to the cab data link connector. Use the Cylinder
Review the oil change intervals in relation to the
Cutout Test. Access the Cylinder Cutout Test
nature and severity of the engine application. Review
by selecting the “Diagnostic Menu” and the
the records for the engine in order to verify that the
“Diagnostics Test Menu”. Run the Cylinder Cutout
recommended intervals are being followed.
Test in order to disable each cylinder. Disabling
each cylinder allows the technician to isolate the
i01641917 misfiring cylinders.
Engine Misfires, Runs Rough If the misfiring cylinder can be isolated to a

or Is Unstable specific cylinder, refer to Troubleshooting, “Injector
Solenoid Circuit - Test”.
SMCS Code: 1000-035
Fuel Supply
Probable Causes 1. Monitor the exhaust for smoke while the engine
The probable root causes are listed in order below: is being cranked.
Note: If the problem is intermittent and the problem If no smoke is present, there may be a problem
can not be duplicated, refer to Troubleshooting, with the fuel quality or there may be a problem
“Intermittent Low Power or Power Cutout”. with the fuel supply.
2. Check the fuel quality. Refer to the Truck

• Individual cylinder malfunction Performance and Driveability Diagnostic Guide,
LEBT3477.
• Fuel supply
• Low injection actuation pressure Adjusting, “Fuel System Pressure - Test”.
• Accelerator pedal position sensor 4. Ensure that the fuel system has been primed.
• Power train data link Prime”.
• Camshaft position sensor 5. Check for fuel supply lines that are restricted.
• Valve lash 6. Check the fuel filters.
Recommended Repairs 7. If the temperature is below 0 °C (32 °F), check

8. Check for air in the fuel system. Refer to Testing
Note: If the problem only occurs under certain and Adjusting, “Air in Fuel - Test”.
conditions, test the engine under those conditions.
Examples of certain conditions are high rpm, full load
and engine operating temperature. Troubleshooting Low Injection Actuation Pressure
the symptoms under other conditions can give
misleading results. 1. Check the engine oil level. Engine oil is used to
activate the high pressure hydraulic pump.
76 RENR1367-11
2. Ensure that the engine oil meets the Camshaft Position Sensor
recommendations of the engine manufacturer.
Refer to Operation and Maintenance Manual for If the signal for the Camshaft Position Sensor is
further details. lost during engine start-up, additional time may be
required to start the engine. The engine may also
3. Crank the engine and monitor the injection misfire during this time until the ECM determines the
actuation pressure and the output of the injection proper firing order. Refer to Troubleshooting, “Engine
actuation pressure control valve. The high Speed/Timing Circuit - Test”.
pressure oil system is operating properly if the
Valve Lash
4. Connect ET and check for event code 164-11
Refer to Systems Operation, Testing and Adjusting
Injection Actuation Pressure system fault. If an
for the correct procedure.
164-11 event code has been logged recently, refer
to Troubleshooting, “Injection Actuation Pressure
System-Test”. i02419766
Accelerator Pedal Position Sensor Engine Vibration

SMCS Code: 1000-035
1. If the engine is in the cruise control mode and the
problem does not occur, check the accelerator
pedal position sensor. Probable Causes
2. Use the Cruise/Idle On/Off Switch to put the • Vibration damper
engine in Idle mode.
• Engine supports
3. Vary the engine rpm with the set/resume switches.
• Driven equipment
If both of the following conditions are met, connect
ET and monitor the status of the accelerator pedal • Engine misfiring or running rough
position sensor.
Recommended Actions
• The engine is stable by using idle mode to
control the engine rpm.
Vibration Damper
• The engine is unstable by using the accelerator Check the vibration damper for damage. Install a
pedal position sensor.
new vibration damper, if necessary. Inspect the
If the status of the accelerator pedal position mounting bolts for damage and/or for wear. Replace
sensor is unstable, refer to Troubleshooting, any damaged bolts. Refer to the Disassembly and
“Accelerator Pedal (Throttle) Position Sensor Assembly manual.
Circuit - Test”.
Engine Supports
Power Train Data Link Inspect the mounts and the brackets while you run
the engine through the speed range. Look for mounts
1. Check the “Power train Data Link”. Ensure that and brackets that are loose and/or broken. Tighten
the SAE J1939 data link is not limiting the power. all of the mounting bolts. Install new components, if
necessary.
2. Connect ET to the cab data link connector.
3. Monitor the “Power Train Data Link” status screen Driven Equipment
while the vehicle is experiencing problems.
Check the alignment and the balance of the driven
If the “Power Train Data Link” status screen equipment.
indicates that the data link is limiting the power or
the rpm, verify that this is not normal operation. If Engine Misfiring or Running Rough
this is not normal operation, refer to the vehicle
OEM for repairs. Refer to troubleshooting without a diagnostic code
Troubleshooting, “Engine Misfires, Runs Rough or
Is Unstable”.
RENR1367-11 77
i01351154 5. If the starting motor cables are corroded, remove

the starting motor cables and clean the starting
Engine Will Not Crank motor cables.
SMCS Code: 1000-035 6. Test starting motor operation.
Probable Causes 7. Inspect flywheel ring gear for damage.
Note: This is NOT an electronic system problem. 8. Ensure free movement of the driveline.
Refer to Testing and Adjusting for additional
information. 9. Remove engine accessories that may lock up the
engine and inspect engine accessories that may
The probable root causes are listed in order below: lock up the engine.
• Batteries The following list illustrates examples of engine

accessories that may lock up the engine:
• Starting circuit
• Air compressor
• Starting motor solenoid
• Power steering pump
• Starting motor
• Engine oil pump
• Flywheel ring gear
10. Check for fluid in the cylinders (hydraulic
• Transmission cylinder lock) by removing the individual hydraulic
electronic unit injectors.
• PTO
Note: Drain the fuel from the cylinder head. Fuel will
• Engine accessory flow from the cylinder head into the cylinders when
the hydraulic electronic unit injector is removed.
• Hydraulic cylinder lock
11. Disassemble the engine. Inspect the internal
• Internal engine problem components for the following conditions:
• Ring gear • Seizure
Recommended Actions • Broken components

• Bent components
Refer to Disassembly and Assembly.
1. Inspect the batteries.
12. Inspect the flywheel ring gear for damage.
a. Charge the batteries. Refer to Special Refer to Disassembly and Assembly for more
Instruction, SEHS7633, “Battery Test information.
Procedure”.
b. Load test the batteries. Refer to Special i02223534

Instruction, SEHS9249, “Use of 4C-4911
Battery Load Tester for 6, 8 and 12 Volt Lead Excessive Black Smoke
Acid Batteries”.
SMCS Code: 1088-035
2. Check the vehicle wiring to the starting motor
solenoid. Refer to the OEM vehicle manual. Probable Causes
3. Check the engine start switch and the relay for • Air inlet system or exhaust system
switch power.
• Valve lash
4. Inspect the starting motor cables for damage or
loose connections. • Hydraulic electronic unit injector
• Electronic system
78 RENR1367-11
• Engine Control Module (ECM) or personality • The fuel position is less than the FRC fuel limit.
module
If the fuel position is equal to the rated fuel limit
and the fuel position is less than the FRC fuel
Recommended Actions limit, the electronics are operating correctly.
4. If the fuel position is not equal to the rated fuel
limit and/or the fuel position is not less than the
Air Inlet System or Exhaust System FRC fuel limit, perform the following tests in order:
Check the air inlet system for restrictions or leakage. 5. When the engine is off, place the keyswitch in the
Check the exhaust system for restrictions or leakage. ON position. Check the boost pressure on the Cat
Refer to Testing and Adjusting, “Air Inlet and Exhaust ET status screen.
System - Inspect”.
When the engine is off, the boost pressure should
Valve Lash be 0 kPa (0 psi).
Check the valve lash. Refer to Testing and Adjusting, ECM or Personality Module
“Engine Valve Lash - Inspect/Adjust”.
Check the ECM or the personality module.
Hydraulic Electronic Unit Injector
Refer to Troubleshooting, “ECM Memory - Test”.
1. Ensure that the J300/P300 hydraulic electronic
unit injector connector is fully connected and free i02424626
of corrosion.
Excessive Valve Lash
2. Ensure that the J2/P2 ECM connector is fully
connected and free of corrosion. SMCS Code: 1105-035
3. Connect Caterpillar Electronic Technician (ET)

to the cab data link connector. Use the cylinder
Probable Causes
cutout test. Access the cylinder cutout test
by selecting the “Diagnostic Menu” and the • Lubrication
“Diagnostics Test Menu”. Run the cylinder cutout
test in order to disable each cylinder. Disabling • Valve lash
each cylinder allows the technician to isolate the
misfiring cylinders. • Valve train components
If the misfiring cylinder can be isolated to a Recommended Actions

specific cylinder, refer to Troubleshooting, “Injector
Solenoid Circuit - Test”. Lubrication
Electronic System 1. Remove the valve mechanism covers. Refer to

the engine’s Disassembly and Assembly manual.
1. Connect Cat ET to the cab data link connector.
2. Check the lubrication in the valve compartment.
2. While the problem is occurring, check for Ensure that there is adequate engine oil flow in
diagnostic codes that are related to the boost the valve compartment. The passages for the
pressure sensor and the atmospheric pressure engine oil must be clean.
sensor. If a diagnostic code is found, refer to
Troubleshooting, “Engine Pressure Sensor Open Valve Lash
or Short Circuit - Test”.
Adjust the engine valve lash. Refer to the engine’s
3. Monitor the fuel position, the rated fuel limit and Systems Operation/Testing and Adjusting manual.
the FRC fuel limit.
Valve Train Components
While the vehicle is operating under full load, the
parameters should meet the following conditions: 1. Inspect the following components of the valve
train:
• The fuel position is equal to the rated fuel limit.
RENR1367-11 79
• Rocker arms Recommended Actions

• Pushrods Air Inlet Restriction
• Valve lifters Check the air inlet system for restrictions. Refer to
Systems Operation/Testing and Adjusting, “Air Inlet
• Camshaft and Exhaust System - Inspect”.
• Valve stems Starting Aids

• Rocker shafts 1. If the engine application is equipped with a jacket
2. Check the components for the following conditions: water heater, check for the proper operation of
abnormal wear, excessive wear, straightness, and the heater control and the heater element. If
cleanliness. Replace parts, if necessary. necessary, repair the jacket water heater.
Note: If you replace the camshaft, you must also 2. Check for the proper operation of the air inlet
replace the valve lifters. heater. Check for the proper operation of the
heater control, the heater element, and the heater
3. Adjust the engine valve lash. Refer to the engine’s relay. If necessary, repair the air inlet heater.
Systems Operation/Testing and Adjusting manual.
If a problem with the operation of the air inlet heater
circuit is suspected, refer to Troubleshooting, “Air
i02366648 Inlet Heater Circuit - Test”.
Excessive White Smoke Coolant Temperature Sensor

SMCS Code: 1088-035 1. Use the Caterpillar Electronic Technician (ET) to
verify that the engine has exited cold mode.
Note: Some white smoke may be present during
cold start-up conditions when the engine is operating 2. Ensure that the coolant temperature that is
normally. If the white smoke persists, there may be
reported from Cat ET is reasonable. If this
a problem. coolant temperature is suspect, use a 6V-9130
Temperature Adapter (MULTIMETER) to confirm
Probable Causes the accuracy.
• Air inlet restriction Water Temperature Regulators

• Starting aids Check the water temperature regulators for correct
operation. Refer to Systems Operation/Testing and
• Coolant temperature sensor Adjusting, “Cooling System” for the proper procedure.
• Water temperature regulators Engine Speed/Timing

• Engine speed/timing 1. Check the calibration of the engine speed/timing
sensor. Refer to Troubleshooting, “Engine
• Unit injectors Speed/Timing Sensor - Calibrate”.
• Flash file 2. Verify that the crankshaft and camshaft drive
gears are set with the proper orientation. Refer to
• Fuel supply the Disassembly and Assembly for information
that is related to the correct installation of the front
• Component wear gear train.
• Cooling system
Unit Injectors
Perform the “Cylinder Cutout Test” on Cat ET in order
to check the unit injectors and the performance of
each cylinder. Refer to Troubleshooting, “Injector
80 RENR1367-11
Cut out each individual cylinder for 30 to 60 seconds. • Problem with a switch
This will help to identify problem injectors.
• Clutch switch or clutch spring
Flash File
• Electrical power to the Engine Control Module
Verify that the latest version of the ECM flash (ECM)
file has been installed. Refer to Troubleshooting,
“System Configuration Parameters” for information Recommended Actions
on obtaining to the current part number for the flash
file that is installed in the ECM. Note: If a kickout occurred, the ECM stores the most
recent cause of the kickout. However, the ECM will
Fuel Supply not store the information if the ECM is powered down.
The ECM is powered down when the keyswitch is
1. Inspect the condition of the fuel system placed in the OFF position. It may be necessary to
components. Inspect each component for leakage operate the vehicle in order to duplicate the problem.
and damage. Then, check the value of the “Cruise Kickout”, the
“Idle Kickout”, or the “PTO Kickout” status parameter
2. Check the fuel pressure during engine cranking. before the ECM is powered down.
Check the filtered fuel pressure. Refer to Systems
Operation/Testing and Adjusting, “Fuel System” Perform the actions that relate to the feature that has
for the correct pressure values. If the fuel pressure the complaint.
is low, replace the fuel filters. If the fuel pressure
is still low, check the following items: fuel transfer Check the Programmable Parameters
pump, fuel transfer pump coupling, and fuel
pressure regulating valve. Refer to Table 144. Use the Caterpillar Electronic
Technician (ET) to verify that configuration
3. Check the fuel quality. Low cetane fuel can create parameters for the feature with the complaint are
white smoke. If necessary, replace the fuel with a programmed correctly:
higher cetane fuel.
4. Cold weather adversely affects the characteristics

of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
Component Wear
Check the engine for the following problems:
Excessive valve wear, piston wear, ring wear, liner
wear, and reduced compression pressure.
Cooling System
Check for an internal coolant leak into the
cylinder and/or the exhaust. Refer to Systems
Operation/Testing and Adjusting, “Cooling System”.
i02319844
Intermittent Cruise Control,

Idle, or PTO Kickout
SMCS Code: 1915-035
Probable Causes
• Programmable parameters
RENR1367-11 81
Table 144
Parameters for the Features
Feature Configuration Parameters Notes
Cruise Control Low Cruise Control Set Speed Limit If the vehicle speed is below the “Low Cruise Control
Set Speed Limit”, the cruise control can not be set or
resumed.
High Cruise Control Set Speed Limit If the vehicle speed exceeds the “High Cruise Control
Set Speed Limit” and the driver attempts to set a cruise
control speed, the cruise set speed will be the “High
Cruise Control Set Speed Limit”.
Extended Idle Idle Vehicle Speed Limit If the driver attempts to set an idle engine rpm and the
vehicle speed exceeds the “Idle Vehicle Speed Limit”,
the idle will not activate.
Idle RPM Limit If the engine rpm is above the “Idle RPM Limit” and
the driver attempts to set an idle engine rpm, the idle
engine rpm will be the idle rpm limit.
PTO PTO Top Engine Limit
PTO Kickout Vehicle Speed Limit If the vehicle speed exceeds the programmed “PTO
Kickout Vehicle Speed Limit”, the ECM will not maintain
the set speed.
PTO On/Off Switch
Remote PTO Set Switch
Remote PTO Resume Switch
Check the Switches If the cause of the kick out is “Brake”, the ECM has
detected an open circuit in the circuit for a service
Typically, the operation of the PTO requires an brake switch. Verify that the operator did not operate
interlock switch such as a parking brake switch. the service brake. Use Cat ET to check the status of
Ensure that all interlocks are set to allow PTO the service brake switches while the service brake is
operation. operated. Refer to Troubleshooting, “Service Brake
Pedal Position (Switch 1) Circuit - Test” or , “Service
Cat ET uses the following status parameters to Brake Pedal Position (Switch 2) Circuit - Test”, if
display the most recent cause of the rubbing: “Cruise necessary.
Kickout”, “Idle Kickout”, and “PTO Kickout”. Check
the cause of the kick out. If the cause of the kick out is “Clutch”, the ECM
If the cause of the kick out is “Switch Turned Off”, clutch switch. Verify that the operator did not operate
the ECM has detected an open circuit in the circuit the clutch. Use Cat ET to check the status of the
for the cruise switch or the PTO switch. Verify that clutch switch while the clutch is operated. Refer
the operator did not turn off the switch. Use Cat ET to Troubleshooting, “Clutch Pedal Position Switch
to check the status of the on/off switch while the Circuit - Test”, if necessary.
switch is operated. Refer to Troubleshooting, “Cruise
Control Switch Circuit - Test” or Troubleshooting,
“PTO Switch Circuit - Test”, if necessary.
82 RENR1367-11
If the cause of the kick out is “Neutral”, the ECM Check the Power Connections to the
has detected an open circuit in the circuit for the ECM
transmission neutral switch. Verify that the operator
did not shift the transmission into neutral. Use Cat A problem with the power wiring to the ECM can
ET to check the status of the transmission neutral cause erratic engine operation. If this is a suspected
switch while the transmission is shifted into neutral. cause, refer to Troubleshooting, “Ignition Key Switch
Refer to Troubleshooting, “Neutral Switch Circuit - Circuit and Battery Supply Circuit - Test”.
Test”, if necessary.
If the cause of the kick out is “Set SW Timeout”, then i02112612

the “Set” position by the operator for more than 15 Intermittent Engine Shutdown
seconds or there is a short circuit in the circuit for the
“Set” position of the switch. Determine the condition SMCS Code: 1000-035
that caused the kickout. Refer to Troubleshooting,
“Cruise Control Switch Circuit - Test”, if necessary. Probable Causes
Turn off the cruise control switch and turn on the
cruise control switch in order to get the cruise control • Diagnostic codes
to work again.
• Battery power or ground
If the cause of the kick out is “Res SW Timeout”, then
the cruise control set/resume switch was placed to • Aftermarket engine protection devices
the “Resume” position by the operator for more than
15 seconds or there is a short circuit in the circuit • Fuel supply
for the “Resume” position of the switch. Determine
the condition that caused the kickout. Refer to • Engine speed/timing sensors
Test”, if necessary. Turn off the cruise control switch • Low injection actuation pressure
and turn on the cruise control switch in order to get
the cruise control to work again. • Engine Control Module (ECM) or personality
module
If the cause of the kick out is “Vehicle Speed < Limit”,
the vehicle speed signal exceeded the programmed Note: Shut down the engine before attempting to
Idle/PTO vehicle speed limit or the vehicle speed troubleshoot the problem.
signal is missing or erratic. Perform the following
steps:
Recommended Actions
1. Inspect the vehicle speed sensor for debris.
Diagnostic Codes
2. Carefully inspect the vehicle’s electrical
connectors for the speed circuit. Look for 1. Connect Caterpillar Electronic Technician (ET) to
corrosion, for debris, and for loose terminals. the data link connector.
3. Check the P1 connector for corrosion, for debris, 2. Check for active diagnostic codes.
and for loose terminals.
Note: Certain diagnostic codes may cause the
4. Use Cat ET to check the vehicle speed while engine to shutdown. Troubleshoot all diagnostic
the vehicle is parked. Also check the vehicle codes before continuing with this procedure.
speed while the vehicle is being driven in order
to determine that the vehicle speed that is
indicated by Cat ET does not vary significantly
Battery Power or Ground
from the vehicle speed that is indicated by the
1. Ensure that the following connectors have been
speedometer. Refer to Troubleshooting, “Vehicle
installed correctly:
Speed and Speedometer Circuit - Test”.
• ECM connectors (J1/P1 and J2/P2)
Check the Clutch Switch and the Clutch
Spring • Injector connector (J300/P300)
Check the clutch switch adjustment and the clutch • Primary engine speed/timing connector
spring. Make repairs, if necessary. (J401/P401)
RENR1367-11 83
• Secondary engine speed/timing connector Refer to Troubleshooting, “Engine Speed/Timing

(J402/P402) Circuit - Test”.
2. Check the power connections for the ECM and

for the ground connections for the ECM. If a
Low Injection Actuation Pressure
problem is suspected, wire a bypass. Refer to
activate the high pressure hydraulic pump.
Battery Supply Circuit - Test”.
2. Ensure that the engine oil meets the Caterpillar
3. If the problem occurs only after engine warm-up
and the problem disappears after the engine Refer to , SEBU6385, “Caterpillar On-Highway
cooldown, the circuit breakers may be tripping
Diesel Truck Engine Fluid Recommendations”.
because of the heat. Check the circuit breakers
on the vehicle in order to determine if the circuit 3. Check the injection actuation pressure. Refer to
breakers reset automatically.
Troubleshooting, “Injection Actuation Pressure
-Test”.
Aftermarket Engine Protection
Devices ECM or Personality Module
1. Check aftermarket engine protection devices. Check the ECM or the personality module.
These devices usually interrupt power to the ECM
and the ECM will not communicate with Cat ET. Refer to Troubleshooting, “ECM Memory - Test”.
2. Check for the correct installation of the aftermarket

i01857376
3. Check for the correct operation of the aftermarket

Intermittent Low Power or
engine protection device. Power Cutout
4. Verify that the ECM is receiving battery voltage. SMCS Code: 1000-035
Fuel Supply Probable Causes

1. Monitor the exhaust for smoke while the engine The probable root causes are listed in order below:
is being cranked.
• Electrical connections
If no smoke is present, there may be a problem
with the fuel quality or there may be a problem • Engine Monitoring
with the fuel supply.
• Battery power or ground to the ECM
2. Check the fuel quality. Refer to , SEBU6385,
“Caterpillar On-Highway Diesel Truck Engine Fluid • Electronic system
Recommendations”.
• Accelerator pedal position sensor
Adjusting, “Fuel System”. • Vehicle speed signal
4. Ensure that the fuel system has been primed. • Power train data link
Refer to Testing and Adjusting, “Fuel System”.
• Fuel supply
• Torque limit switch
• Low injection actuation pressure
for solidified fuel (wax). Recommended Actions
Engine Speed/Timing Sensors Perform the following diagnostic procedures in order:
Check the engine speed/timing sensors.

84 RENR1367-11
Electrical Connectors If the fuel position is equal to the rated fuel limit
and the fuel position is less than the FRC fuel limit,
Check the vehicle harness and the connectors. Refer the electronics are operating correctly. Proceed to
to Troubleshooting, “Electrical Connectors - Inspect”. “Vehicle Speed Signal”.

Engine Monitoring limit and/or the fuel position is not less than the
FRC fuel limit, perform the following tests in order:
1. Check the parameters for “Engine Monitoring”.
4. When the engine is off, turn the ignition key switch
to the ON position. Check the boost pressure on
link connector.
the electronic service tool status screen.
3. Check for diagnostic codes that are capable of
When the engine is off, the boost pressure should
derating the engine when “Engine Monitoring” is
be 0 kPa (0 psi).
programmed to “Derate” or “Shutdown”.
• 110-00 High Coolant Temperature Warning (61) Accelerator Pedal Position Sensor
• 110-11 Very High Coolant Temperature (61) Monitor the status of the accelerator pedal position
sensor. Operate the engine at high idle with the
• 111-11 Very Low Coolant Level (62) vehicle in neutral.
If the engine can not reach the programmed Top

Battery Power or Ground to the Engine Limit, check the duty cycle of the accelerator
ECM pedal position sensor in order to ensure that the duty
cycle is within calibration (75 to 90 Percent at high
1. Ensure that the following connectors have been idle).
installed correctly:
If the accelerator pedal position is unstable, check
• ECM connectors (J1/P1 and J2/P2) the duty cycle of the accelerator pedal position
sensor. Check the duty cycle of the accelerator pedal
• Injector connector (J300/P300) position sensor by slowly operating the accelerator
pedal in order to verify that the accelerator pedal
• Camshaft position sensor connector (J401/P401 position sensor is within calibration. The accelerator
and J402/P402) pedal position sensor is within calibration when both
of the following conditions are met:
2. Use the electronic service tool to check for a
diagnostic code 168-02 (Intermittent Battery • 10 to 22 percent at low idle
Power to the ECM). Check the power connections
for the ECM and the ground connections for the • 75 to 90 percent at high idle
ECM. If a problem is suspected, wire a bypass.
Refer to Troubleshooting, “Ignition Key Switch Also, ensure that the duty cycle changes as the pedal
Circuit and Battery Supply Circuit - Test”(51). position changes.
Electronic System If a problem with the accelerator pedal position sensor

is suspected, refer to Troubleshooting, “Accelerator
1. Connect the electronic service tool to the cab data Pedal (Throttle) Position Sensor Circuit - Test”.
link connector.
Vehicle Speed Signal
2. Monitor the fuel position, the rated fuel limit and
the FRC fuel limit. Monitor the vehicle speed signal. Ensure the
While the vehicle is operating under full load, the the vehicle speed signal to the actual vehicle speed.
parameters should meet the following conditions:
If the vehicle speed is greater than the “VSL”, the
• The fuel position is equal to the rated fuel limit. Power is limited. If a problem is discovered, refer to
Troubleshooting, “Vehicle Speed and Speedometer
• The fuel position is less than the FRC fuel limit. Circuit - Test”.
RENR1367-11 85
Power Train Data Link If the “Torque Limit” is programmed below

2712 N·m (2000 lb ft), check the status screen
1. Check the “Powertrain Data Link”. Ensure that the for the torque limit switch. Ensure that the status
SAE J1939 data link is not limiting the power. screen indicates that the torque limit switch is
off. If the status of the torque limit switch is
2. Connect the electronic service tool to the cab data on and a “Torque Limit” is programmed, the
link connector. system is operating correctly. If the switch that is
connected to this signal input is not switching on
3. Monitor the “Powertrain Data Link” status screen and switching off, refer to Troubleshooting, “PTO
while the vehicle is experiencing problems. Switch Circuit - Test”.
If the “Powertrain Data Link” status screen Low Injection Actuation Pressure
the rpm, verify that this is not normal operation. If 1. Check the engine oil level. Engine oil is used to
this is not normal operation, refer to the vehicle activate the high pressure hydraulic pump.
OEM for repairs.
2. Ensure that the engine oil meets the
Fuel Supply recommendations of the engine manufacturer.
Refer to Operation and Maintenance Manual for
1. Monitor the exhaust for smoke while the engine further details.
is being cranked.
3. Crank the engine and monitor the injection
If no smoke is present, there may be a problem actuation pressure and the output of the injection
with the fuel quality or there may be a problem actuation pressure control valve. The high
with the fuel supply. pressure oil system is operating properly if the
2. Check the fuel quality. Refer to the Truck
Performance and Driveability Diagnostic Guide, 4. Connect the electronic service tool to the cab data
LEBT3477. link connector and check for event code 164-11
injection actuation pressure system fault . If an
3. Check the fuel pressure. Refer to Testing and 164-11 event code has been logged recently, refer
Adjusting, “Fuel System Pressure - Test”. to Troubleshooting, “Injection Actuation Pressure
-Test”.
4. Ensure that the fuel system has been primed.
i01940729
Prime”.

Low Power/Poor or No
Response to Throttle
SMCS Code: 1000-035
for solidified fuel (wax). Probable Causes
8. Check for air in the fuel system. Refer to Testing
and Adjusting, “Air in Fuel - Test”.
• Customer specified parameters (normal operation)
• Cold mode
Torque Limit Switch
link connector. • Electronic system
2. Check the setting for the Customer Parameter for • Vehicle speed signal
the “Torque Limit”.
• Power train data link
• Fuel supply
• Air Inlet and exhaust system
• Malfunction of an individual cylinder
86 RENR1367-11
• Low injection actuation pressure If the “Torque Limit” is programmed below

2712 N·m (2000 lb ft), check the status screen
for the torque limit switch. Ensure that the status
Recommended Actions screen indicates that the torque limit switch is
off. If the status of the torque limit switch is
Customer Specified Parameters on and a “Torque Limit” is programmed, the
system is operating correctly. If the switch that is
1. Connect the Caterpillar Electronic Technician (Cat connected to this signal input is not switching on
ET) to the data link connector. and switching off, refer to Troubleshooting, “PTO
Switch Circuit - Test”.
2. Check the “Engine Monitoring Mode” parameter.
3. Verify that the “Engine Monitoring Mode”

Electronic System
parameter is programmed to the desired option:
1. Monitor the Fuel Position, the Rated Fuel Limit and
the Fuel Limit for the Fuel Ratio Control (FRC).
• “Warning”
While the vehicle is operating under full load, the
• “Derate” parameters should meet the following conditions:
• “Shutdown”
4. Check the following parameters:
• The fuel position is less than the FRC limit.
• “Rating Number” If the fuel position is equal to the rated fuel limit
and the fuel position is less than the FRC limit,
• “Top Engine Limit” the electronics are operating correctly. Proceed to
“Vehicle Speed Signal”.
• “Lower Gears Engine RPM Limit” limit and/or the fuel position is not less than the
FRC limit, perform the following tests in order:
• “Intermediate Gears Engine RPM Limit”
3. When the engine is off, turn the ignition key switch
• “Gear Down Protection Engine RPM Limit” to the ON position. Check the boost pressure on
5. Set each parameter to the parameter’s maximum the status screen.
value one at a time and determine whether the
When the engine is off, the correct boost pressure
problem is corrected.
is 0 kPa (0 psi).
Cold Mode
Accelerator Pedal Position
Note: This is normal operation if the problem occurs
1. Monitor the status of the accelerator pedal position
sensor. Operate the engine at high idle with the
1. Monitor the status screen on Cat ET in order to vehicle in neutral.
verify that the engine has progressed from cold
If the engine cannot reach the programmed top
mode.
engine limit, check the duty cycle of the accelerator
pedal position sensor in order to ensure that the
An active cold mode is indicated in the upper
duty cycle of the accelerator pedal position sensor
corner of any status screen.
is within calibration (75 to 90 percent at high idle).
Torque Limit Switch If the accelerator pedal position is unstable,
check the duty cycle of the accelerator pedal
1. Check the setting for the “Torque Limit” parameter. position sensor. Check the duty cycle of the
accelerator pedal position sensor by slowly
operating the accelerator pedal in order to verify
that the accelerator pedal position sensor is within
calibration. The accelerator pedal position sensor
is within calibration when both of the following
conditions are met:
RENR1367-11 87
• 10 to 22 percent at low idle 8. Check for air in the fuel system. Refer to Testing
and Adjusting, “Air in Fuel - Test”.
• 75 to 90 percent at high idle
Air Inlet and Exhaust System
Also, ensure that the duty cycle changes as the
pedal position changes. 1. Check for leakage in the air-to-air aftercooler core
. Refer to Testing and Adjusting, “Aftercooler -
If a problem with the accelerator pedal position Test”.
sensor is suspected, refer to Troubleshooting,
“Accelerator Pedal (Throttle) Position Sensor 2. Check the air inlet system for restrictions or for
Circuit - Test”. leakage. Check the exhaust system for restrictions
or for leakage. Refer to Testing and Adjusting, “Air
Vehicle Speed Signal Inlet and Exhaust System - Inspect”.
Monitor the vehicle speed signal. Ensure the Individual Cylinder Problem
the vehicle speed signal to the actual vehicle speed. 1. Ensure that the J300/P300 electronic unit injector
connector is fully connected and ensure that
If the vehicle speed is greater than the “VSL”, the the electronic unit injector connector is free of
power is limited. If a problem is discovered, refer to corrosion.
Troubleshooting, “Vehicle Speed Circuit - Test”.
2. Ensure that the J2/P2 ECM connector is fully
Power Train Data Link connected and ensure that the ECM connector is
free of corrosion.
1. Check the power train data link. Ensure that the
power train data link is not limiting the power. 3. Perform the “Cylinder Cutout Test”. Access the
“Cylinder Cutout Test” by selecting the “Diagnostic
2. Monitor the “Powertrain Data Link” status screen Menu” and the “Diagnostics Test Menu”. Run
while the vehicle is experiencing problems. the “Cylinder Cutout Test” in order to disable
each cylinder. Disabling each cylinder allows the
If the “Powertrain Data Link” status screen technician to isolate the misfiring cylinders.
the rpm, verify that this is not normal operation. If If the misfiring cylinder can be isolated to a
this is not normal operation, refer to the vehicle specific cylinder, refer to Troubleshooting, “Injector
OEM for repairs. Solenoid Circuit - Test”.
Fuel Supply 4. Perform a Performance Analysis Report (PAR).
1. Monitor the exhaust for smoke while the engine Low Injection Actuation Pressure
is being cranked.
If no smoke is present, there may be a problem activate the high pressure hydraulic pump.
with the fuel supply. 2. Ensure that the engine oil meets the
2. Check the fuel quality. Refer to the Truck Refer to the Operation and Maintenance Manual
Performance and Driveability Diagnostic Guide, for further details.
LEBT3477.
3. Refer to Troubleshooting, “Injection Actuation
3. Check the fuel pressure. Refer to Testing and Pressure -Test”.
Adjusting, “Fuel System Pressure - Test”.
i01642129
4. Ensure that the fuel system has been primed.
Prime”.
Poor Acceleration or Response
SMCS Code: 1000-035
6. Check the fuel filters. Probable Causes

7. If the temperature is below 0 °C (32 °F), check The probable root causes are listed in order below:
88 RENR1367-11
• Customer Specified Parameters 2. While the problem is occurring, check for

diagnostic codes that are related to the boost
• Electronic system pressure sensor and the atmospheric pressure
sensor. If a diagnostic code is found, refer to
• Cold Mode operation Troubleshooting, “Engine Pressure Sensor Open
or Short Circuit - Test”.
• Malfunction of an individual cylinder
3. Monitor the fuel position, the rated fuel limit and
• Power Train Data Link the fuel limit for fuel ratio control (FRC).
• ECM or Personality Module While the vehicle is operating under full load, the
parameters should meet the following conditions:
• Theft Deterrent
• The fuel position is less than the FRC limit.
• Injection actuation pressure
If the fuel position is equal to the rated fuel limit
• Combustion problem and the fuel position is less than the FRC limit, the
electronics are operating correctly.
Recommended Actions 4. If the fuel position is not equal to the rated fuel
Perform the following diagnostic procedures in order: limit and/or the fuel position is not less than the
FRC limit, perform the following tests in order:
Customer Specified Parameters 5. When the engine is OFF, turn the ignition key
switch to the ON position. Check the boost
1. Check Customer Specified Parameters. pressure on the ET status screen. When the
engine is OFF, the boost pressure should be
2. Verify that the complaint is not normal operation 0 kPa (0 psi).
(programmed parameter).
3. Connect Caterpillar Electronic Technician (ET) to

Cold Mode Operation
the cab data link connector.
Note: This is normal operation if the problem occurs
4. Check the following parameters:
• “Rating Number”
2. Use ET to verify that the engine has progressed
• “Top Engine Limit” from cold mode. An active cold mode is indicated
in the upper corner of any status screen.
• “Lower Gears Engine RPM Limit” Individual Cylinder Malfunction
• “Intermediate Gears Engine RPM Limit” 1. Ensure that the electronic unit injector connector
(J300/P300) is fully connected and ensure that the
• “Gear Down Protection Engine RPM Limit” electronic unit injector connector (J300/P300) is
free of corrosion.
5. Set each parameter to the parameter’s maximum
value one at a time and determine whether the 2. Ensure that the ECM engine harness connector
problem is corrected. (J2/P2) is fully connected and ensure that the
engine harness connector (J2/P2) is free of
corrosion.
Electronic System
RENR1367-11 89
3. Connect ET to the cab data link connector. Use Injection Actuation Pressure
the Cylinder Cutout Test. Access the Cylinder
Cutout Test by selecting the “Diagnostic Menu”
System
and the “Diagnostics Test Menu”. Run the Cylinder
Note: Check the actual injection actuation pressure
Cutout Test in order to disable each cylinder.
against the desired injection actuation pressure.
Disabling each cylinder allows the technician to
isolate the misfiring cylinders.
1. Crank the engine and monitor the Injection
actuation pressure and the injection actuation
If the misfiring cylinder can be isolated to a
pressure control valve. The high pressure oil
specific cylinder, refer to Troubleshooting, “Injector
system is operating properly if the pressure output
is a minimum of 6 MPa (870 psi).
4. Perform a Performance Analysis Report (PAR).
2. Connect ET and check for event code 164-11
injection actuation pressure system fault. If an
Power Train Data Link 164-11 event code has been logged recently, refer
to Troubleshooting, “Injection Actuation Pressure
1. Check the “Powertrain Data Link”. Ensure that the System - Test”.
SAE J1939 data link is not limiting the power.
3. If higher than actual pressure is being indicated,
2. Connect ET to the cab data link connector. then disconnect the injection actuation pressure
sensor and try to start the engine. If the engine
3. Monitor the “Powertrain Data Link” status screen starts, refer to Troubleshooting, “Injection
while the vehicle is experiencing problems. Actuation Pressure Sensor - Test”.
If the “Powertrain Data Link” status screen

Combustion Problem
the rpm, verify that this is not normal operation. If
Check for combustion problems.
this is not normal operation, refer to the vehicle
OEM for repairs.
Examples of combustion problems are shown in the
following list:
ECM or Personality Module
• Outside temperatures are too cold.
Check the ECM or the Personality Module.
• Mechanical problem
Refer to Troubleshooting, “ECM Memory - Test”.
Torque Limit Switch

2. Check the setting for the Customer Parameter

for the “Torque Limit”. If the “Torque Limit” is
programmed below 2712 N·m (2000 lb ft), check
the status screen for the torque limit switch.
Ensure that the status screen indicates that
the torque limit switch is off. If the status of the
torque limit switch is on and a “Torque Limit” is
programmed, the system is operating correctly. If
the switch that is connected to this signal input
is not switching on and switching off, refer to
Troubleshooting, “PTO Switch Circuit - Test”.
Theft Deterrent
Ensure that the theft deterrent (if equipped) is not
active. Turn the ignition switch to the ON position.
Observe the display screen on the CAT ID. If the
display screen on the CAT ID indicates that the theft
deterrent is enabled, the Theft Deterrent Passwords
must be entered before the engine will start.
90 RENR1367-11
Troubleshooting with a
Diagnostic Code
i02301805
Diagnostic Codes
SMCS Code: 1900
Table 145
Flash
Code SPN-FMI code Description of Code
Code
96-03 96-03 Fuel Level Voltage High
96-04 96-04 Fuel Level Voltage Low
224-11 Theft Deterent Active
00 224-14 Theft Deterent Active with Engine Cranking
231-12 J1939 Device Not Responding
246-11 Brake Pedal Switch #1 Fault
247-11 Brake Pedal Switch #2 Fault
01 71-00 Idle Shutdown Override
111-02 Coolant Level signal invalid
12 111-03 Coolant Level voltage high
111-04 111-04 Coolant Level voltage low
164-02 164-02 Injection Actuation Pressure Signal Erratic
15 164-03 164-03 Injection Actuation Pressure Voltage High
164-04 164-04 InjectionActuation Pressure Voltage Low
17 164-00 164-00 Excessive Injection Actuation Pressure
18 42-11 Injection Actuation Pressure output fault
41-03 678-03 8 Volt Supply voltage high
41-04 678-04 8 Volt Supply voltage low
21
232-03 620-03 5 Volt Supply voltage high
232-04 620-04 5 Volt Supply voltage low
100-03 100-03 Oil Pressure voltage high
24
100-04 100-04 Oil Pressure voltage low
102-02 102-02 Boost Pressure signal erratic
102-03 102-03 Boost Pressure voltage high
25
102-04 102-04 Boost Pressure voltage low
102-07 102-07 Boost Pressure not responding
108-03 108-03 Barometric Pressure voltage high
26
108-04 108-04 Barometric Pressure voltage low
110-03 110-03 Coolant Temperature voltage high
27
110-04 110-04 Coolant Temperature voltage low
(continued)
RENR1367-11 91
(Table 145, contd)

Flash
Code
28 91-13 Throttle Position out of Calibration
30-08 PTO Throttle signal invalid
29
30-13 PTO Throttle out of calibration
31 84-01 Vehicle Speed loss of signal
32 91-08 Throttle Position Invalid
64-02 Secondary Engine Speed loss of signal
64-11 Secondary Engine Speed no pattern
34
190-02 Primary Engine Speed loss of signal
190-11 Primary Engine Speed no pattern
35 190-00 190-15 Engine Overspeed Warning
84-02 Vehicle Speed signal invalid
36 84-08 Vehicle Speed signal out of range
84-10 Vehicle Speed signal rate of change
105-03 105-03 Intake Manifold Air Temperature voltage high
38
105-04 105-04 Intake Manifold Air Temperature voltage low
39 164-11 164-11 Injection Actuation Pressure system fault
41 84-00 Vehicle Overspeed Warning
22-11 637-11 Primary to Secondary Engine Speed Signal Calibration
42
22-13 637-13 Engine Speed Signal Calibration Not Performed
128-03 Secondary Fuel Level voltage high
44
128-04 Secondary Fuel level voltage low
46 100-11 100-18 Very Low Oil Pressure
71-01 Idle Shutdown
47 71-14 PTO Shutdown
186-14 PTO Engine Shutdown Switch Occurrence
70-05 729-05 Inlet Air Heater current low
49
70-06 729-06 Inlet Air Heater current high
168-00 168-00 Excessive ECM Battery Power
51 168-01 168-01 Low ECM Battery Power
168-02 168-02 ECM Battery Power Intermittent
253-02 630-02 Check Customer or System Parameters
56
253-14 Truck Manufacturer Paremater Not Programmed
231-02 639-02 J1939 Data Incorrect
58
231-11 639-12 J1939 Data Link Fault
59 252-11 631-11 Engine Software Incorrect
110-00 110-15 High Coolant Temperature Warning
61
110-11 110-16 Very High Coolant Temperature
(continued)
92 RENR1367-11
(Table 145, contd)

Flash
Code
111-01 111-17 Low Coolant Level Warning
62
111-11 111-18 Very Low Coolant Level
105-00 1636-15 High Intake Manifold Air Temperature Warning
64
105-11 1636-16 Very High Intake Manifold Air Temperature
71 43-02 Key Switch Fault
1-11 651-11 Cylinder #1 Injector current fault
72
73
74
i02127641 Troubleshooting:
0001-11 Cylinder #1 Injector Perform the following diagnostic procedure: “Injector
current fault (72) Solenoid Circuit - Test”
SMCS Code: 1290-038 Results:
Conditions Which Generate This Code: • OK – STOP.

The Engine Control Module (ECM) detects one of i02127647
the following items after attempting to operate the
injector: 0002-11 Cylinder #2 Injector
• A low current condition (open circuit) exists in the current fault (72)
wiring for the cylinder injector solenoid.
SMCS Code: 1290-038
• A high current condition (short circuit) exists in the
injector solenoid. Conditions Which Generate This Code:
System Response: The Engine Control Module (ECM) detects one of

The ECM will log the diagnostic code and the ECM injector:
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The • A low current condition (open circuit) exists in the
automatic “Cylinder Cutout Test” will not work when wiring for the cylinder injector solenoid.
there is an active diagnostic code.
Possible Performance Effect: injector solenoid.
The injector may not operate while the diagnostic System Response:
codes are active. The following conditions may exist:
The ECM will log the diagnostic code and the ECM
• Engine misfires will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. The
automatic “Cylinder Cutout Test” will not work when
• Low power
RENR1367-11 93
Possible Performance Effect: i02127657
The injector may not operate while the diagnostic 0004-11 Cylinder #4 Injector
codes are active. The following conditions may exist: current fault (73)
• Engine misfires SMCS Code: 1290-038
• Low power Conditions Which Generate This Code:

Troubleshooting: The Engine Control Module (ECM) detects one of
Perform the following diagnostic procedure: “Injector injector:
Solenoid Circuit - Test”
• A low current condition (open circuit) exists in the
Results: wiring for the cylinder injector solenoid.
• OK – STOP. • A high current condition (short circuit) exists in the

injector solenoid.
i02127654
System Response:
0003-11 Cylinder #3 Injector
current fault (73) will trigger a snapshot. The check engine lamp will
SMCS Code: 1290-038 automatic “Cylinder Cutout Test” will not work when
Conditions Which Generate This Code:
Possible Performance Effect:
The Engine Control Module (ECM) detects one of
the following items after attempting to operate the The injector may not operate while the diagnostic
injector: codes are active. The following conditions may exist:
• A low current condition (open circuit) exists in the • Engine misfires
• Low power
injector solenoid. Troubleshooting:
System Response: Perform the following diagnostic procedure: “Injector
will trigger a snapshot. The check engine lamp will Results:
• OK – STOP.
The injector may not operate while the diagnostic 0005-11 Cylinder #5 Injector
codes are active. The following conditions may exist: current fault (74)
• Engine misfires SMCS Code: 1290-038
• Low power Conditions Which Generate This Code:

Troubleshooting: The Engine Control Module (ECM) detects one of
Perform the following diagnostic procedure: “Injector injector:
Results: wiring for the cylinder injector solenoid.
• OK – STOP.
94 RENR1367-11
• A high current condition (short circuit) exists in the • Engine misfires

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

The injector may not operate while the diagnostic
i02127664
0022-11 Primary to Secondary
• Engine misfires
Engine Speed Signal
• Low power Calibration (42)
Troubleshooting:
SMCS Code: 1912-038
Perform the following diagnostic procedure: “Injector Conditions Which Generate This Code:
The Engine Control Module (ECM) detects the
Results: following conditions:
• OK – STOP. • The primary speed/timing sensor and the
secondary speed/timing sensor are off by more
i02127662 than three degrees.
0006-11 Cylinder #6 Injector • A timing calibration has been successfully

current fault (74) completed.
SMCS Code: 1290-038 • The battery voltage is above 9 V.
Conditions Which Generate This Code: System Response:
Default timing is used. This code is active only. This

the following items after attempting to operate the code will not be logged. The check engine lamp will
be illuminated when this code is active.
injector:
The engine may run rough when this code is active.
• A high current condition (short circuit) exists in the Troubleshooting:
injector solenoid.
System Response: Engine Speed/Timing Sensors

A. Check the engine speed/timing sensors for proper
will trigger a snapshot. The check engine lamp will installation. The engine speed/timing sensors can
not be interchanged.
The injector may not operate while the diagnostic

RENR1367-11 95
B. Verify that the sensor wires are connected Possible Performance Effect:
properly. Refer to the electrical schematic for
proper wiring. Make sure that the positive terminal The engine may run rough or the engine may emit
on the ECM is connected to the positive terminal white smoke in the exhaust.
on the engine speed/timing sensors. Also, make
sure that the negative terminal on the ECM is Troubleshooting:
connected to the negative terminal on the engine
speed/timing sensors. Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor - Calibrate”
Expected Result:
Results:
The engine speed/timing sensors are properly
installed. Also, the engine speed/timing sensors are • OK – STOP.
wired correctly.
i02127764
Results:
0030-08 PTO Throttle signal
• OK – The engine speed/timing sensors are
properly installed. Also, the engine speed/timing invalid (29)
sensors are wired correctly.
SMCS Code: 1913-038
Repair: Refer to Troubleshooting, “Engine
Speed/Timing Sensor Circuit - Test”. Conditions Which Generate This Code:
STOP. The Engine Control Module (ECM) detects the

following conditions:
• Not OK – There is a problem with the installation
or the wiring of the engine speed/timing sensors. • The “PTO Configuration” is programmed to
“Remote Throttle”.
Repair: Install the sensors properly or repair the
wiring. • The ECM is not receiving a valid signal from the
PTO throttle.
Run the engine until the engine reaches operating
temperature. • The ECM has been powered for at least three
seconds.
Verify that the repair eliminates the problem.
Note: If the “PTO Configuration” is programmed to
STOP. “Remote Throttle”, the ECM must receive a proper
signal from the remote throttle at all times. The
remote throttle signal must be present even when the
i02127666 PTO ON/OFF switch is in the OFF position.
0022-13 Engine Speed Signal System Response:
Calibration Not Performed (42)
The ECM returns the engine to low idle when the
SMCS Code: 1912-038 problem is detected. “DIAG” will be displayed next
to the status for “Throttle Position” on Caterpillar
Conditions Which Generate This Code: Electronic Technician (ET).
The Engine Control Module (ECM) detects the Possible Performance Effect:
The engine will remain at low idle while the diagnostic
• A timing calibration has never been performed on code is active.
a new ECM or the timing is off by more than three
degrees. Troubleshooting:
System Response: Perform the following diagnostic procedure: “Remote

PTO Accelerator Position Sensor Circuit - Test”
This code will not be logged. The check engine lamp
will illuminate while this diagnostic code is active. The Results:
ECM uses default timing.
• OK – STOP.
96 RENR1367-11
i02127769 • The ECM has been powered for more than three
seconds.
0030-13 PTO Throttle out of
calibration (29) System Response:
SMCS Code: 1913-038 The ECM will log the diagnostic code and the ECM
Conditions Which Generate This Code: illuminate while this diagnostic code is active. An
active diagnostic code may not cause any noticeable
The Engine Control Module (ECM) detects the effect on engine response unless the voltage is
following conditions: above 12 or 13 VDC.
• The duty cycle of the signal for the PTO throttle is Possible Performance Effect:
less than 5 percent or more than 95 percent for
more than two seconds. The engine may be limited to low idle.
• The PTO Configuration is programmed to “Remote Note: The 8 volt supply provides power to the
Throttle”. accelerator pedal position sensor.
• The ECM has been powered for at least three Troubleshooting:

seconds.
Perform the following diagnostic procedure:
System Response: “Accelerator Pedal (Throttle) Position Sensor Circuit -
Test”
problem is detected. “DIAG” will be displayed next Results:
to the status for “Throttle Position” on Caterpillar
Electronic Technician (ET). • OK – STOP.
The engine will remain at low idle while the diagnostic 0041-04 8 Volt Supply voltage
code is active.
low (21)
Troubleshooting:
SMCS Code: 5574-038
Note: The remote accelerator pedal position sensor
can not be calibrated. Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Remote The Engine Control Module (ECM) detects the
PTO Accelerator Position Sensor Circuit - Test” following conditions:
Results: • The 8 volt supply is less than 7.5 VDC for more
than one second.
• OK – STOP.
• The ECM has been powered for more than three
seconds.
i01942209
System Response:
0041-03 8 Volt Supply voltage
high (21) The ECM will log the diagnostic code and the ECM
SMCS Code: 5574-038 illuminate while this diagnostic code is active. An
active diagnostic code may not cause any noticeable
Conditions Which Generate This Code: effect on engine response unless the voltage drops
below 6.5 VDC.
following conditions: Possible Performance Effect:
• The 8 volt supply is more than 8.5 VDC for more The engine may be limited to low idle.
than one second.
RENR1367-11 97
Note: The 8 volt supply provides power to the i02127803

accelerator pedal position sensor.
0043-02 Key Switch Fault (71)
Troubleshooting:
SMCS Code: 1408-038; 1553-038
“Accelerator Pedal (Throttle) Position Sensor Circuit - Conditions Which Generate This Code:
Test”
Results: following condition:
• OK – STOP. • The key switch was rapidly cycled at least three

times within the last second.
i02065224 This indicates that the battery circuit to the key

switch has an intermittent condition or a low battery
0042-11 Injection Actuation condition while the engine is running.
Pressure output fault
Note: This code can be generated by rapidly cycling
SMCS Code: 1408-081; 5051-038 the key switch. Some control modules on the vehicle
require this action in order to prompt flash codes. If
Conditions Which Generate This Code: this occurs, clear the logged diagnostic codes in order
to prevent future confusion or an incorrect diagnosis.
The ECM detected one of the following conditions:
Note: This code can also be generated when
• Open circuit an attempt is made in order to restart the engine
immediately after a shutdown. The engine may not
• Short to ground start if the engine speed did not reach zero rpm prior
to the restart.
• Short to + battery
System Response:
• Short across the solenoid when the engine is
running. The ECM will log the diagnostic code and the ECM
System Response: illuminate while this diagnostic code is active. The
ECM will stop energizing the injector solenoids.
Electronic System Response The ECM will cycle
the control valve for the injection actuation system on Possible Performance Effect:
and off. The ECM will cycle the control valve several
times in a second when the engine is running. The Engine shutdown
fault is active.
Troubleshooting:
Engine Response The engine will stop running if
the signal line for the control valve for the injection Perform the following diagnostic procedure: “Ignition
actuation system is shorted to ground. Key Switch Circuit and Battery Supply Circuit - Test”
If the pressure sensor common for the control valve is Results:

shorted to ground, the following conditions may exist:
• OK – STOP.
• The engine may continue to run.
i02127806
• The idle may be unstable.
0064-02 Secondary Engine
Troubleshooting:
Speed loss of signal (34)
Perform the following diagnostic procedure: “Injection
Actuation Pressure Control Valve Circuit - Test” SMCS Code: 1912-038
Results: Conditions Which Generate This Code:
• OK – STOP. The Engine Control Module (ECM) detects the

98 RENR1367-11
• The secondary engine speed/timing signal was lost System Response:

and then returned within one second.
The ECM uses the primary engine speed/timing
• The engine has been running for more than three sensor to calculate the engine speed. The ECM will
seconds. illuminate the check engine lamp after this code has
been active for ten hours. The code is logged.
• The engine speed did not pass through the 350
to 500 rpm range. Possible Performance Effect:
• The battery voltage is more than 9 VDC for at least The performance will not be affected unless both
two seconds prior to the loss of signal. speed signals are lost. The loss of both timing sensor
signals will cause the ECM to shut down the engine.
System Response:
Troubleshooting:
The ECM will use the primary speed/timing sensor to
calculate the engine speed. “DIAG” will be displayed Perform the following diagnostic procedure: “Engine
next to the status for “Engine Speed” on Caterpillar Speed/Timing Sensor Circuit - Test”
Electronic Technician (ET). The check engine lamp
will not be illuminated for this code unless the code Results:
has been active for ten hours. The code is logged.
• OK – STOP.
i02127817
The performance will not be affected unless both
sensor signals are lost. The loss of both timing sensor
signals will cause the ECM to shut down the engine.
0070-05 Inlet Air Heater current
low
Troubleshooting:
SMCS Code: 1090-038
Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor Circuit - Test” Conditions Which Generate This Code:
Results: The Engine Control Module (ECM) has detected a

low current condition (open circuit) after attempting
• OK – STOP. to activate the air inlet heater. The ECM detects the
i02127812
• The engine is not cranking.
0064-11 Secondary Engine • The ECM has been powered for more than one
Speed no pattern (34) second.
SMCS Code: 1912-038 • There is a low current condition (open circuit) for
more than eight seconds.
• Battery voltage is more than 9 V for more than two
The Engine Control Module (ECM) detects the seconds prior to the low current condition (open
following conditions: circuit).
• The secondary engine speed/timing signal was System Response:

lost and then returned within one second while the
primary engine speed/timing signal remained valid. The ECM will log the code. There is a delay of
two hours before the check engine lamp will be
• The secondary engine speed/timing signal is lost illuminated. The ECM is unable to activate the air
and/or intermittent. inlet heater.
• The secondary engine speed/timing signal is lost Possible Performance Effect:

for more than 15 seconds while the engine is
cranking. The engine may be difficult to start in the cold
temperature and the exhaust may emit white smoke.
RENR1367-11 99
Troubleshooting: i02127822
Perform the following diagnostic procedure: “Air Inlet 0071-00 Idle Shutdown
Heater Circuit - Test” Override (01)
Results: SMCS Code: 1901-038
• OK – STOP. Conditions Which Generate This Code:
i02127820
the following conditions:
0070-06 Inlet Air Heater current
high • The “Allow Idle Shutdown Override” parameter is
programmed to “Yes” and the status of the brake
switch or the clutch switch changes.
SMCS Code: 1090-038

• The “Allow Idle Shutdown Override” parameter
is programmed to “J1587 Outside Temp Based”
or “Outside Temperature Based”. The outside
The Engine Control Module (ECM) has detected a temperature is above the maximum programmed
high current condition (short circuit) after attempting temperature or the outside temperature is below
to activate the air inlet heater. The ECM detects the the minimum programmed temperature.
The ECM also detects the following conditions:
• The engine is not cranking.
• The idle shutdown timer is within the final 90
• The ECM has been powered for at least one seconds.
second.
• The “Idle Shutdown Time” parameter is
• There is a high current condition (open circuit) for programmed to at least three minutes.
more than two seconds.
System Response:
• Battery voltage is more than 9 V for more than two
seconds prior to the high current condition (open The idle shutdown timer stops counting. “OVERRIDE”
circuit). will be displayed next to the status for “Idle Shutdown
Status” on Caterpillar Electronic Technician (ET).
System Response:
Note: The idle shutdown timer will not begin counting
The ECM will log the code. There is a delay of again for shutdown until the vehicle is moved and the
two hours before the check engine lamp will be accelerator pedal is depressed.
illuminated. The ECM is unable to activate the air
inlet heater. Customer passwords are required to clear this
diagnostic code.
The engine may be difficult to start in the cold
temperature and the exhaust may emit white smoke. None
Troubleshooting: Troubleshooting:
Perform the following diagnostic procedure: “Air Inlet Perform the following diagnostic procedure: “Idle
Heater Circuit - Test” Shutdown Timer - Test”
Results: Results:
• OK – STOP. • OK – STOP.
100 RENR1367-11
i02215914 • The “PTO Configuration” parameter is programmed

to “Cab Switches”, “Remote Switches”, or “Remote
0071-01 Idle Shutdown (47) Throttle”.
SMCS Code: 1901-038 • The “PTO Shutdown Time” parameter is
programmed to at least three minutes.
System Response:
following conditions: The ECM remains powered after the engine
shutdown. “NOT ACTIVE” will be displayed next
• The idle shutdown timer has expired and the to the status for “PTO Shutdown” on Caterpillar
engine has shut down. Electronic Technician (ET).
• The “Idle Shutdown Time” parameter is Customer passwords are required to clear this
programmed to at least three minutes. diagnostic code.
• Vehicle speed is zero mph. Possible Performance Effect:
• Coolant temperature is greater than 38 °C (100 °F). The engine is shut down.
System Response: Troubleshooting:
The ECM remains powered after the engine Perform the following diagnostic procedure: “PTO
shutdown. “COUNTING” will be displayed next to Shutdown Timer - Test”
the status for “Idle Shutdown Status” on Caterpillar
Electronic Technician (ET). Results:
Customer passwords are required to clear this • OK – STOP.
diagnostic code.
The engine is shut down. 0084-00 Vehicle Overspeed

Warning (41)
Troubleshooting:
SMCS Code: 7463-038
Perform the following diagnostic procedure: “Idle
Shutdown Timer - Test” Conditions Which Generate This Code:
Results: The Engine Control Module (ECM) detects the

following condition:
• OK – STOP.
• Vehicle speed exceeds the programmable “Vehicle
Overspeed Threshold” for one second.
i02127845
0071-14 PTO Shutdown (47) System Response:
SMCS Code: 1901-038 The ECM will not energize the injector solenoids
while the diagnostic code is active. “Vehicle Speed
Conditions Which Generate This Code: Limit” will be displayed on the status screen.
The Engine Control Module (ECM) detects the Customer passwords are required to clear this code.
• The timer for the PTO has expired and the engine
has shut down. Injection is disabled until the vehicle speed falls
below the programmed “Vehicle Overspeed”.
• The PTO on/off switch is in the ON position.
RENR1367-11 101
This diagnostic code does not necessarily indicate Check the fuel pressure in order to ensure that a fuel
that there is an electronic problem. If the vehicle system restriction is not the cause of the problem
speed calibration is wrong, perform the following when the vehicle is not moving.
procedure:
Perform the following diagnostic procedure: “Vehicle
Perform the following diagnostic procedure: “Vehicle Speed and Speedometer Circuit - Test”
Speed Circuit - Calibrate”
Results:
Results:
• OK – STOP.
• OK – STOP.
i02127961
i02127947
0084-02 Vehicle Speed signal
0084-01 Vehicle Speed loss of invalid (36)
signal (31)
SMCS Code: 7463-038
SMCS Code: 7463-038
The Engine Control Module (ECM) detects the following conditions:
following condition:
• The “VSL Protection” is not programmed to the
• The “VSL Protection” is not programmed to “TEL”. programmed “TEL”.
• The ECM does not detect vehicle speed when • The vehicle speed is constant when the engine
conditions indicate that vehicle speed should be parameters indicate that the vehicle speed should
present. be changing.
• Desired engine speed is greater than the • Engine speed is greater than 950 rpm for more
programmed “VSL Protection”. than 60 ms.
System Response: Note: This code typically occurs when someone has
tampered with the vehicle speed signal.
The ECM will limit engine rpm to the programmed
“VSL Protection”. If the ECM is providing the System Response:
speedometer signal, the speedometer will reflect the
loss of speed when the vehicle is moving and the Engine rpm is limited to the programmed “VSL
problem occurs. Caterpillar Electronic Technician Protection” for one hour. If the ECM is providing the
(ET) will display “DIAG” next to “Vehicle Speed” on speedometer signal, the speedometer will reflect
the status screen while the diagnostic code is active. the loss of speed when the problem occurs and the
The check engine lamp will illuminate. vehicle is moving.
Possible Performance Effect: Caterpillar Electronic Technician (ET) will display

“DIAG” next to “Vehicle Speed” on the status screen
The driver may think that the engine power is low and while the diagnostic code is active.
that the engine is unable to reach the expected rpm.
Note: A fuel system restriction has been known to
cause this diagnostic code although this occurrence The driver may think that the engine power is low
is not common. This situation exists because the and that the engine is unable to reach the expected
injectors are unable to provide sufficient fuel in rpm. The derate will remain for one hour after the
order to achieve the desired rpm under normal load fault is no longer active.
conditions. Because the ECM cannot reach the
desired rpm under the normal load conditions, the Troubleshooting:
ECM suspects that the vehicle is under load. This
should only occur when the vehicle is in motion. Perform the following diagnostic procedure: “Vehicle
Speed and Speedometer Circuit - Test”
102 RENR1367-11
Results: i02127980
• OK – STOP. 0084-10 Vehicle Speed signal

rate of change (36)
i02127969
SMCS Code: 7463-038
0084-08 Vehicle Speed signal
out of range (36)
SMCS Code: 7463-038 following condition:
Conditions Which Generate This Code: Note: If “ABS” is used as the source for vehicle
speed, “ABS” must be inactive in order for this code
The Engine Control Module (ECM) detects the to be active.
• A vehicle speed that is changing at an impossible
• The “VSL Protection” parameter is not programmed rate
to “TEL”.
• The engine has been running for more than three
• The vehicle speed is greater than 204 km/h (127 seconds.
mph) for at least two seconds.
Note: This code will not be logged unless the engine

• The “VSL Protection” is not programmed to “TEL”.
has been running for more than three seconds. System Response:
System Response: Engine rpm is limited to the programmed “VSL
Protection”. Caterpillar Electronic technician (ET)
Vehicle speed is set to 0 km/h (0 mph) and engine will display “DIAG” next to “Vehicle Speed” on the
rpm is limited to the programmed “VSL Protection”. status screen while the diagnostic code is active. The
If the ECM is providing the speedometer signal, the Check Engine Lamp will illuminate.
speedometer will reflect the loss of speed when the
problem occurs and the vehicle is moving. Caterpillar Possible Performance Effect:
Electronic Technician (ET) will display “DIAG” next
to “Vehicle Speed” on the status screen while the The driver may think that the engine power is low and
diagnostic code is active. The check engine lamp that the engine is unable to reach the expected rpm.
will illuminate.
Troubleshooting:
The driver may think that the engine power is low and Speed and Speedometer Circuit - Test”
that the engine is unable to reach the expected rpm.
Results:
Troubleshooting:

• OK – STOP.
Speed and Speedometer Circuit - Test”
i02303725
Results:
0091-08 Throttle Position
• OK – STOP. Invalid (32)
SMCS Code: 1913-038

RENR1367-11 103
• The signal frequency from the accelerator pedal Troubleshooting:

position sensor is less than 150 Hz or the signal
frequency is greater than 1050 Hz for more than Perform the following diagnostic procedure:
two seconds. “Accelerator Pedal (Throttle) Position Sensor Circuit -
Test”
• The ECM has been powered for at least three
seconds. Results:
System Response: • OK – STOP.

The ECM sets the “Throttle Position” to
i02128020
“0%”. “DIAG” will be displayed next
to the status for “Throttle Position” on
Caterpillar Electronic technician (ET).
0096-03 Fuel Level voltage
high
SMCS Code: 5574-038
The engine will remain at low idle while the diagnostic
code is active. Conditions Which Generate This Code:
Troubleshooting: This diagnostic code is used only by GMT-560

applications.
“Accelerator Pedal (Throttle) Position Sensor Circuit - The Engine Control Module (ECM) detects the
Test” following condition:
Results: • The primary fuel level signal voltage is above the

acceptable range for more than ten seconds.
• OK – STOP.
System Response:
i02128015 If the parameter “Secondary Fuel Tank Size” is
0091-13 Throttle Position out programmed and a diagnostic code for the secondary
fuel level sensor is not active, the ECM will use the
of calibration (28) secondary fuel level sensor to determine the fuel
level.
SMCS Code: 1913-038
If the parameter “Secondary Fuel Tank Size” is not
Conditions Which Generate This Code: programmed and a diagnostic code is active for the
secondary fuel level sensor, the ECM will broadcast
The Electronic Control Module (ECM) detects the an error code over the J1939 data link. The ECM will
following condition: also broadcast the fuel level as zero over the ATA
data link.
• The duty cycle for the signal to the accelerator
pedal position sensor is less than 5 percent or Caterpillar Electronic Technician (ET) will display
more than 95 percent. “DIAG” next to “Primary Fuel Level” on the status
screen while the diagnostic code is active.
System Response:
problem is detected. The Caterpillar Electronic None
Technician (ET) will display “0%” and “DIAG” next
to “Throttle Position” on the status screen while the Troubleshooting:
diagnostic code is active.
Perform the following diagnostic procedure: “Fuel
Possible Performance Effect: Level Sensor Circuit - Test”
The engine will remain at low idle while the diagnostic Results:
code is active.
• OK – STOP.
104 RENR1367-11
i02128054 System Response:

0096-04 Fuel Level voltage low Electronic System Response Oil pressure is set
to 600 kPa (87 psi).
SMCS Code: 5574-038
Service Tool Display or Lamps Caterpillar
Conditions Which Generate This Code: Electronic Technician (ET) will indicate 600 kPa
(87 psi) and display “DIAG” next to “Engine Oil
This diagnostic code is used only by GMT-560 Pressure ” on the status screen while the diagnostic
applications. code is active. The Check Engine Lamp will
illuminate.
following condition: Engine Response The engine may experience low
power when the diagnostic code is active.
• The primary fuel level signal voltage is below the
acceptable range for more than ten seconds. Troubleshooting:
System Response: Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
If the parameter “Secondary Fuel Tank Size” is
programmed and a diagnostic code for the secondary Results:
secondary fuel level sensor to determine the fuel • OK – STOP.
level.
If the parameter “Secondary Fuel Tank Size” is not i02065238

programmed and a diagnostic code is active for the
secondary fuel level sensor, the ECM will broadcast 0100-04 Oil Pressure voltage
an error code over the J1939 data link. The ECM will low (24)
also broadcast the fuel level as zero over the ATA
data link. SMCS Code: 1924-038
Caterpillar Electronic Technician (ET) will display Conditions Which Generate This Code:
“DIAG” next to “Primary Fuel Level” on the status
screen while the diagnostic code is active. The oil pressure signal voltage is below the
acceptable range.
System Response:
None
Electronic System Response Oil pressure is set
Troubleshooting: to 600 kPa (87 psi).
Perform the following diagnostic procedure: “Fuel Service Tool Display or Lamps Caterpillar
Level Sensor Circuit - Test” Electronic Technician (ET) will indicate 600 kPa
(87 psi) and display “DIAG” next to “Engine Oil
Results: Pressure ” on the status screen while the diagnostic
code is active. The Check Engine Lamp will
• OK – STOP. illuminate.
Engine Response The engine may experience low

i02065232
0100-03 Oil Pressure voltage
Troubleshooting:
high (24)
SMCS Code: 1924-038 Pressure Sensor Open or Short Circuit - Test”
Conditions Which Generate This Code: Results:
The oil pressure signal voltage is above the • OK – STOP.
acceptable range.
RENR1367-11 105
i01926898 Expected Result:

0100-11 Very Low Oil Pressure The engine oil level is OK.
(46)
Results:
SMCS Code: 1924-038
• OK – The engine oil level is OK. Proceed to Test
Conditions Which Generate This Code: Step 2.
The ECM detects the following conditions: • Not OK – The engine oil level is low.
• The engine oil pressure is below the trip line in Repair: Add engine oil to the proper level. Refer to
Illustration 15 for more than eight seconds. the Operation and Maintenance Manual for more
information.
STOP.
Test Step 2. Verify Proper Sensor

Installation
A. Check the installation of the engine oil pressure
sensor.
B. Check the wiring of the engine oil pressure sensor.

Refer to the Electrical Schematic for the proper
wiring. Ensure that all of the wires and connectors
are properly connected.
Illustration 15
g00821786 Expected Result:
Very low oil pressure
The sensor is properly installed and the wiring is
System Response: correct.
The Caterpillar Electronic Technician (Cat ET) will Results:

display “LOW OIL PRESSURE” and “DIAG” next
to the status for “Engine Oil Pressure”. The check • OK – The sensor is properly installed. Proceed
engine lamp and the warning lamp will illuminate. to Test Step 3.
Customer passwords are required to clear this • Not OK – The sensor is not installed properly.
diagnostic code.
Repair: Install the engine oil pressure sensor
Possible Performance Effect: properly. Repair the wiring and/or the connectors
to the sensor.
The ECM will use the default torque map. The engine
speed is limited to 1350 RPM and the vehicle speed Verify that the repair eliminates the problem.
is limited to 72 km/h (45 mph).
STOP.
Note: If the “Engine Monitoring” parameter is
programmed to “Shutdown”, the engine will be Test Step 3. Check for Active Diagnostic
shutdown after this code has been active for 30 Codes
seconds.
A. Connect Cat ET to the data link connector.
Note: If “Engine Monitoring” is programmed to
“Warning” the engine power will not be affected. B. Check for active diagnostic codes that are related
to the barometric pressure sensor (atmospheric
Troubleshooting: pressure) or the boost pressure sensor.
Test Step 1. Check the Engine Oil Level Expected Result:
A. Check the engine oil level. There are no diagnostic codes that are related to the
barometric pressure sensor (atmospheric pressure)
or the boost pressure sensor.
106 RENR1367-11
Results: Results:
• OK – There are no diagnostic codes. Proceed to • OK – The voltage is within the range.
Test Step 4.
Repair: Reconnect the engine oil pressure sensor
• Not OK – There is a diagnostic code that is related and the boost pressure sensor.
to the barometric pressure sensor (atmospheric
pressure) and/or the boost pressure sensor. Temporarily connect a new barometric pressure
sensor (atmospheric pressure).
Repair: Troubleshoot the diagnostic code before
continuing with this procedure. If the new sensor fixes the problem, reconnect the
suspect sensor.
STOP.
If the problem returns, permanently replace the
Test Step 4. Check the Status Screen sensor.
A. Turn the key switch to the ON position. The engine Verify that the repair eliminates the problem.
should be off.
STOP.
B. Monitor the status for “Boost Pressure” and
“Engine Oil Pressure” on Cat ET. • Not OK – There is a problem with the 5 volt supply.
Expected Result: Repair: Check the J2/P2 ECM connector and the
sensor connectors for corrosion and moisture.
“Boost Pressure” and “Engine Oil Pressure” should
be less than 10 kPa (2 psi). Check the 5 volt supply wire. Verify that the wire
is not cut and that the wire is completely inserted
Results: into the connectors for the pressure sensors on
the engine harness.
• OK – The boost pressure and the engine oil
pressure are less than 10 kPa (2 psi). Proceed to Verify that the repair eliminates the problem.
Test Step 6.
STOP.
• Not OK - Boost Pressure – The boost pressure is
greater than 10 kPa (2 psi). Proceed to Test Step 8. Test Step 6. Install a Pressure Gauge
• Not OK - Engine Oil Pressure – The engine oil A. Remove the engine oil pressure sensor.
pressure is greater than 10 kPa (2 psi). Proceed
to Test Step 9. B. Install a 1U-5470 Engine Pressure Group into
the oil gallery with a Tee fitting in the port for the
• Not OK - Both – The boost pressure and the engine oil pressure sensor.
engine oil pressure are greater than 10 kPa (2 psi).
Proceed to Test Step 5. C. Connect the engine oil pressure sensor to the
Tee fitting.
Test Step 5. Check the Supply Voltage to
the Pressure Sensors D. Turn the key switch to the ON position.
A. Disconnect the barometric pressure sensor E. Monitor the status for “Engine Oil Pressure” on
(atmospheric pressure), the boost pressure Cat ET.
sensor, and the engine oil pressure sensor.
F. Start the engine and run the engine at low idle.
B. Turn the key switch to the ON position.
G. Compare the pressure reading on the gauge to
C. Measure the voltage between terminal A (Engine the pressure reading on Cat ET.
Pressure Sensor +5V) and terminal B (Engine
Pressure Sensor Common) of each pressure H. Monitor the status screen and the gauge while
sensor connector on the engine harness. you increase the engine speed.
Expected Result:
The voltage is 5.0 ± 0.16 VDC.

RENR1367-11 107
Expected Result: Expected Result:
The gauge and the status screen are within 35 kPa The voltage is 5.0 ± 0.16 VDC.
(5.0 psi) of each other.
Results:
Results:
• OK – The voltage is within the range.
• OK – The sensor is functioning properly. Proceed
to Test Step 7. Repair: Temporarily connect a new boost pressure
sensor.
• Not OK – The sensor is not functioning properly.
If the new sensor fixes the problem, reconnect the
Repair: Temporarily install a new engine oil suspect sensor.
pressure sensor.
If the problem returns, permanently replace the
If the new sensor repairs the problem, reinstall the sensor.
suspect sensor.
If the problem returns, replace the sensor.
STOP.
• Not OK – There is a problem with the 5 volt supply.
STOP.
Repair: Check the sensor connector for corrosion
Test Step 7. Compare the Readings to the and moisture.
Oil Pressure Map
Check the 5 volt supply wire. Verify that the wire
A. Compare the readings from the pressure gauge to is not cut and that the wire is completely inserted
the oil pressure maps in Illustration 15. into the connector for the boost pressure sensor
on the engine harness.
Expected Result:
The engine oil pressure is above the trip points in
Illustration 15. STOP.
Results: Test Step 9. Check the Supply Voltage to

the Engine Oil Pressure Sensor
• OK – The engine oil pressure appears to be OK
at this time. STOP. A. Disconnect the engine oil pressure sensor.
• Not OK – The engine oil pressure is lower than B. Turn the key switch to the ON position.
the trip line on the oil pressure map. There is a
mechanical problem. C. Measure the voltage between terminal A (Engine
Pressure Sensor +5V) and terminal B (Engine
Repair: Refer to Testing and Adjusting, “Engine Pressure Sensor Common) of the connector for
Oil Pressure - Test”. the engine oil pressure sensor on the engine
harness.
STOP.
Expected Result:
Test Step 8. Check the Supply Voltage to
the Boost Pressure Sensor The voltage is 5.0 ± 0.16 VDC.
A. Disconnect the boost pressure sensor. Results:
B. Turn the key switch to the ON position. • OK – The voltage is within the range.
C. Measure the voltage between terminal A (Engine Repair: Temporarily connect a new engine oil
Pressure Sensor +5V) and terminal B (Engine pressure sensor.
Pressure Sensor Common) of the connector for
the boost pressure sensor on the engine harness. If the new sensor fixes the problem, reconnect the
suspect sensor.
108 RENR1367-11
If the problem returns, permanently replace the i02065307

sensor.
0102-04 Boost Pressure
Verify that the repair eliminates the problem. voltage low (25)
STOP. SMCS Code: 1917-038
• Not OK – There is a problem with the 5 volt supply. Conditions Which Generate This Code:
Repair: Check the sensor connector for corrosion The boost pressure signal voltage is below the
and moisture. acceptable range.
Check the 5 volt supply wire. Verify that the wire is System Response:
not cut and that the wire is completely inserted into
the connector for the engine oil pressure sensor Electronic System Response Boost pressure is set
on the engine harness. to 0 kPa (0 psi).
Verify that the repair eliminates the problem. Service Tool Display or Lamps Caterpillar
Electronic Technician (ET) will indicate 0 kPa (0 psi)
STOP. and display “DIAG” next to “Boost Pressure” on the
status screen while the diagnostic code is active. The
i02065289
Check Engine Lamp will illuminate.
0102-03 Boost Pressure Engine Response The engine may experience low
voltage high (25)
Troubleshooting:
SMCS Code: 1917-038
Conditions Which Generate This Code: Pressure Sensor Open or Short Circuit - Test”
The boost pressure signal voltage is above the Results:
acceptable range.
System Response:
• OK – STOP.
Electronic System Response Boost pressure is set i01925767

to 0 kPa (0 psi).
0102-07 Boost Pressure not
Service Tool Display or Lamps Caterpillar responding
Electronic Technician (ET) will indicate 0 kPa (0 psi)
and display “DIAG” next to “Boost Pressure” on the SMCS Code: 1917-038
status screen while the diagnostic code is active. The
Check Engine Lamp will illuminate. Conditions Which Generate This Code:
Engine Response The engine may experience low The boost pressure is higher than the boost pressure
power when the diagnostic code is active. that is required for normal operating conditions.
Troubleshooting: Note: The diagnostic code indicates a mechanical
problem. The ECM and the electronic control system
Perform the following diagnostic procedure: “Engine is operating correctly.
System Response:
Results:
Boost pressure is set to 0 kPa (0 psi). “DIAG” will be
• OK – STOP. displayed next to the status for “Boost Pressure” on
the Caterpillar Electronic Technician (ET). The check
engine lamp will illuminate.
RENR1367-11 109
Possible Performance Effect: C. Check for air in the cooling system. Air can enter
the cooling system from different sources. The
The engine may experience low power when the most common causes of air in the cooling system
diagnostic code is active. are the incorrect filling of the cooling system and
combustion gas leakage into the cooling system.
Troubleshooting: Combustion gas can get into the system through
internal cracks, a damaged cylinder head, or a
The diagnostic code indicates a problem with damaged cylinder head gasket.
the turbocharger, the wastegate, or a pinched
turbocharger line. The diagnostic code does not D. Check the cooling system hoses and clamps.
indicate a problem with the ECM or the electronic Damaged hoses that leak can normally be seen.
control system. Hoses that have no visual leaks can soften during
operation. The soft areas of the hose can become
Results: kinked or crushed during operation. These areas
of the hose can restrict the coolant flow. Hoses
• OK – STOP. become soft and/or get cracks after a period of
time. The inside of a hose can deteriorate, and the
loose particles of the hose can restrict the coolant
i02298153
flow.
0105-00 High Intake Manifold E. Check the water pump. A damaged impeller will
Air Temperature Warning (64) not pump an adequate amount of coolant through
the cooling system. Remove the water pump and
SMCS Code: 1921-038 the impeller for damage.
Conditions Which Generate This Code: F. Check the water temperature regulator. A water
temperature regulator that does not open properly
The Engine Control Module (ECM) detects the can cause engine overheating.
G. If the cooling system for this application is
• The engine has been running for at least 30 equipped with an expansion tank, check the shunt
seconds. line for the expansion tank. The shunt line must
be below the coolant level in the expansion tank.
• The engine coolant temperature is above 99 °C A restriction of the shunt line from the expansion
(210 °F). tank to the inlet of the jacket water pump will
cause a reduction in water pump efficiency. A
The inlet air temperature has risen to 90 °C (194 °F). reduction in water pump efficiency will result in
low coolant flow.
System Response:
H. Check the aftercooler for damage and restrictions.
The ECM logs the diagnostic code into permanent A restriction of air flow through the air to air
memory. aftercooler can cause overheating. Check for
debris or deposits which would prevent the free
Note: This diagnostic code requires a customer flow of air through the aftercooler.
password in order to be cleared.
I. Check for a restriction in the air inlet system. A
Troubleshooting: restriction of the air that is coming into the engine
can cause high cylinder temperatures. High
Check the Engine’s Cooling System cylinder temperatures cause higher than normal
temperatures in the cooling system.
A. Verify that the cooling system is filled to the proper
level. If the coolant level is too low, air may be J. Check for a restriction in the exhaust system. A
allowed to enter the cooling system. Air in the restriction of exhaust gas flow out of the engine
cooling system will cause a reduction in coolant can cause high cylinder temperatures.
flow.
K. Consider high ambient temperatures. When
B. Check the quality of the coolant. Follow ambient temperatures are too high for the rating
the recommendations in the Operation and of the cooling system, there is not enough of a
Maintenance Manual. temperature difference between the ambient air
and coolant temperatures.
110 RENR1367-11
L. Consider high altitude operation. The cooling Troubleshooting:

capacity of the cooling system is reduced at higher
altitudes. The engine must have a pressurized Perform the following diagnostic procedure: “Engine
cooling system that has the capacity that will Temperature Sensor Open or Short Circuit - Test”
prevent the coolant from boiling.
Results:
M. Check the engine’s operating conditions. If
the engine is being operated above the rated • OK – STOP.
operating load, the engine lugging can cause an
overheating condition. When the engine is running
i02065365
in the lug condition, the fuel rate is increased with
no increase in engine speed. The cooling capacity
of the engine’s cooling system can be overcome
0105-04 Intake Manifold Air
by the increased heat of the added fuel. This will Temperature voltage low (38)
cause engine overheating.
SMCS Code: 1921-038
Expected Result:
A thorough inspection of the cooling system revealed
a problem. The Air Temperature signal voltage for the inlet air
temperature sensor is below the acceptable range.
Results:
System Response:
• OK – There is a problem with the cooling system.
Electronic System Response The inlet manifold
Repair: Repair the problem. Ensure that the repair air temperature is set to 85 °C (185 °F) while the
eliminates the problem. diagnostic code is active.
STOP. Service Tool Display or Lamps Caterpillar

Electronic Technician (ET) will indicate 85 °C
(185 °F) and display “DIAG” next to “Intake Manifold
i02065363 Air Temperature” on the status screen while the
0105-03 Intake Manifold Air diagnostic code is active. The Check Engine Lamp
will NOT illuminate unless this diagnostic code has
Temperature voltage high (38) been active for 10 hours.
SMCS Code: 1921-038 Engine Response Occasionally, the engine may

emit white smoke on start-up and misfire during cold
Conditions Which Generate This Code: ambient air temperatures.
The Air Temperature signal voltage for the inlet air Troubleshooting:
temperature sensor is above the acceptable range.
System Response: Temperature Sensor Open or Short Circuit - Test”
Electronic System Response The Inlet Manifold Results:

Air Temperature is set to 85 °C (185 °F) while the
diagnostic code is active. • OK – STOP.
i02298467
(185 °F) and display “DIAG” next to “Intake Manifold
Air Temperature” on the status screen while the
0105-11 Very High Intake
diagnostic code is active. The Check Engine Lamp Manifold Air Temperature (64)
been active for 10 hours. SMCS Code: 1921-038
Engine Response Occasionally, the engine may Conditions Which Generate This Code:
emit white smoke on start-up and misfire during cold
ambient air temperatures. The Engine Control Module (ECM) detects the
RENR1367-11 111
• The engine has been running for at least 30 Repair: Repair the diagnostic codes that
seconds. are present. For further details, refer to
Troubleshooting, “Troubleshooting With a
• The engine coolant temperature is above 99 °C Diagnostic Code”.
(210 °F).
Ensure that the repair eliminates the problem.
The inlet air temperature has risen to 110 °C (230 °F).
STOP.
System Response:
Test Step 2. Inspect Electrical Connectors
The value of the “Engine Monitoring Mode” parameter And Wiring.
will determine the actions that are taken by the ECM.
The engine monitoring system can be programmed A. Thoroughly inspect the following connectors:
for the following actions: OFF, WARNING, DERATE,
and SHUTDOWN. • J2/P2 ECM engine harness connector
OFF – Engine performance will not be affected. • J1/P1 ECM vehicle harness connector
WARNING – Engine performance will not be • connector terminals for the sensor
affected.
DERATE – Engine speed is limited to a maximum of Inspect” for details.
1350 rpm. The vehicle speed is limited to a maximum
of 72 km/h (45 mph), and the power is limited. B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated
SHUTDOWN – The engine will shut down if the with the appropriate diagnostic code.
engine is derated for the specified period of time.
C. Check the ECM connector (allen head screw) for
Refer to Troubleshooting, “Customer Configuration the proper torque of 6.0 N·m (55 lb in).
Parameters” for information that is related to
monitoring system parameters. D. Check the harness and wiring for abrasion and
pinch points from the appropriate sensor back to
The ECM logs the diagnostic code into permanent the ECM.
memory.
Expected Result:
Note: This diagnostic code requires a customer
password in order to be cleared. All connectors, pins and sockets should be completely
coupled and/or inserted and the harness and wiring
Troubleshooting: should be free of corrosion, abrasion or pinch points.
Test Step 1. Check for Diagnostic Codes. Choose the OK option in order to select the sensor
that requires troubleshooting or select the NOT OK
A. Connect ET to the cab data link connector. option if the wiring is causing the problem.
B. Turn the keyswitch to the ON position. The engine Results:

should be off.
• OK – Proceed to Test Step 3.
C. Check for any active diagnostic codes or logged
diagnostic codes. • Not OK – Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
Expected Result: the seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
There should be no diagnostic codes that are present. repair eliminates the problem. STOP.
Results: Test Step 3. Check the Sensor In The

Engine.
A. Ensure that the temperature of the engine is cool
• Not OK before starting this procedure.
B. Connect ET to the cab data link connector.
C. Turn the ignition key switch to the ON position.

112 RENR1367-11
D. Note the temperature for the sensor on the ET Note: Do not expect the sensor and the thermocouple
status screen. probe from the 6V-9130 Temperature Adapter to
respond to the temperature change at the same rate.
E. Start the engine but remain parked.
Results:
F. Monitor the temperature for the sensor on the ET
status screen as the engine is warming. • Yes – The sensor is functioning correctly. If
a problem is still suspected the problem is a
Expected Result: mechanical problem. The problem is not an
electronic problem.
The temperature before starting the engine should
be within reasonable limits, and the temperature Repair: Perform the following diagnostic
increases as the engine warms. procedure:
Note: The engine may require several hours to cool Refer to Troubleshooting, “Troubleshooting without
down depending on the ambient air temperature a Diagnostic Code” for a procedure that best
around the vehicle. describes the conditions.
Results: STOP.
• Yes – The sensor is functioning correctly. If • No

a problem is still suspected the problem is a
mechanical problem. The problem is not an Repair: Perform the following diagnostic
electronic problem. procedure:
Repair: Perform the following diagnostic 1. Temporarily install another sensor.

procedure:
2. Repeat this test step.
Refer to Troubleshooting, “Troubleshooting without
a Diagnostic Code” for a procedure that best 3. If the problem is resolved with the new sensor,
describes the conditions. replace the sensor.
STOP. 4. Verify that the repair eliminates the problem.
• No – Proceed to Test Step 4. STOP.
Test Step 4. Compare The Temperature

Reading To The Temperature From i02065382
Another Gauge. 0108-03 Barometric Pressure

A. Remove the temperature sensor from the engine. voltage high (26)
B. Connect the sensor to the engine harness. Hold SMCS Code: 1923-038
the sensor and the thermocouple probe from the
6V-9130 Temperature Adapter in the air. Allow Conditions Which Generate This Code:
three minutes for the sensor and the probe to
respond to the temperature of the air. The atmospheric pressure signal voltage is above
the acceptable range.
C. The ET status screen will display the temperature
reading from the sensor. Compare the temperature System Response:
reading to the temperature reading from the
6V-9130 Temperature Adapter. Electronic System Response Atmospheric
pressure is set to 100 kPa (15 psi).
D. Hold the sensor and the thermocouple probe in
your hand and check the temperatures again. Do Service Tool Display or Lamps Caterpillar
not expose the sensor to a flame. Electronic Technician (ET) will indicate 100 kPa
(15 psi) and display “DIAG” next to “Atmospheric
Expected Result: Pressure” on the status screen while the diagnostic
The two measurements are within 15 °C (27 °F) of illuminate.
each other.
RENR1367-11 113
Engine Response The engine may experience low System Response:

“DIAG” will be displayed next to the status for “Engine
Troubleshooting: Coolant Temperature” on the Caterpillar Electronic
Technician (Cat ET). The check engine lamp and the
Perform the following diagnostic procedure: “Engine warning lamp will illuminate.
Customer passwords are required to clear this
Results: diagnostic code.
• OK – STOP. Possible Performance Effect:
None
i02065386
0108-04 Barometric Pressure Troubleshooting:
voltage low (26) Check the Cooling System

SMCS Code: 1923-038 Refer to Testing and Adjusting, “Cooling System -
Check”.
Results:
The atmospheric pressure signal voltage is below
the acceptable range. • OK – STOP.
System Response:
i02065390
Electronic System Response Atmospheric

pressure is set to 100 kPa (15 psi).
0110-03 Coolant Temperature
voltage high (27)
Electronic Technician (ET) will indicate 100 kPa SMCS Code: 1906-038
(15 psi) and display “DIAG” next to “Atmospheric
Pressure” on the status screen while the diagnostic Conditions Which Generate This Code:
illuminate. The coolant temperature signal voltage is above the
acceptable range.
Engine Response The engine may experience low
power when the diagnostic code is active. System Response:
Troubleshooting: Electronic System Response Coolant temperature

is set to 90 °C (194 °F) while the diagnostic code
Perform the following diagnostic procedure: “Engine is active. Cold Mode is disabled. If the ECM is
Pressure Sensor Open or Short Circuit - Test” controlling the cooling fan, the fan will be ON.
Results: Service Tool Display or Lamps Caterpillar

• OK – STOP. (194 °F) and display “DIAG” next to “Engine
Coolant Temperature” on the status screen while the
diagnostic code is active. The Check Engine Lamp
i01926950
0110-00 High Coolant been continuously active for 10 hours.
Temperature Warning (61) Engine Response Occasionally, the engine may

emit white smoke on start-up because Cold Mode
SMCS Code: 1906-038 is not active.
Conditions Which Generate This Code: Troubleshooting:
The coolant temperature is equal to 108 °C (226 °F) Perform the following diagnostic procedure: “Engine
or above 108 °C (226 °F). For emergency vehicles, Temperature Sensor Open or Short Circuit - Test”
the coolant temperature is equal to 113 °C (235 °F)
or above 113 °C (235 °F).
114 RENR1367-11
Results: System Response:
• OK – STOP. “DIAG” will be displayed next to the status for “Engine

Coolant Temperature” on the Caterpillar Electronic
Technician (Cat ET). The check engine lamp and the
i02065396
warning lamp will illuminate.
0110-04 Coolant Temperature Customer passwords are required to clear this
voltage low (27) diagnostic code.
SMCS Code: 1906-038 Possible Performance Effect:
Conditions Which Generate This Code: The engine will be derated. The engine power and
the vehicle speed will be limited. The amount of
The coolant temperature signal voltage is below the derate depends on the engine coolant temperature.
acceptable range. If the “Engine Monitoring” parameter is programmed
to “Shutdown”, the engine will be shutdown once this
System Response: code has been active for 20 seconds.
Electronic System Response Coolant temperature Note: If the “Engine Monitoring” parameter is
is set to 90 °C (194 °F) while the diagnostic code programmed to “Warning”, the engine power is not
is active. Cold Mode is disabled. If the ECM is affected.
controlling the cooling fan, the fan will be ON.
Troubleshooting:
Electronic Technician (ET) will indicate 90 °C Check the Cooling System
(194 °F) and display “DIAG” next to “Engine
Coolant Temperature” on the status screen while the Refer to Testing and Adjusting, “Cooling System -
diagnostic code is active. The Check Engine Lamp Check”.
been continuously active for 10 hours. Results:
Engine Response Occasionally, the engine may • OK – STOP.

emit white smoke on start-up because Cold Mode
is not active.
i02298563
Troubleshooting: 0111-01 Low Coolant Level

Perform the following diagnostic procedure: “Engine Warning (62)
Temperature Sensor Open or Short Circuit - Test”
SMCS Code: 5574-038-CLT
Results:
• OK – STOP.
The coolant level is below the coolant level sensor.
i01926956
System Response:
0110-11 Very High Coolant The ECM logs the diagnostic code into permanent
Temperature (61) memory.
SMCS Code: 1906-038 Note: This diagnostic code requires a customer

password in order to be cleared.
Troubleshooting:
The coolant temperature is equal to 111 °C (232 °F)
or above 111 °C (232 °F). For emergency vehicles, • The coolant level is most likely low.
the coolant temperature is equal to 116 °C (241 °F)
or above 116 °C (241 °F). • There may be a problem with the coolant level
sensor.
RENR1367-11 115
Check the Coolant Level System Response:
Electronic System Response The ECM sets the

Coolant Level to OK while this diagnostic code is
Pressurized System: Hot coolant can cause seri- Active.
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system Service Tool Display or Lamps The Caterpillar
components are cool. Loosen the cooling system Electronic Technician (ET) will indicate “LOW” and
pressure cap slowly in order to relieve the pres- “DIAG” next to “Engine Coolant Level”on the status
sure. screen while the diagnostic code is active. The check
engine lamp will not come on unless the diagnostic
code has been continuously active for 10 hours.
A. Stop the engine.
Engine Response There is no effect on engine
B. After allowing the engine to cool, check the coolant response due to this diagnostic code.
level. Refer to the Operation and Maintenance
Manual for the proper procedure. Troubleshooting:
Expected Result: Perform the following diagnostic procedure: “Coolant

Level Sensor Circuit - Test”
The coolant level is low.
Results:
Results:
• OK – STOP.
• OK – The coolant level is low.
i02065432
Repair: Check the cooling system for leaks. Repair
any problems that are found. Refill the cooling
system to the proper level.
0111-03 Coolant Level voltage
high (12)
STOP.
SMCS Code: 5574-038-CLT
• Not OK – The coolant level is not low.
Repair: There may be a problem with the coolant
level sensor. Refer to the diagnostic functional test This condition occurs when there is an open in the
Troubleshooting, “Coolant Level Sensor Circuit - circuit for the 2-wire float sensor. “Engine Monitoring”
Test” in order to verify that the coolant level sensor must be programmed to “WARNING”, “DERATE”,
is operating correctly. or “SHUTDOWN”, and the parameter “Coolant
Level Sensor” must be programmed to “2-wire float
Ensure that any repairs eliminate the problem. sensor” before this diagnostic code can occur. If the
parameter “Coolant Level Sensor” is programmed
STOP. to “2-pin switch” or to “4-pin”, this diagnostic code
is disabled.
i02065400
System Response:
0111-02 Coolant Level signal Electronic System Response The ECM sets the
invalid (12) Coolant Level to OK while this diagnostic code is
active. Coolant Level Engine Monitoring is disabled
SMCS Code: 5574-038-CLT while this code is active.
Conditions Which Generate This Code: Service Tool Display or Lamps The Caterpillar
Caterpillar Electronic Technician (Cat ET) will indicate
This condition occurs when the coolant level sensor “OK” and “DIAG” next to “Engine Coolant Level”on
signals indicate a low condition and a normal the status screen while the diagnostic code is active.
condition at the same time. “Engine Monitoring” The check engine lamp will illuminate.
must be programmed to “WARNING”, “DERATE”, or
“SHUTDOWN”, and the parameter “Coolant Level Engine Response There is no effect on engine
Sensor” must be programmed to “4-pin”, or “2-wire response due to this diagnostic code.
float sensor” before this diagnostic code can occur. If
the parameter “Coolant Level Sensor” is programmed
to “2-pin switch”, this diagnostic code is disabled.
116 RENR1367-11
Perform the following diagnostic procedure: “Coolant 0111-11 Very Low Coolant
Level Sensor Circuit - Test” Level (62)
Results: SMCS Code: 5574-038-CLT
• OK – STOP. Conditions Which Generate This Code:
i02065444
This condition indicates that the coolant level is very
low.
0111-04 Coolant Level voltage
System Response:
low (12)
The value of the “Engine Monitoring Mode” parameter
SMCS Code: 5574-038-CLT will determine the actions that are taken by the
Engine Control Module. The engine monitoring
Conditions Which Generate This Code: system can be programmed for the following actions:
This condition occurs when there is a short in the OFF – Engine performance will not be affected.
circuit for the 2-wire float sensor. “Engine Monitoring”
must be programmed to “WARNING”, “DERATE”, WARNING – Engine performance will not be
or “SHUTDOWN”, and the parameter “Coolant affected.
Level Sensor” must be programmed to “2-wire float
sensor” before this diagnostic code can occur. If the DERATE – Engine speed is limited to a maximum of
parameter “Coolant Level Sensor” is programmed 1350 rpm. The vehicle speed is limited to a maximum
to “2-pin switch” or to “4-pin”, this diagnostic code of 72 km/h (45 mph), and the power is limited.
is disabled.
SHUTDOWN – The engine will shut down if the
System Response: engine is derated for the specified period of time.
Electronic System Response The ECM sets the Refer to Troubleshooting, “Customer Configuration
Coolant Level to OK while this diagnostic code is Parameters” for information that is related to
active. Coolant Level Engine Monitoring is disabled monitoring system parameters.
while this code is active.
The ECM logs the diagnostic code into permanent
Service Tool Display or Lamps The Caterpillar memory.
Caterpillar Electronic Technician (Cat ET) will indicate
“OK” and “DIAG” next to “Engine Coolant Level”on Note: This diagnostic code requires a customer
the status screen while the diagnostic code is active. password in order to be cleared.
The check engine lamp will illuminate.
Check the Coolant Level
Engine Response There is no effect on engine
response due to this diagnostic code.
Troubleshooting:
Pressurized System: Hot coolant can cause seri-
Perform the following diagnostic procedure: “Coolant ous burns. To open the cooling system filler cap,
Level Sensor Circuit - Test” stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
Results: pressure cap slowly in order to relieve the pres-
sure.
• OK – STOP.
A. Stop the engine.
B. After allowing the engine to cool, check the coolant

level. Refer to the Operation and Maintenance
Manual for the proper procedure.
RENR1367-11 117
Expected Result: The electronic service tool will display “DIAG” next to
“Secondary Fuel Level”on the status screen while the
The coolant level is low. diagnostic code is active.
Results: Perform the following diagnostic procedure: “Fuel

Level Sensor Circuit - Test”
• OK – The coolant level is low.
Results:
Repair: Check the cooling system for leaks. Repair
any problems that are found. Refill the cooling • OK – STOP.
system to the proper level.
i01902402
STOP.
0128-04 Secondary Fuel Level
• Not OK – The coolant level is not low.
voltage low
Repair: There may be a problem with the coolant
level sensor. Refer to the diagnostic functional test SMCS Code: 5574-038
Troubleshooting, “Coolant Level Sensor Circuit -
Test” in order to verify that the coolant level sensor Conditions Which Generate This Code:
is operating correctly.
This diagnostic code is used only by GMT-560
Ensure that any repairs eliminate the problem. applications.
STOP. The ECM detects the following:
• The Secondary Fuel Level signal voltage is below

i01902400 the acceptable range for more than 10 seconds.
0128-03 Secondary Fuel Level System Response:
voltage high
If the parameter “Primary Fuel Tank Size” is
SMCS Code: 5574-038 programmed and a diagnostic code for the primary
Conditions Which Generate This Code: primary fuel level sensor to determine the fuel level.
This diagnostic code is used only by GMT-560 If the parameter “Primary Fuel Tank Size” is not
applications. programmed and a diagnostic code is active for the
primary fuel level sensor, the ECM will broadcast an
The ECM detects the following condition: error code over the J1939 data link. The ECM will
also broadcast the fuel level as 0 over the ATA data
• The Secondary Fuel Level signal voltage is above link.
the acceptable range for more than 10 seconds.
The electronic service tool will display “DIAG” next to
System Response: “Secondary Fuel Level”on the status screen while the
If the parameter “Primary Fuel Tank Size” is
programmed and a diagnostic code for the primary Perform the following diagnostic procedure: “Fuel
fuel level sensor is not active, the ECM will use the Level Sensor Circuit - Test”
primary fuel level sensor to determine the fuel level.
Results:
If the parameter “Primary Fuel Tank Size” is not
programmed and a diagnostic code is active for the • OK – STOP.
primary fuel level sensor, the ECM will broadcast an
error code over the J1939 data link. The ECM will
also broadcast the fuel level as 0 over the ATA data
link.
118 RENR1367-11
i01926977 i02065446
0164-00 Excessive Injection 0164-02 Injection Actuation

Actuation Pressure (17) Pressure Signal Erratic (15)
SMCS Code: 1925-038 SMCS Code: 1925-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The ECM detected the following conditions: The ECM detected one of the following conditions:
• The injection actuation pressure is greater than • Injection actuation pressure with the engine
26.5 MPa (3844 psi) for more than six seconds. shutdown
• Engine speed is greater than 0 MPH. • The actual pressure and the desired pressure are
substantially different.
• Engine coolant temperature is more than 18 °C
(64 °F). • The change in injection actuation pressure was not
consistent with the change in sensor current.
• The ECM has been powered for at least three
seconds. System Response:
• Cold Mode is not active. Electronic System Response The ECM will indicate
an active code and the code will be logged.
Note: The diagnostic code indicates a mechanical
problem. The ECM and the electronic control system Service Tool Display or Lamps Caterpillar
is operating correctly. Electronic Technician (Cat ET) will display 17.5 MPa
(2538 psi) next to “Desired Injection Actuation
System Response: Pressure” and “Actual Injection Actuation Pressure”on
the status screen while the diagnostic code is active.
“0%”will be displayed next to “Injector Output %” on The Check Engine Lamp will illuminate.
the status screen.
Engine Response This code can occur when the
The check engine lamp will illuminate. engine is off.
Possible Performance Effect: Troubleshooting:
The ECM limits power output to 89.5 kW (120.0 hp) Perform the following diagnostic procedure: “Injection
and the vehicle speed is limited to 73 km/h (45 mph). Actuation Pressure Sensor - Test”
The engine may emit white smoke at start-up Results:

because Cold Mode is not active.
• OK – STOP.
Note: The problem may only exist at operating
temperature.
i02065503
Troubleshooting: 0164-03 Injection Actuation

Perform the following diagnostic procedure: “Injection Pressure voltage high (15)
Actuation Pressure - Test”
SMCS Code: 1925-038
Results:
• OK – STOP.
The voltage in the injection actuation pressure circuit
is higher than normal.
RENR1367-11 119
System Response: Troubleshooting:
Electronic System Response The ECM will assume Perform the following diagnostic procedure: “Engine
that the injection actuation pressure is 17.5 MPa Pressure Sensor Open or Short Circuit - Test”
(2538 psi). The control valve for the “Injection
Actuation Pressure System” is set to a fixed position. Results:
The fuel delivery is limited.
• OK – STOP.
Electronic Technician (ET) will display 17.5 MPa
i02065514
(2538 psi) next to “Desired Injection Actuation
Pressure” and “Actual Injection Actuation Pressure”on
the status screen while the diagnostic code is active.
0164-11 Injection Actuation
The Check Engine Lamp will illuminate. Pressure system fault (39)
Engine Response The engine will run rough at idle. SMCS Code: 1925-038
Power output will be below normal and the vehicle
speed will be limited to 72 km/h (45 mph). Conditions Which Generate This Code:
Troubleshooting: The ECM detected one of the following conditions:
Perform the following diagnostic procedure: “Engine • The actual pressure and the desired pressure are
Pressure Sensor Open or Short Circuit - Test” substantially different.
Results: • The “Injection Actuation Pressure Control Valve

Driver” was at the maximum output or the minimum
• OK – STOP. output for a longer time then needed.
Note: The diagnostic code indicates a mechanical

i02065510 problem. The ECM and the electronic control system
0164-04 Injection Actuation are operating correctly.
Pressure voltage low (15) System Response:
SMCS Code: 1925-038 Engine Response The engine may be low on power
and the idle may be unstable. The engine may be
Conditions Which Generate This Code: difficult to start at normal operating temperatures, but
the engine may start easily when the engine is cold.
The voltage in the injection actuation pressure circuit
is below normal. Note: The problem may only exist at operating
temperature. Air may be trapped in the injection
System Response: actuation system if the system has been serviced
recently. Start the engine and run the engine at 1500
Electronic System Response The ECM will assume rpm for a few minutes in order to remove the trapped
that the injection actuation pressure is 17.5 MPa air.
(2538 psi). The control valve for the “Injection
Actuation Pressure System” is set to a fixed position. Troubleshooting:
The fuel delivery is limited.
Perform the following diagnostic procedure: “Injection
Service Tool Display or Lamps Caterpillar Actuation Pressure - Test”
Electronic Technician (ET) will display 17.5 MPa
(2538 psi) next to “Desired Injection Actuation Results:
Pressure” and “Actual Injection Actuation Pressure”on
the status screen while the diagnostic code is active. • OK – STOP.
The Check Engine Lamp will illuminate.
Engine Response The engine will run rough at idle.

Power output will be below normal and the vehicle
speed will be limited to 72 km/h (45 mph).
120 RENR1367-11
i02065525 • The parameter “PTO Engine Shutdown Switch” is

programmed to “J1/P1:7” or “J1/P1:23”.
0168-02 ECM Battery Power
Intermittent (51) • The PTO engine shutdown switch is off and the
PTO switch is active for 0.5 seconds.
SMCS Code: 1401-038
• The PTO engine shutdown switch changes
Conditions Which Generate This Code: condition for 0.5 seconds.
This condition indicates that the battery circuit to System Response:

the ECM has a battery condition that is intermittent
or a battery condition that is low while the engine Caterpillar Electronic technician (ET) will not display
is running. If battery voltage disappears without a status.
returning, the ECM will not log this diagnostic code
and the engine will shut down. Possible Performance Effect:
System Response: The engine will shut down and PTO mode will be
deactivated. The Engine Control Module (ECM) will
Electronic System Response The ECM may stop not allow the PTO to engage while this code is active.
injecting fuel. This may be dependent on the length
of time of the occurrence of the fault. Troubleshooting:
Engine Response The engine may experience Perform the following diagnostic procedure: “PTO
changes in the engine rpm, and intermittent engine Engine Shutdown Switch Circuit - Test”
shutdowns or complete engine shutdowns while
the conditions that cause this diagnostic code are Results:
present.
• OK – STOP.
Service Tool Display or Lamps The Check Engine
Lamp and the Warning Lamp may come on as if the i01640819
ignition key switch was just turned on and the engine
started. 0190-00 Engine Overspeed
Troubleshooting: Warning (35)
Perform the following diagnostic procedure: “Ignition SMCS Code: 1912-038
Key Switch Circuit and Battery Supply Circuit - Test”
Results:
This condition indicates that the engine speed has
exceeded 3300 rpm.
• OK – STOP.
System Response:
i02129399
Electronic System Response The ECM shuts off
0186-14 PTO Engine Shutdown the fuel injection delivery above the programmed
Switch Occurrence (47) “Top Engine Limit” (TEL).
SMCS Code: 7332-038 This diagnostic code requires a Factory Password in

order to be cleared.
This diagnostic code represents a critical event. This
All of the following conditions must be met. diagnostic code does not represent an electronic
system fault.
• The parameter “PTO Configuraton” is programmed
to “Cab Switches”, “Remote Switches”, or “Remote Service Tool Display or Lamps Caterpillar
Throttle”. Electronic Technician (ET) will display “TOP ENGINE
LIMIT” in a unique area of the status screen when
• The PTO switch is on the ON position. the engine rpm has reached the top engine limit or
when the engine rpm has exceeded the top engine
limit. The Check Engine Lamp will illuminate.
RENR1367-11 121
Troubleshooting: System Response:
There are no problems that require troubleshooting. Electronic System Response The check engine
lamp will not be illuminated for this code unless the
This diagnostic code indicates an excessive engine code has been active for 10 hours. The code is
speed. This diagnostic code does not indicate a logged.
problem with the ECM or the engine speed/timing
sensor. Service Tool Display or Lamps Caterpillar
Electronic Technician (ET) will not display a status.
Results:
Engine Response There should not be a noticeable
• OK – STOP. change in engine response unless the signal for the
camshaft position sensor 2 (bottom) is lost. This loss
will shut down the engine.
i02065531
0190-02 Primary Engine Speed Troubleshooting:
Loss of Signal (34) Perform the following diagnostic procedure: “Engine

Speed/Timing Sensor Circuit - Test”
SMCS Code: 1912-038
Results:
• OK – STOP.
The signal for the camshaft position sensor 1 (top) is
intermittent or lost.
i02129525
System Response:
0224-11 Theft Deterrent Active
Electronic System Response The check engine (00)
lamp will not be illuminated for this code unless the
code has been active for 10 hours. The code is SMCS Code: 1901-038
logged.
Electronic Technician (ET) will not display a status. The theft deterrent feature has been enabled. The
correct password must be entered in order to disable
Engine Response There should not be a noticeable the theft deterrent. Then, the engine can be started.
change in engine response unless the signal for the
camshaft position sensor 2 (bottom) is lost. This loss Note: This diagnostic code represents an event. This
will shut down the engine. diagnostic code does not represent an electronic
system fault.
Troubleshooting:
The Engine Control Module (ECM) will operate in the
Perform the following diagnostic procedure: “Engine “Secure Idle” mode if the theft deterrent password
Speed/Timing Sensor Circuit - Test” is entered. The engine must be running in order to
operate in the “Secure Idle” mode. The ECM will be
Results: in the “Secure Idle” mode until the theft deterrent
password is entered again.
• OK – STOP.
System Response:
i02065538
The diagnostic code is active only. The diagnostic
0190-11 Primary Engine Speed code will be active when the theft deterrent feature
is enabled.
no pattern (34)
Caterpillar Electronic Technician (ET) will not display
SMCS Code: 1912-038 a status. The check engine lamp will be illuminated.
Conditions Which Generate This Code: Possible Performance Effect:
The signal for the camshaft position sensor 1 (top) The engine will not start until the correct password is
is lost. entered. The engine will be limited to the low idle rpm
if the “Secure Idle” mode is active.
122 RENR1367-11
This diagnostic code indicates that the theft deterrent 0231-02 J1939 Data Incorrect
feature has been enabled. There is no electronic (58)
system fault.
SMCS Code: 1901-038
No Troubleshooting is required.
Results:
This condition indicates that the J1939 data link is
• OK – STOP. receiving information from a specified device but the
information is incomplete or corrupted.
i02129561
The parameter “Powertrain Data Link” must be
0224-14 Theft Deterrent Active programmed to J1939.
with Engine Cranking (00) One of the following conditions must be met:
SMCS Code: 1901-038
• The device is broadcasting a fault code.
• The Engine Control Module (ECM) is unsuccessful
in receiving a specific message from a device.
• The device is broadcasting a code that is not
supported.
• The engine is cranking.
System Response:
• The theft deterrent is active.
Caterpillar Electronic Technician (ET) will indicate
System Response: a safe default value or display “DIAG” on a status
screen. If the device sends a message that is not
The diagnostic code is active only. The diagnostic supported, Cat ET will display “J1939 No Support”.
code will be active when the theft deterrent is Cat ET will display a list of the devices that are
enabled and the engine is cranking for more than five causing this code on the “Active Faults” screen. If the
seconds. list of devices that are causing this code is too large,
all of the devices will not be listed until some of the
Possible Performance Effect: incorrect messages are corrected.
The engine will not start until the correct password Possible Performance Effect:
is entered.
J1939 communications to the engine and from the
Troubleshooting: engine are terminated for the specific message while
this code is active. The functionality of some features
Enter the correct passwords. may be affected while this code is active. Traction
control or transmission controls may be disabled.
There are no problems that require troubleshooting.
Troubleshooting:
Results:
• OK – STOP. “Powertrain Data Link Circuit - Test”
Results:
• OK – STOP.
RENR1367-11 123
i02129727 System Response:

0231-11 J1939 Data Link Fault The ECM will disable features that require an input
(58) from the J1939 device.
SMCS Code: 1901-038 Possible Performance Effect:
Conditions Which Generate This Code: The J1939 device may not operate correctly. Certain
control systems may not operate correctly.
This condition indicates that the SAE J1939 data
link is not communicating correctly. The parameter Troubleshooting:
“Powertrain Data Link” must be programmed to
J1939. Perform the following diagnostic procedure:
“Powertrain Data Link Circuit - Test”
System Response:
Results:
Note: If the vehicle is not using the J1939 data link,
program “Powertrain Data Link” to “None”. After the • OK – STOP.
“Powertrain Data Link” is programmed correctly this
active diagnostic code should deactivate. i02065542
Possible Performance Effect: 0232-03 5 Volt Supply voltage

Communications with other control modules that use high (21)
the J1939 data link may be interrupted while this
diagnostic code is active. SMCS Code: 5574-038
Troubleshooting: Conditions Which Generate This Code:
Contact the OEM dealer in order to determine if the The supply voltage for the pressure sensors of the
vehicle was configured for the J1939 data link. If the engine is exceeding a level that is normal.
vehicle is not using the J1939 data link, program
“Powertrain Data Link” to “None”. This will correct System Response:
the problem.
Electronic System Response All pressure sensors
If the vehicle is using the J1939 data link, proceed of the engine are set to default values. All diagnostic
with the following procedure: codes for the pressure sensors of the engine are
disabled while this diagnostic code is active.
“Powertrain Data Link Circuit - Test” Service Tool Display or Lamps Caterpillar
Electronic Technician (ET) will display the default
Results: status of the sensors. This default status is indicated
in the following list:
• OK – STOP.
• Boost pressure 0 kPa (0 psi)
i02129842 • Engine Oil Pressure 600 kPa (87 psi)
0231-12 J1939 Device Not • Atmospheric Pressure 100 kPa (15 psi)
Responding
• Injection Actuation Pressure 17.5 kPa (2.53 psi)
SMCS Code: 1901-038
• Injection Actuation Driver Current 40%
ET will also display “DIAG” next to the status of
The Engine Control Module (ECM) detects the the sensor in order to indicate that the sensor is
following conditions: operating at the value that is shown due to an active
diagnostic code.
• The ECM is unsuccessful in receiving a message
from a J1939 source. Engine Response An active diagnostic code may
not cause any noticeable effect on engine response.
• The ECM is not receiving a valid message from a However, the active diagnostic code may cause the
J1939 source. engine to have the following effects:
124 RENR1367-11
• Run rough. • Run rough.

• Low power • Low power
These effects are dependent on the operating These effects are dependent on the operating
conditions that exist at the time when the code conditions that exist at the time when the code
occurs. occurs.
Perform the following diagnostic procedure: “5 Volt Perform the following diagnostic procedure: “5 Volt
Engine Pressure Sensor Supply Circuit - Test” Engine Pressure Sensor Supply Circuit - Test”
Results: Results:
• OK – STOP. • OK – STOP.
i02065549 i02130074
0232-04 5 Volt Supply voltage 0246-11 Brake Pedal Switch #1

low (21) Fault
SMCS Code: 5574-038 SMCS Code: 1435-038-BRK
Conditions Which Generate This Code: Conditions Which Generate This Code:
The supply voltage for the pressure sensors of the The engine is running and both of the following
engine is below normal level. conditions exist:
System Response: • The status of the service brake pedal position

switch 1 indicates that the brake pedal has been
Electronic System Response All pressure sensors depressed.
of the engine are set to default values. All diagnostic
codes for the pressure sensors of the engine are • The status of the service brake pedal position
disabled while this diagnostic code is active. switch 2 indicates that the pedal has been released.
Service Tool Display or Lamps Caterpillar System Response:

Electronic Technician (ET) will display the default
status of the sensors. This default status is indicated The diagnostic code is logged into memory only if the
in the following list: engine is running. This diagnostic code will prevent
cruise control, PTO operation, or idle operation.
• Boost pressure 0 kPa (0 psi) The check engine lamp will not illuminate for this
diagnostic code.
• Engine Oil Pressure 600 kPa (87 psi)
• Atmospheric Pressure 100 kPa (15 psi)
The engine will disengage or the engine will not allow
• Injection Actuation Pressure 17.5 kPa (2.50 psi) the setting of the cruise control, the PTO, or the idle
speed.
• Driver Current for the Injection Actuation System
40% Troubleshooting:
ET will display “DIAG” next to the status of the sensor Perform the following diagnostic procedure: “Service
in order to indicate that the sensor is operating at the Brake Pedal Position (Switch 1) Circuit -Test”
value that is shown due to an active diagnostic code.
Results:
Engine Response An active diagnostic code may
not cause any noticeable effect on engine response. • OK – STOP.
However, the active diagnostic code may cause the
engine to have the following effects:
RENR1367-11 125
i02130078 Possible Performance Effect:

0247-11 Brake Pedal Switch #2 The engine will not start.
Fault
Troubleshooting:
SMCS Code: 1435-038-BRK
The flash file in the ECM is from the wrong engine
Conditions Which Generate This Code: family.
The engine is running and both of the following Perform the following diagnostic procedure: “ECM
conditions exist: Memory - Test”
• The status of the service brake pedal position Results:

switch 2 indicates that the brake pedal has been
depressed. • OK – STOP.
• The status of the service brake pedal position i01641234

switch 1 indicates that the pedal has been released.
0253-02 Check Customer or
System Response:
System Parameters (56)
The diagnostic code is logged into memory only if the
engine is running. This diagnostic code will prevent SMCS Code: 1901-038
cruise control, PTO operation, or idle operation.
The check engine lamp will not illuminate for this Conditions Which Generate This Code:
diagnostic code.
This condition indicates a “Customer Specified
Possible Performance Effect: Parameter” or a system configuration parameter that
requires programming has not been programmed.
The engine will disengage or the engine will not Once this parameter has been programmed, the
allow setting of the cruise control, the PTO, or the code may still be active. This can happen if there is
idle speed. yet another parameter that requires programming.
Troubleshooting: System Response:
Perform the following diagnostic procedure: “Service Electronic System Response The fault is active
Brake Pedal Position (Switch 2) Circuit - Test” only and the fault is not logged. If the Personality
Module Code of the new personality module does
Results: not match the code of the old personality module, the
engine is limited to low idle. If the “Rating Number”
has not been programmed, the ECM limits the
• OK – STOP. engine to 89.5 kW (120.0 hp). When a new ECM is
initially powered up, the following parameters must
i02336574 be programmed to avoid this diagnostic code:
0252-11 Engine Software • “Full Load Setting” (FLS)
Incorrect (59)
• “Full Torque Setting” (FTS)
SMCS Code: 1901-038
• “Vehicle Speed Calibration”
• “Rating Number”
The Engine Control Module (ECM) detects incorrect
engine software . • “Engine Serial Number”
System Response:
The ECM will turn on the check engine lamp.
Factory passwords are required to clear this

diagnostic code.
126 RENR1367-11
Service Tool Display or Lamps Caterpillar • Tachometer

Electronic Technician (ET) will display a list of the
parameters that require programming. If two or more • Engine monitoring lamps
Multi I/O parameters are programmed to the same
input/output, only one of the Multi I/O parameters will Troubleshooting:
be listed at one time. If the list of parameters exceeds
the limit, the Multi I/O parameters will not be listed Determine the type of chassis.
until some of the other parameters are corrected.
This will make space on the list in order to display Perform the following diagnostic procedure: “ECM
the Multi I/O parameters. The Check Engine Lamp Memory - Test”
will illuminate.
Results:
Engine Response The ECM will limit the engine to
low idle if the parameter is the FLS or the FTS. The • OK – STOP.
ECM may also limit the power if the parameter is a
rating number.
Troubleshooting:
Perform the following diagnostic procedure: “ECM

Memory - Test”
Results:
• OK – STOP.
i02336583
0253-14 Truck Manufacturer

Parameter Not Programed
SMCS Code: 1901-038
The “Truck Manufacturer Parameter” has not been

programmed. The parameter must be programmed
for the manufacturer of the chassis in order to
configure the correct options and ranges for the
engine.
Note: The “Truck Manufacturer Parameter” must be

programmed before the “Customer Parameters” are
programmed.
System Response:
The code is active, but the code is not logged. The

check engine lamp will be on when the code is active.
The Engine Control Module (ECM) will select the

GM parameter as the default until the appropriate
parameter is programmed.
The following items will not work correctly:
• Speedometer
RENR1367-11 127
Diagnostic Functional
Tests
i02298809
5 Volt Engine Pressure Sensor

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

one of the following diagnostic codes is active or
easily repeated:
• 232-03 5 Volt Supply voltage high

• 232-04 5 Volt Supply voltage low
Also, use this procedure to troubleshoot the system
when you have been directed here by another
troubleshooting procedure.
The Engine Control Module (ECM) supplies the

following sensors with regulated 5.0 ± 0.2 VDC from
the same power supply:
• Boost pressure sensor

• Atmospheric pressure sensor (specific ratings only)
• Engine oil pressure sensor (optional)
• Injection actuation pressure sensor
The power supply for the pressure sensors is routed
from J2-2 (+5 V pressure sensor supply) to terminal
“A” of each pressure sensor connector.
The most likely cause of a diagnostic code for +5 V

pressure sensor supply is a short circuit or an open
circuit in the harness. The next probable cause is a
faulty sensor and the least probable cause is the
ECM.
128 RENR1367-11
g01151304
Illustration 16
Schematic for the +5 V pressure sensor supply
Test Step 1. Inspect the Electrical

Connectors and the Wiring
g01151317
Illustration 17
Left side engine view (typical example)
(1) Injection actuation pressure sensor
(2) Atmospheric pressure sensor
(3) Boost pressure sensor
(4) Engine oil pressure sensor (option)
(5) J2/P2 ECM connector
A. Thoroughly inspect ECM connector (5). Also

inspect the connectors for pressure sensors
(1), (2), (3), and (4). Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details.
RENR1367-11 129
g01123211
Illustration 19
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal
B. Perform a 45 N (10 lb) pull test on each of the

with the +5 V pressure sensor supply.
C. Check the torque of the allen head screw on the

ECM connectors and the customer connector.
Illustration 18
g01151333 Inspect” for the correct torque values.
P2 ECM connector
D. Check the harness and wiring for abrasion and
(P2-2) +5 V pressure sensor supply
(P2-3) Pressure sensor return for pinch points from each pressure sensor back
(P2-41) +5 V oil pressure sensor supply to the ECM.
(P2-42) Oil pressure sensor return
Expected Result:
All connectors, pins and sockets are completely

are free of corrosion, of abrasion and of pinch points.
Results:

• Not OK
Repair: Perform the following repair:
Repair the connectors or wiring and/or replace

the connectors or wiring. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled.
STOP.
130 RENR1367-11
Test Step 2. Check for Active Diagnostic • Injection actuation pressure sensor
Codes
C. Turn the keyswitch to the ON position.
A. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector. Refer to Note: Be sure to wiggle the harness during the
Troubleshooting, “Electronic Service Tools”. following measurements in order to reveal an
intermittent condition.
B. Turn the ignition key switch to the ON position.
D. Measure the voltage between terminals A and B
C. Monitor the “Active Diagnostic Code” screen of at each sensor connector on the engine harness.
Cat ET. Wait at least 15 seconds in order for the
diagnostic codes to become active. Check and Expected Result:
record active diagnostic codes.
Each voltage measurement is 5.0 ± 0.2 VDC.
Look for these codes:
Results:
• 232-03
• OK – Each voltage measurement is 5.0 ± 0.2 VDC.
• 232-04 The sensors are receiving the correct voltage.
Expected Result: Repair: Connect all of the sensor connectors.

Clear all diagnostic codes. Check the engine
One of the above codes is active. again for active diagnostic codes. If the problem is
intermittent, refer to Troubleshooting, “Electrical
Results: Connectors - Inspect”.
• Active 232-03 code – A 232-03 diagnostic code is STOP.

active. Proceed to Test Step 3.
• Not OK – At least one voltage measurement is not
• Active 232-04 code – A 232-04 diagnostic code is 5.0 ± 0.2 VDC. There is a problem with the wiring
active. Proceed to Test Step 5. or with the ECM. Proceed to Test Step 5.
• No active codes – None of the above codes are Test Step 4. Disconnect the +5 V Pressure
active. Sensors and Check for Active Diagnostic
Codes
Repair: If any of the above codes are logged
and the engine is not running properly, refer to A. Disconnect the following sensors one at a time.
Troubleshooting, “Troubleshooting Without a Wait for 15 seconds after you disconnect each
Diagnostic Code”. sensor. Check for the active 232-04 diagnostic
code again.
If the engine is running properly at this time, there
may be an intermittent problem in a harness • Boost pressure sensor
that is causing the codes to be logged. Refer to
Troubleshooting, “Electrical Connectors - Inspect”. • Atmospheric pressure sensor (specific ratings
only)
STOP.
Test Step 3. Check the Voltage on the +5
V Supply Wire • Injection actuation pressure sensor
A. Turn the keyswitch to the OFF position. Expected Result:
B. Disconnect the harness connectors for the The 232-04 diagnostic code deactivates when a
following sensors: particular sensor is disconnected.
• Boost pressure sensor Results:
• Atmospheric pressure sensor (specific ratings • OK – The 232-04 diagnostic code deactivates
only) when a particular sensor is disconnected.

RENR1367-11 131
Repair: Connect the suspect sensor. If the code Repair: Repair the wire and/or the connector,
returns, replace the sensor. when possible. Replace parts, if necessary. Verify
that the problem is resolved.
Connect all of the connectors. Verify that the
problem is resolved. STOP.
STOP. Test Step 6. Check the +5 V Supply and

the Sensor Common for an Open Circuit
• Not OK – The 232-04 diagnostic code remains
after all of the sensors are disconnected. Leave A. Install a wire jumper between terminals P2-2 (+5
the sensors disconnected. Proceed to Test Step 5. V pressure sensor supply) and P2-3 (pressure
sensor return).
Test Step 5. Check the +5 V Supply Wire
for a Short B. Install a wire jumper between terminals P2-41
(+5 V oil pressure sensor supply) and P1-42 (oil
A. Turn the keyswitch to the OFF position. pressure sensor return).
B. Disconnect the J2/P2 ECM connector. Disconnect Note: Wiggle the harness during the following
the J1/P1 ECM connector. measurements in order to reveal any intermittent
short condition.
C. Verify that all of the pressure sensors are
disconnected. C. Measure the resistance between terminals A and
B at the harness connector for each pressure
Note: Wiggle the harness during the following sensor.
measurements in order to reveal an intermittent
condition. Expected Result:
D. Check for a short circuit in the harness. Each resistance measurement is less than five Ohms.
a. Measure the resistance between terminal P2-2 Results:

(+5 V pressure sensor supply) and all of the
other terminals on the P1 ECM connector and • OK – Each measurement is less than five Ohms.
the P2 ECM connector. There is no open circuit. Proceed to Test Step 7.
b. Measure the resistance between terminal • Not OK – At least one resistance measurement is
P2-41 (+5 V oil pressure sensor supply) and all greater than five Ohms. The +5 V supply wire or
of the other terminals on the P1 ECM connector the return wire has an open circuit. There may be a
and the P2 ECM connector. problem in a connector.
E. Measure the resistance between terminal P2-2 Repair: Repair the wire and/or the connector,
and the engine ground. Also, measure the when possible. Replace parts, if necessary. Verify
resistance between terminal P2-41 and the engine that the problem is resolved.
ground.
STOP.
Expected Result:
Test Step 7. Check the +5 V Supply at the
Each resistance measurement indicates an open ECM
circuit.
A. Remove terminal P2-2 (+5 V pressure sensor
Results: supply) from the ECM connector. Install a wire
jumper with socket terminals on both ends into
• OK – Each resistance measurement indicates an P2-2.
open circuit. Proceed to Test Step 6.
B. Remove terminal P2-41 (+5 V oil pressure sensor
• Not OK – At least one of the resistance supply) from the ECM connector. Install a wire
measurements does not indicate an open circuit. jumper with socket terminals on both ends into
A +5 V supply wire has a short circuit that is in the P2-41.
harness. There may be a problem with a connector.
C. Connect ECM connectors J2/P2.
D. Turn the keyswitch to the ON position.

132 RENR1367-11
E. Measure the voltage between the wire jumper in Accelerator Pedal Position Sensor
P2-2 and the engine ground.
The accelerator pedal position sensor is used to
F. Measure the voltage between the wire jumper in provide a throttle position signal to the Engine
P2-41 and the engine ground. Control Module (ECM). Sensor output is a constant
frequency signal with a pulse width that varies with
G. Turn the keyswitch to the OFF position. the pedal position. This output signal is referred to
as either a duty cycle or a pulse width modulated
H. Restore both wires to the original configuration. signal (PWM) and this output signal is expressed as
a percentage between 3 and 100 percent.
Expected Result:
The accelerator pedal position sensor is attached
Both voltage measurements are 5.0 ± 0.2 VDC. directly to the accelerator pedal assembly. The
accelerator pedal position sensor requires no
Results: adjustment.
• OK – Both voltage measurements are 5.0 ± 0.2 The accelerator pedal position sensor will produce
VDC. The ECM is OK. a duty cycle of 10 to 22 percent at low idle and 75
to 90 percent when the accelerator pedal is fully
Repair: Clear all diagnostic codes. Check for active depressed. The percent of duty cycle is translated
diagnostic codes. There may be an intermittent in the ECM into an accelerator pedal position of 3
electrical problem. If the problem is intermittent, to 100 percent.
refer to Troubleshooting, “Electrical Connectors
- Inspect”. The accelerator pedal position sensor is powered by
the ECM supply voltage (+8 VDC) from connector
STOP. P1-4 to terminal “A” of the accelerator pedal position
sensor connector. The accelerator pedal position
• Not OK – At least one voltage measurement is not sensor can be replaced separately from the pedal
5.0 ± 0.2 VDC. The ECM is not operating correctly. assembly. An incorrectly calibrated pedal assembly
can not be adjusted. The entire pedal assembly must
Repair: Replace the ECM. Refer to be replaced.
Troubleshooting, “Replacing the ECM”.
If the vehicle is using the ECM dedicated PTO
STOP. functions, the accelerator pedal position sensor will
be ignored while the engine is in PTO mode and the
“PTO Configuration” is programmed to one of the
i02336386
following parameters:
Accelerator Pedal (Throttle)
• Remote switches
Position Sensor Circuit - Test
• Remote throttle
SMCS Code: 1913-038
Note: In the cab switches configuration, the cab
System Operation Description: accelerator pedal can be used in order to control
the engine rpm for the PTO operation. The cab
Use this procedure under the following situation: accelerator pedal can also be ignored in the “Cab
Switches” PTO configuration. Programming of
Use this procedure if any of the following diagnostic customer parameters is required in order to ignore
codes are indicated: the cab accelerator pedal in the “Cab switches”
configuration.
• 91-08 Throttle position invalid (32)
The ECM is in PTO mode if the “PTO On/Off Switch”
• 91-13 Throttle position out of calibration (28) is on. This can be checked with Caterpillar Electronic
Technician (ET). Refer to Troubleshooting, “PTO
• 41-03 8 Volt supply voltage high (21) Switch Circuit - Test” for testing if the PTO is being
used.
• 41-04 8 Volt supply voltage low (21)
Also, use this procedure if the accelerator pedal
position sensor is suspected of improper operation.
RENR1367-11 133
g00642016
Illustration 20
This is a typical schematic for cab accelerator pedal position sensor.
The return wire may be connected to P1-3, P1-5, or P1-18.

with the accelerator pedal position sensor:
• P1-3
• P1-4
• P1-5
• P1-66
C. Check the ECM connector (allen head screw)
for the proper torque. Refer to Troubleshooting,

pinch points from the accelerator pedal position
sensor to the ECM.
Expected Result:

are free of corrosion, of abrasion or of pinch points.
Results:

• Not OK
Illustration 21
g01150754 Repair the connectors or wiring and/or replace
Pin locations for ECM connector
(P1-3) Input sensor connectors are completely coupled.
(P1-4) + 8V
(P1-5) “Accelerator pedal sensor/switch sensor”
and Wiring STOP.
A. Thoroughly inspect ECM vehicle harness Test Step 2. Check for Active Diagnostic
connector J1/P1, the firewall bulkhead connector Codes
and the accelerator pedal position sensor
connector. Refer to Troubleshooting, “Electrical A. Connect Cat ET to the data link connector.
Connectors - Inspect” for details.
134 RENR1367-11
C. Monitor the active diagnostic code screen on Cat Expected Result:

ET. Check and record active diagnostic codes.
The duty cycle is between 10 and 22 percent with the
Note: When the ECM automatically calibrates new accelerator pedal assembly in the Low Idle position,
duty cycle values for the low idle throttle position and and the duty cycle is between 75 and 90 percent
the high idle throttle position the ECM assumes 22 with the accelerator pedal assembly in the High Idle
percent duty cycle at low idle and 75 percent duty position.
cycle at high idle. As a result, you may notice that
the throttle position status reaches 100 percent well Results:
before the accelerator pedal is fully depressed. This
is normal. After some cycling of the accelerator pedal • OK – The accelerator pedal position sensor is
to the high idle position, the ECM will adjust the operating correctly. Proceed to Test Step 6.
calibration automatically. The ECM will adjust the
calibration automatically provided that the high idle • Not OK – The accelerator pedal position sensor
stop position is within the 75 to 90 percent duty cycle circuit is not operating correctly. Proceed to Test
range, and the low idle is in the 10 to 22 percent duty Step 4.
cycle range. During normal operation, you may also
notice that more movement of the accelerator pedal Test Step 4. Check the Supply Voltage
is required for the throttle position status to increase at the Sensor for the Accelerator Pedal
above three percent. You may also observe that the Position Sensor
status reaches the 100 percent value prior to the
limit of the high idle position. This is done in order A. Turn the ignition key switch to the OFF/RESET
to ensure that the throttle reaches these two critical position.
points for engine operation.
B. Install a breakout T with three terminals at the
Expected Result: accelerator pedal position sensor connector
J403/P403.
Result 1 Diagnostic Code 91-08 or 91-13 is active.
Result 2 Diagnostic Code 41-03 or 41-04 is active.
D. Measure the voltage at terminal “A” (+8 V) with
Result 3 There are no active diagnostic codes that reference to terminal “B” (accelerator/switch
are related to the accelerator pedal position sensor sensor common).
circuit at this time, but a problem is suspected with
operation of the accelerator pedal position sensor Expected Result:
circuit.
The measured voltage is between 7.5 VDC and 8.5
Results: VDC for the pedal mounted throttle position sensor
that is used in the cab.
• Result 1 – Proceed to Test Step 3.
Results:
• Not OK – The sensor is not receiving the correct
Test Step 3. Check the Duty Cycle of the voltage. Proceed to Test Step 5.
Accelerator Pedal Position Sensor
Test Step 5. Monitor Cat ET while the
A. Verify that the ignition key switch is in the ON Accelerator Pedal Position Sensor is
position. Being Disconnected
B. Monitor the duty cycle of the throttle sensor on Cat A. Access the active diagnostic code screen on Cat
ET. Access the following display screens in order: ET. Ensure that one of the following diagnostic
code is active before proceeding:
• “Service”
• 41-03 (21)
• “Calibrations”
• 41-04 (21)
• “Monitor Throttle Position Sensor”
RENR1367-11 135
B. Monitor the active diagnostic code screen while B. Start the engine. While the “Throttle Position”
the accelerator pedal position sensor is being status is being monitored on Cat ET, depress the
disconnected and reconnected. accelerator pedal and release the accelerator
pedal. The “Throttle Position” status and the
Expected Result: engine should respond to the change in the
accelerator pedal position.
One of the following diagnostic codes is still active
after the accelerator pedal position sensor has been C. Go to the “System Troubleshooting Settings”
disconnected: portion of Cat ET and turn off the “Power Train
Data Link”.
• 41-03 (21)
D. While the “Throttle Position” status is being
• 41-04 (21) monitored, depress the accelerator pedal and
release the accelerator pedal. Also depress the
Results: accelerator pedal and release the accelerator
pedal while the engine response is being
• OK – Ensure that the accelerator pedal position monitored.
sensor has been reconnected before continuing.
Proceed to Test Step 7. Expected Result:
• Not OK The “Throttle Position” status and the engine should

respond to the change in the accelerator pedal
Repair: Perform the following diagnostic position.
procedure:
Result 1 The cab accelerator functions properly.
Temporarily install another accelerator pedal
position sensor. Use Cat ET to check for an active Result 2 The throttle response is limited by a power
+8 V diagnostic code. Replace the accelerator train data link message.
pedal position sensor if both of the following
conditions occur: Result 3 The PTO limits the throttle response.
• The problem is corrected with the new Results:

accelerator pedal position sensor.
• Result 1 – The accelerator pedal position sensor is
• The problem returns after the old accelerator operating correctly. Continue troubleshooting until
pedal position sensor has been reconnected. the original condition is resolved. STOP.
STOP. • Result 2 – If the engine responds with the “Power

Train Data Link” in a disabled condition and the
Test Step 6. Check the Status of the engine does not respond with the “Power Train
PTO On/Off Switch and the Status of the Data Link” in an enabled condition, a component
Power Train Data Link with Cat ET of the “Power Train Data Link” is causing the
response problem of the accelerator pedal position
A. Check the status of the “PTO ON/OFF Switch” on sensor. Send the truck to the vehicle manufacturer
Cat ET in order to verify that the “PTO ON/OFF in order to repair the faulty component of the
Switch” is off. The PTO mode may cause the ECM “Power Train Data Link”. STOP.
to ignore the accelerator pedal position sensor if
the “PTO Configuration” is programmed to one of • Result 3 – The ECM is operating in PTO mode.
the following parameters:
Repair: If the PTO should not be active, refer to the
• Remote switches following diagnostic procedure:Troubleshooting,
“PTO Switch Circuit - Test”
• Remote throttle
STOP.
• Cab switches
Test Step 7. Disconnect the Power Supply
Note: If the “PTO Configuration” is programmed to Connections for the Accelerator Pedal
“Cab Switches” and the “PTO Cab Controls RPM Position Sensor at the ECM
Limit” is programmed to “Low Idle”, the PTO mode
may cause the ECM to ignore the accelerator pedal A. Turn the ignition key switch to the OFF/RESET
position sensor. This will occur when the “PTO position.
ON/OFF Switch” is in the ON position.
136 RENR1367-11
B. Remove P1-4 (+8 V) and remove P1-5 There is a problem in the wiring between the
(accelerator/switch sensor common) from vehicle ECM and the accelerator pedal position sensor.
harness connector P1. Disconnect ECM vehicle While active diagnostic codes are being monitored,
harness connector J1/P1, if necessary. connect the removed wires one at a time in order
to verify that the active diagnostic codes reappear.
C. Reconnect ECM connector J1/P1. First connect P1-5 and then connect P1-4. This
procedure is used to find the wire that is causing
D. Turn the ignition key switch to the ON position. the problem. Repair the wire or replace the wire,
as required. Verify that the repair eliminates the
E. Use Cat ET to check for active diagnostic codes. problem.
Expected Result: STOP.
One of the following diagnostic codes is still active Test Step 8. Check the Duty Cycle of the
after the terminals for sensor power have been Accelerator Pedal Position Sensor at the
disconnected: Sensor
• 41-03 (21) Note: Performing certain steps within this procedure
requires the use of a multimeter that is capable of
• 41-04 (21) measuring a PWM duty cycle.
Results: A. Turn the ignition key switch to the OFF/RESET

position.
• OK
B. Remove the signal wire for the accelerator pedal
Repair: Perform the following repair: position sensor (terminal “C”) from P403. This is
the vehicle harness side of the accelerator pedal
Check the battery voltage from P1-51 & 53 position sensor connector.
(unswitched +battery) to P1-65 & 67 (-battery). The
measured voltage should be in one of the following C. Install a breakout T with three terminals at the
ranges: accelerator pedal position sensor connector
J403/P403.
• For 12 volt systems, the voltage should be
between 11.0 VDC and 13.5 VDC. D. Connect the multimeter probes to terminal “C”
(accelerator pedal position) and terminal “B”
• For 24 volt systems, the voltage should be (accelerator/switch sensor common) of the
between 22.0 VDC and 27.0 VDC. breakout T.
If the battery voltage is correct, temporarily connect E. Turn the ignition key switch to the ON position.
a test ECM. Use Cat ET to verify that the active
diagnostic code is resolved. If the problem is F. While the duty cycle is being monitored on the
corrected with the test ECM, reconnect the suspect multimeter, depress the accelerator pedal and
ECM. Verify that the active diagnostic code returns. release the accelerator pedal.
If the active diagnostic code returns with the
suspect ECM, replace the ECM. Expected Result:
STOP. The duty cycle is between 10 and 22 percent with the

accelerator pedal assembly in the Low Idle position,
• Not OK and the duty cycle is between 75 and 90 percent
with the accelerator pedal assembly in the High Idle
Repair: Perform the following repair: position.
Results:
• OK – Reinsert the wire (terminal “C”) into the

vehicle harness connector. The accelerator pedal
position sensor is working correctly. Proceed to
Test Step 9.
RENR1367-11 137
• Not OK – Leave the PWM probe connected to the • Not OK – There is a problem with signal wire for
breakout T. Insert the wire (terminal “C”) into the the accelerator pedal position sensor in the vehicle
vehicle harness connector. The accelerator pedal wiring harness. Proceed to Test Step 11.
position sensor or the accelerator pedal assembly
is faulty. Proceed to Test Step 10. Test Step 10. Remove the Accelerator
Pedal Position Sensor from the
Test Step 9. Check the Duty Cycle of the Accelerator Pedal Assembly
Accelerator Pedal Position Sensor at the
ECM A. Verify that the ignition key switch is in the
OFF/RESET position.
Note: Performing certain steps within this procedure
requires the use of a multimeter that is capable of B. Remove the accelerator pedal position sensor
measuring a PWM duty cycle. from the accelerator pedal assembly. Note sensor
orientation in the accelerator pedal assembly,
A. Turn the ignition key switch to the OFF/RESET and the sensor pigtail routing prior to sensor
position. removal. Thoroughly inspect the pigtail for signs
of abrasion.
B. Remove the wire for the accelerator pedal position
sensor P1:66. You may be required to disconnect C. Connect the multimeter that is capable of
ECM connector P1 in order to remove the terminal measuring a PWM duty cycle to terminal “C” of
for the signal input of the accelerator pedal the breakout T.
position sensor.
D. Turn the ignition key switch to the ON position.
C. Connect the multimeter probes between the
removed wire and P1-5 (accelerator/switch sensor E. Display the duty cycle output of the accelerator
common). pedal position sensor while the sensor slot is
released. Use a screwdriver to advance the
D. Reconnect ECM connector P1 to the ECM. sensor slot to the maximum position. Refer to
Illustration 22.
E. Turn the ignition key switch to the ON position.
When the sensor is removed from the accelerator
F. Use the multimeter in order to display the duty pedal assembly, the following diagnostic code
cycle output of the accelerator pedal position may be generated:
sensor. While the duty cycle output of the
accelerator pedal position sensor is being • 91-13 (28)
monitored on the multimeter, move the accelerator
assembly from the Low Idle position to the High This is normal. The diagnostic code should
Idle position. Record the results. disappear when the sensor is properly assembled
back into the accelerator pedal assembly.
G. Turn the ignition key switch to the OFF/RESET
position.
H. Insert P1-66 into the ECM vehicle connector P1.
Expected Result:

accelerator pedal assembly in the Low Idle position,
and the duty cycle is between 75 and 90 percent
with the accelerator pedal assembly in the High Idle
position.
Results:
• OK – A good signal from the accelerator pedal

position sensor is reaching the ECM. Verify that
the ECM is receiving the proper battery voltage. If
the ECM is receiving the proper battery voltage,
temporarily connect a test ECM and verify that the
problem is resolved. If the problem disappears with
the test ECM, reconnect the suspect ECM. If the
problem returns with the suspect ECM, replace the
ECM. STOP.
138 RENR1367-11
g00706977
Illustration 22
Accelerator pedal assembly
Expected Result: • Not OK – The accelerator pedal position sensor

is faulty. Check the accelerator pedal assembly
When the sensor is removed from the accelerator in order to ensure that the accelerator pedal
pedal assembly and the sensor slot is released, the assembly is not causing damage to the sensor. If
duty cycle is 10 percent or less. When the sensor slot the accelerator pedal assembly is causing damage
is moved to the maximum position, the duty cycle to the sensor, refer to the OEM dealer for correct
increases to 90 percent or more. replacement of the accelerator pedal assembly.
If the accelerator pedal assembly appears OK,
Results: replace the accelerator pedal position sensor.
STOP.
• OK – The accelerator pedal position sensor is
working correctly. Clear any diagnostic codes that Test Step 11. Route the Supply Bypass
were caused by performing this test procedure. Wires to the Accelerator Pedal Position
Refer to the OEM dealer for correct replacement of Sensor
the accelerator pedal assembly. STOP.
A. Turn the ignition key switch to the OFF/RESET
position.
RENR1367-11 139
B. Remove the signal wire for the accelerator pedal This procedure can also be used to troubleshoot the
position sensor from the ECM connector P1-66. following components:
C. Remove terminal “C” (accelerator pedal position) • The air inlet heater
from the accelerator pedal position sensor
connector. • The air inlet heater relay
D. Route new wiring from the ECM to the accelerator • The lamp for the air inlet heater
pedal position sensor.
The following background information is related
E. Turn the ignition key switch to the ON position. to the following procedure:
F. Check the duty cycle of the accelerator pedal The air inlet heater is used in order to improve the
position sensor on Cat ET while the accelerator engines’ ability to start when the engine is cold. The
pedal assembly is being moved over the full range. use of an air inlet heater during start-up also reduces
the amount of white smoke emissions.
Expected Result:
The Engine Control Module (ECM) controls the
The duty cycle is between 10 and 22 percent with the operation of the air inlet heater relay. The air inlet
accelerator pedal assembly in the Low Idle position, heater relay provides battery voltage to the heater
and the duty cycle is between 75 and 90 percent element. The ECM also controls the operation of the
with the accelerator pedal assembly in the High Idle lamp for the air inlet heater.
position.
Three different cycle times are used by the ECM to
Results: control the air inlet heater:
• OK • ECM powerup and preheat cycle

Repair: Perform the following repair: • Engine cranking
The wiring from the ECM to the accelerator pedal • Engine on (running)
position sensor appears faulty. Permanently install
new wiring. The cycle time is determined by the following items:
Verify that the repair eliminates the problem. • Engine parameters

STOP. • Vehicle speed
• Not OK – Double check the wiring, the ECM • Service brake
vehicle harness connector J1/P1 and the sensor
connector. If a problem still exists, restart the test Effects of Vehicle Speed on the Operation of the
procedure. STOP. Air Inlet Heater and on the Operation of the Brake
Pedal Position.
i02300322
The air inlet heater is turned off when the brake pedal
Air Inlet Heater Circuit - Test is depressed and the vehicle speed is equal to 8 km/h
(5 mph) or greater than 8 km/h (5 mph).
SMCS Code: 1090-038
If a diagnostic code for the vehicle speed sensor is
System Operation Description: active, the ECM will assume that the vehicle speed is
above 8 km/h (5 mph). If an active diagnostic code is
Use this procedure under the following situation: triggered for the vehicle speed sensor, the ECM will
disable the heater when the brakes are applied.
Use this procedure to troubleshoot any suspect
problems with the air inlet heater circuit. The ECM Powerup and Preheat Cycle.
This procedure covers the following diagnostic codes: The temperatures that are indicated below are not
conversions. These temperatures are representations
of the sum of two variables. The following procedure
• 70-05 Inlet Air Heater current low explains the process for calculating the temperatures
that are shown in °F:
• 70-06 Inlet Air Heater current high
140 RENR1367-11
• Convert the reading for the coolant temperature Note: MAY99 and newer ECM software use the boost
from °C to °F. pressure reading to determine atmospheric pressure.
This will indicate if the engine is operating above
• Convert the reading for the inlet manifold 1678 m (5505 ft). If the altitude is above 1678 m
temperature from °C to °F. (5505 ft), the temperature is adjusted in order to
compensate for the extreme altitude. The combined
• Add the two conversions together in order to arrive temperature is used in order to determine the
at the correct conversion for the sum in °F. operation of the air inlet heater. Refer to Illustration
23 for more details.
The lamp for the air inlet heater should turn on for
a minimum of two seconds when the ECM is first Active Open Circuit or Short Circuit Diagnostic
powered up. The lamp should turn on regardless of Codes
the coolant temperature.
The air inlet heater will turn on if the coolant
The air inlet heater and the lamp for the air inlet temperature sensor has an active open circuit
heater should turn on. The air inlet heater and the diagnostic code or an active short circuit diagnostic
lamp for the air inlet heater should turn off when the code and the inlet manifold air temperature is less
cycle is complete. than 10 °C (50 °F).
The ECM will control the air inlet heater during engine The air inlet heater will turn on if the air temperature
cranking if the operator starts the engine before the sensor for the inlet manifold has an active open circuit
end of the heating cycle. diagnostic code or an active short circuit diagnostic
code and the coolant temperature is less than 40 °C
Engine Cranking (104 °F).
The operation of the air inlet heater is determined Note: The coolant temperature and the inlet manifold
by the coolant temperature and the inlet manifold temperature are measured in degrees Celsius.
air temperature while the engine is cranking. If the Caterpillar Electronic Technician (ET) can display
combined temperature is less than 25 °C or 109 the coolant temperature and the inlet manifold
°F, the air inlet heater will turn on when the engine temperature in °C or in °F. The ECM adds the coolant
is cranking. The heater will then remain on for the temperature and the inlet manifold temperature
duration of the crank cycle. The air inlet heater will together. Then, the ECM uses the sum of the coolant
reactivate for 30 seconds if the engine fails to start. temperature and the air inlet temperature in order to
determine if the air inlet heater should be on or off.
Engine On (Running) Illustration 23 is a visual aid for troubleshooting the
operation of the air inlet heater.
The operation of the air inlet heater is determined
by the coolant temperature and the inlet manifold
air temperature after the engine has started. If the
combined temperature is less than 25°C or 109 °F,
the engine start cycle begins. The engine start cycle
has two segments:
• Continuous mode
• On/off cycling mode
The continuous mode lasts for a maximum of 7
minutes. The on/off cycling mode can last for a
maximum of 13 minutes. The air inlet heater is turned
on and the air inlet heater is turned off for ten seconds
during the on/off cycling mode. The air inlet heater
will turn off when the sum of the coolant temperature
and the inlet manifold air temperature exceeds 35
degrees Celsius or 127 degrees Fahrenheit.
RENR1367-11 141
g01151814
Illustration 23
Operational chart for the air inlet heater
142 RENR1367-11

g01151831
Illustration 25
(1) J501/P501 Air inlet heater relay connector
(2) Air inlet heater relay
g01117616 (3) +Battery terminal for the heating element
Illustration 24
(4) -Battery for the heating element
Schematic of the air inlet heater (5) Heating element for the air inlet heater
(6) J1/P1 ECM connectors
A. Thoroughly inspect the connectors (1) and (6).

Also inspect the connections at locations (2),
(3), and (4). Visually inspect the condition of the
heating element (5). Refer to Troubleshooting,
RENR1367-11 143
• Not OK

STOP.
Test Step 2. Check for Active Diagnostic

Codes
(ET) to the service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”.
B. Turn the keyswitch to the ON position.
C. Observe the “Active Diagnostic” screen on Cat ET.

Wait at least 15 seconds so that any codes may
become active. Look for these codes:
• 70-05
• 70-06
Expected Result:
One of the above codes is active.
Illustration 26
g01117624 Results:
P2 ECM connector
• Active 70-05 code – A 70-05 diagnostic code is
(P2-8) Air inlet heater relay active. Proceed to Test Step 3.
B. Perform a 45 N (10 lb) pull test on each of the • Active 70-06 code – A 70-06 diagnostic code is
wires that are associated with the air inlet heater. active. Proceed to Test Step 6.
C. Check the torque of the allen head screws for • No active codes – None of the above codes are
the ECM connectors. Refer to Troubleshooting, active. There may be a problem with the high
“Electrical Connectors - Inspect” for the correct power circuit. Proceed to Test Step 7.
torque value.
D. Check the harness and wiring for abrasion and for

pinch points from the air inlet heater relay back
to the ECM and from the air inlet heater back to
the battery.
Expected Result:
All connectors, pins and sockets should be

completely coupled and/or inserted and the harness
and wiring should be free of corrosion, of abrasion
and of pinch points.
Results:

144 RENR1367-11
Test Step 3. Check for an Open Circuit in Test Step 4. Check the Wiring Between
the Relay’s Control Circuit the ECM and the Relay’s Control Circuit
A. Disconnect the J2/P2 connectors and the
J501/P501 connectors.
B. Measure the resistance of the wire that is between

terminal P501-2 and the relay control.
Note: Be sure to wiggle the harness during the

following measurement in order to reveal an
C. Measure the resistance between terminals P2-8

and P501-2.
Expected Result:
g01118589
Illustration 27
Small terminals for the relay’s control circuit (typical example) The resistance measurements are less than five
Ohms.
A. Disconnect the wires from the small terminals for
the relay’s control circuit. Results:
B. Install a test lamp across the wires. • OK – The resistance measurement is less than
five Ohms. The wiring from the ECM to the air
C. Start the “Air Inlet Heater Override” on Cat ET and inlet heater relay is OK. Connect the J501/P501
observe the test lamp. connectors. Proceed to Test Step 5.
Note: Do not leave the “Air Inlet Heater Override” • Not OK – At least one of the resistance
on. This prevents unnecessary cycling of the air inlet measurements is more than five Ohms. There is
heater and the battery from discharging. The “Air a problem with the wiring between the ECM and
Inlet Heater Override” has a one minute timer that the air inlet heater relay. There may be a problem
disables the test when the time expires. with a connector.
D. Stop the “Air Inlet Heater Override” and turn the Repair: Repair the wire and/or the connector,
keyswitch to the OFF position. when possible. Replace parts, if necessary. Verify
Expected Result:
STOP.
The test lamp turned on while the override was active.
Test Step 5. Check for Battery Voltage for
Results: the Relay’s Control Circuit
• OK – The test lamp turned on while the override Note: Be sure to wiggle the harness during the
was active. The open circuit is in the relay. following measurements in order to reveal an
Repair: Replace the air inlet heater relay. Clear
any diagnostic codes. Verify that the problem is A. Locate the +Battery connection at the small
resolved. terminals of the relay control. Connect a test lamp
between the wire for the +Battery and the engine
STOP. ground stud.
• Not OK – The test lamp did not turn on while the B. Disconnect the J501/P501 connectors. Connect a
override was active. Leave the wires disconnected test lamp between terminal P501-1 and the engine
from the small terminals of the relay. Proceed to ground stud.
Test Step 4.
C. Disconnect the J648/P648 connectors. Connect
a test lamp between terminal P648-A and the
engine ground stud.
RENR1367-11 145
The test lamp illuminates for each voltage check. The short circuit diagnostic code (70-06) changed
to an open circuit diagnostic code (70-05) when the
Results: wires to the relay control were disconnected.
• OK – The test lamp illuminated for each voltage Results:

check.
• OK – The short circuit diagnostic code (70-06)
Repair: The relay’s control circuit is correctly changed to an open circuit diagnostic code (70-05)
receiving an unswitched +Battery voltage. Connect when the wires to the relay were disconnected.
the connectors for the air inlet heater relay. Connect The short circuit is in the relay.
the wires to the terminals for the relay control.
Replace the ECM. Refer to Troubleshooting, Repair: Replace the relay. Clear the diagnostic
“Replacing the ECM”. codes.
STOP. Verify that the problem is resolved.
• Not OK – The test lamp did not illuminate for at STOP.

least one voltage check.
• Not OK – The short circuit diagnostic code
Repair: There is a problem with the wiring between (70-06) remained when the wires to the relay were
the +Battery and the air inlet heater relay. There disconnected. There is a problem in the wiring
may be a problem with a connector. Check for a between the ECM and the relay. There may be a
tripped circuit breaker. Repair the wiring, and/or problem with a connector.
the connector, when possible. Replace parts,
if necessary. Restore the wiring to the original Repair: Repair the wire and/or the connector,
configuration. Verify that the problem is resolved. when possible. Replace parts, if necessary. Verify
STOP.
STOP.
Test Step 6. Check for a Short Circuit in
the Wiring for the Relay’s Control Circuit Test Step 7. Check for Battery Supply
Voltage at the Relay’s Secondary Circuit
A. Connect a test lamp between the +Battery side of
the air inlet heater relay and the engine ground.
Expected Result:
The test lamp turns on.
Results:
• OK – Battery supply voltage is reaching the relay’s

secondary circuit. Proceed to Test Step 8.
g01118589
• Not OK – The test lamp does not turn on. Battery
Illustration 28 voltage is not reaching the relay’s secondary
Small terminals for the relay’s control circuit (typical example) circuit.
A. Disconnect the wires from the small terminals for Repair: There is an open circuit in the wiring
the air inlet heater relay. between the battery and the relay. There may be
a problem with a connection. There may be a
B. Turn the keyswitch to the ON position. problem with the circuit protection.
C. Observe the “Active Diagnostic” screen on Cat Check for a tripped circuit breaker. Repair the wire
ET. Wait at least 15 seconds so that any codes and/or the connection, when possible. Replace
may become active. parts, if necessary. Verify that the problem is
resolved.
D. Turn the keyswitch to the OFF position.
STOP.
146 RENR1367-11
Test Step 8. Check for Voltage Output at

the Relay’s Secondary Circuit
A. Connect a test lamp between the output terminal
of the air inlet heater relay and the engine ground.
Note: Observe the test lamp. The test lamp should

be off, since the relay is not energized. If the test
lamp is on, ensure that the test lamp is connected to
the output side of the relay.
B. Turn the keyswitch to the ON position.

g01152270
Illustration 29
C. Run the “Air Inlet Heater Override” on Cat ET and Left side engine view (typical example)
observe the test lamp. (7) Wiring between the relay and the heating element
(8) Grounding strap
Note: Do not leave the “Air Inlet Heater Override”
ON. This prevents unnecessary cycling of the air inlet B. Disconnect wire (7) from the air inlet heater relay
heater and the battery from discharging. The “Air and the heating element that is at the air inlet
Inlet Heater Override” has a one minute timer that manifold.
disables the test when the time expires.
C. Remove grounding strap (8) from the air inlet
D. Stop the “Air Inlet Heater Override” and turn the manifold and the engine ground stud.
keyswitch to the OFF position.
D. Measure the resistance of both wires.
Expected Result:
Expected Result:
The test lamp turned on when the “Air Inlet Heater
Override” was enabled. The measured resistance is less than five Ohms.
Results: Results:
• OK – The test lamp turned on when the “Air Inlet • OK – Both measurements are less than five Ohms.
Heater Override” was enabled. The air inlet heater
relay is operating correctly. Proceed to Test Step 9. Repair: The problem is with the heating element
for the air inlet heater. Replace the heating
• Not OK – The test lamp did not turn on when the element. Verify that the problem is resolved.
“Air Inlet Heater Override” was enabled.
STOP.
Repair: The relay’s secondary circuit is not passing
voltage through the secondary circuit. Replace the • Not OK
relay.
Repair: Repair the damaged wire. Verify that the
Verify that the problem is resolved. problem is resolved.
STOP. STOP.
Test Step 9. Check the Wiring Between

the Relay and the Heating Element and i02301166
Between the Heating Element and the ATA (SAE J1587 / J1708) Data
Engine Block
Link Circuit - Test
A. Turn the keyswitch to the OFF position.
SMCS Code: 1901-038
Use this procedure under the following situation:

RENR1367-11 147
Use this procedure if Caterpillar Electronic Technician

(ET) will not power up. Also, use this procedure if
Cat ET will not communicate with the Engine Control
Module (ECM) through the data link connector.

to this procedure:
The ATA data link (American Trucking Association)

is the standard for data link communications that is
used by the ECM to communicate with electronic
service tools. The SAE specification J1587 defines
the format of the messages and data that is being
communicated. The SAE specification J1708 defines
the hardware requirements and the protocol of the
serial communications. Some electronic dashboards
use this data link to receive information. Some
automatic transmissions also receive information
from this data link.
The ECM provides the following two terminals at the

J1 ECM connector for the ATA data link:
• Terminal 8 (J1587 Data Link Positive)

• Terminal 9 (J1587 Data Link Negative)
The vehicle OEM provides twisted pair wiring from
the ECM to the data link connector.
Remember that there are potentially several devices

that are installed in the vehicle and remember that
these devices are connected to the ATA data link at
one time. These devices include dash displays, trip
recorders and transmission controls. These devices
may cause problems with the data link. These
problems can disrupt communications to the ECM
and from the ECM.
Communication
When the keyswitch is in the OFF position, the ECM

may communicate with Cat ET. The communications
may be disrupted and the communications may
require frequent reconnection. In order to avoid this
problem, place the engine control in the ON mode
when Cat ET is being used.
Cat ET may indicate the following error message:
• The version of the ECM is not recognized and the

integrity of the changed parameters and displayed
data is not guaranteed.
This message will indicate that the latest version of

Cat ET has not been installed or this message will
indicate that the software in the ECM is newer than
the software for Cat ET.
148 RENR1367-11
g00650338
Illustration 30
Schematic for ATA Data Link with 6-pin connector

Connectors And the Wiring
g01146374
Illustration 31
B. Thoroughly inspect connector (1).
Also inspect the following electrical connectors:
• Cab data link connector

• Firewall bulkhead connector g01104200
Illustration 32
• Service tool connectors P1 ECM connector
(P1-8) J1587 Data Link +
• ATA data link (terminal 8 and terminal 9) in the (P1-9) J1587 Data Link −
connectors
Refer to Troubleshooting, “Electrical Connectors

-Inspect” for details.
RENR1367-11 149
g00650354
Illustration 33
Data link connectors
C. Perform a 45 N (10 lb) pull test on each of the Test Step 2. Determine the Nature of the
wires in the ECM connector that are associated Problem
with the ATA data link.
D. Check the allen head screw on each ECM
connector for the proper torque. Refer to B. Start the engine.
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque value. Expected Result:
E. Check the harness and wiring for abrasion and for The engine starts. Cat ET powers up and Cat ET
pinch points from the connector to the ECM. communicates without error.
Expected Result: Note: Check the display screen or check the

communication adapter display in order to determine
All connectors, pins and sockets are completely if Cat ET has powered up. Cat ET will display
coupled and/or inserted and the harness and wiring information that shows if the tool is receiving power.
are free of corrosion, of abrasion or of pinch points. If Cat ET or the communication adapter powers up,
the data link connector is receiving power.
Results:
Results:
• OK – The harness and connectors appear to be
OK. Proceed to Test Step 2. • OK – There is not a problem with the ATA data
link at this time. If an intermittent condition exists,
• Not OK – There is a problem with the connectors thoroughly inspect all wiring and connectors.
and/or wiring.
Repair: Perform the following diagnostic
Repair: Perform the following repair: procedure:
Repair the connectors or wiring and/or replace Troubleshooting, “Electrical Connectors - Inspect”
seals are properly in place and ensure that the STOP.
• Not OK – Cat ET displays an error message. The
Verify that the repair eliminates the problem. ECM is receiving battery power. Proceed to Test
Step 5.
STOP.
• Not OK – The engine cranks but the engine will
not start.
150 RENR1367-11
Repair: Perform the following diagnostic Test Step 4. Check Cat ET on Another
procedure: Engine
Troubleshooting, “Engine Cranks But Will Not A. If another engine is available with an ECM,
Start” connect ET to the other vehicle by using the same
cables.
STOP.
B. Turn the keyswitch to the ON position. Determine
• Not OK – The engine will not crank. if Cat ET communicates correctly with the other
engine.
procedure: C. If another engine is not available in the shop, find
a different set of the electronic service tool cables.
Troubleshooting, “Engine Will Not Crank” Ensure that the set of cables is a complete set.
STOP. D. Use the other cables or use new cables in order to

connect Cat ET to the data link connector.
• Not OK – Cat ET does not power up or the
communications adapter does not power up. E. Turn the keyswitch to the ON position.
Ensure that the ECM is receiving the correct
battery power. Proceed to Test Step 3. F. If changing cables allows Cat ET to communicate
properly, use the following procedure:
Test Step 3. Check the Battery Supply
Voltage to the Cab Data Link Connector a. Turn the keyswitch to the OFF position.
A. Turn the keyswitch to the ON position. b. Replace the pieces from the old set of cables
into the new set of cables that is able to
B. Use a multimeter in order to measure the voltage communicate with the ECM. Replace one cable
from the +Battery to the −Battery of the cab data at a time.
link connector.
c. Power Cat ET after each of the pieces is
Refer to Illustration 33. replaced. Use this method to find the faulty
piece.
Expected Result:
G. If changing cables does not allow Cat ET to
The voltage is between 11.0 and 13.5 VDC for a 12 communicate properly, connect another electronic
Volt system or between 22.0 and 27.0 VDC for a 24 service tool to the engine.
Volt system.
H. Turn the keyswitch to the ON position.
Results:
Expected Result:
• OK – The cab data link connector is currently
receiving the correct voltage. Proceed to Test Step Cat ET is communicating correctly with a different
4. engine. Cat ET will not communicate with the original
ECM.
• Not OK – The cab data link connector is not
receiving the correct voltage. Results:
Repair: Inspect the wiring and fuses to the • OK – Cat ET seems to be communicating
connector. Repair the wiring or batteries and/or correctly. Proceed to Test Step 5.
replace the wiring or batteries, as required.
Send the vehicle to the OEM dealer for repair, if • Not OK – Installing a different service tool allows
necessary. Verify that the repair eliminates the Cat ET to communicate correctly. The original
problem. electronic service tool is faulty.
Repair: Send the faulty electronic service tool for

repairs.
STOP.
STOP.
RENR1367-11 151
Test Step 5. Check the Battery Voltage at Repair: Perform the following diagnostic
the ECM procedure:

Battery Supply Circuit - Test”
STOP.
g01152362
Illustration 34
ECM breakout T-connector and terminal locations for ECM P1
(52) Unswitched +Battery
(65) -Battery
(67) -Battery
(70) Keyswitch
A. Turn the ignition key switch to the OFF position.
B. Ensure that Cat ET is connected to the data link

connector.
C. Disconnect the J1/P1 ECM connector and insert

a breakout T.
E. Measure the voltage between P1-52 (unswitched

+Battery) and P1-65 (− Battery).
F. Measure the voltage between P1-53 (unswitched

+Battery) and P1-67 (− Battery).
G. Measure the voltage between P1-70 (keyswitch)

and terminal P1-65 (− Battery). Measure the
voltage between P1-70 (switched +Battery) and
P1-67 (− Battery).
Expected Result:
The voltage is between 11.0 and 13.5 VDC for a 12

volt system or between 22.0 and 27.0 VDC for a 24
volt system.
Results:
• OK – The ECM is currently receiving the correct

voltage. Proceed to Test Step 6.
• Not OK – The ECM is not receiving the correct

voltage. Ensure that there is not an aftermarket
engine protection switch that is overriding battery
power to the ECM.
152 RENR1367-11
Test Step 6. Connect Cat ET Directly to

the ECM
g00741090
Illustration 35
Note: This bypass directly connects the circuit for the

keyswitch to the ECM. The ECM will remain powered
until the connection to the unswitched +Battery is
Batteries give off flammable fumes which can ex-
disconnected. Remove the 20 Amp fuse from the
plode.
in-line fuse holder to power down the ECM. Do not
connect the bypass to the battery posts without
To avoid injury or death, do not strike a match,
first removing the 20 Amp in-line fuse or do not
cause a spark, or smoke in the vicinity of a battery.
remove the bypass from the battery posts without
first removing the 20 Amp in-line fuse.
NOTICE
Do not connect the bypass harness to the battery until Expected Result:
the 20 Amp in-line fuse has been removed from the
+Battery line. If the fuse is not removed before con- Cat ET is operating correctly.
nection to the battery a spark may result.
Results:
A. Turn the keyswitch to the ON position. • OK – Cat ET is operating correctly.

B. Disconnect the J1/P1 (ECM connectors). Repair: Perform the following repair:
C. Install an electronic service tool power bypass There is a problem in the vehicle wiring, or another
cable. Connect a bypass harness to ECM device in the vehicle is causing problems on
connector J1. the data link. Either determine the device that is
causing the problem or send the vehicle to the
Refer to Illustration 35 for the bypass harness. OEM dealer for repair.
STOP.
RENR1367-11 153
• Not OK – Verify that the 20 Amp fuse in the bypass 7. Verify that the repair eliminates the problem.
harness of Cat ET is not open. A fuse that is open
is a blown fuse. Proceed to Test Step 7. STOP.
Test Step 7. Connect Cat ET and the ECM

to Another Battery i02375169
Change Oil Lamp Circuit - Test

SMCS Code: 7431-038
plode. System Operation Description:
To avoid injury or death, do not strike a match, Use this procedure under the following situation:
Use this procedure to determine if the circuit for the
change oil lamp is operating properly. There are no
NOTICE diagnostic codes for this circuit.
Do not connect the bypass harness to the battery un-
til all of the in-line fuses have been removed from the Output 1 can operate as a change oil lamp or as a
+Battery line. If the fuses are not removed before con- PTO switch on lamp. The parameter “Change Oil
nection to the battery a spark may result. Lamp” must be programmed to “J1/P1:30” in order to
use “Output 1” as a change oil lamp. The change oil
lamp illuminates when the engine oil change interval
A. Connect the battery wires from the bypass has been exceeded.
harness of Cat ET to a different battery that is not
on the vehicle. The following parameters determine when the Engine
Control Module (ECM) will illuminate the change oil
Expected Result: lamp.
Cat ET is operating correctly. • “Maintenance indicator mode”
Results:
• “PM1 interval”
• OK – The vehicle battery is causing the problem. • “PM1 engine oil capacity”
Repair: Perform the following diagnostic If “Maintenance Indicator Mode” is programmed
procedure: to “Manual - Distance” or “Manual - Hours”, the
parameter “PM1 Interval” must be programmed.
Troubleshooting, “Ignition Key Switch Circuit and If “Maintenance Indicator Mode” is programmed
Battery Supply Circuit - Test” to “Automatic - Distance” or “Automaitc - Hours”,
the parameter “PM1 Engine Oil Capacity” must be
STOP. programmed.
• Not OK Electrical Connections of the Lamp
Repair: Perform the following repair: One terminal of the lamp must be connected to
battery voltage through the vehicle wiring. The other
1. Temporarily connect a test ECM. terminal is connected to the ECM at the vehicle
harness connector J1/P1-30.
2. Remove all jumpers and replace all connectors.
The ECM provides a path to ground that will turn on
3. Recheck the system for active diagnostic codes. the lamp.
4. Repeat the test step. The following components can cause problems with
the circuit for the change oil lamp:
5. If the problem is resolved with the test ECM,
reconnect the suspect ECM. • Wiring or an electrical connector
6. If the problem returns with the suspect ECM,
• Lamp
replace the ECM.
• ECM
154 RENR1367-11
The most likely cause of a problem is the wiring or a

connector. The least likely cause is a problem with
the ECM.
g01152388
Illustration 36
Circuit schematic for the change oil lamp

g01152390
Illustration 38
P1 connector
(P1-30) Change oil lamp
(P1-52) Unswitched +Battery
(P1-65) -Battery
C. Perform a 45 N (10 lb) pull test on each of the

with the change oil lamp.
D. Check the allen head screw for the ECM

connectors for the proper torque. Refer to
for the correct torque value.
g01146374
Illustration 37
Left side engine view (typical example) E. Check the harness and wiring for abrasion and for
(1) J1/P1 ECM connectors pinch points from the sensor to the ECM.
B. Thoroughly inspect ECM vehicle harness Expected Result:

connector J1/P1, the firewall bulkhead connector,
and the terminals for the change oil lamp. All connectors, pins, and sockets are completely
Refer to Troubleshooting, “Electrical Connectors - are free of corrosion, of abrasion or of pinch points.
Inspect” for details.
Results:
• OK – The connectors and wiring appear to be OK.

Proceed to Test Step 2.
RENR1367-11 155
• Not OK – The connectors and/or wiring are in Expected Result:

need of repair.
Result 1 The change oil lamp turns on while the
Repair: Repair the connectors or wiring and/or jumper is connected. Also, the change oil lamp turns
replace the connectors or wiring. Ensure that all of off when the jumper is removed.
the seals are properly in place and ensure that the
connectors are completely coupled. Verify that the Result 2 The change oil lamp does not turn on while
repair eliminates the problem. the jumper is connected to both sockets.
STOP. Result 3 The change oil lamp remains on while the

ECM connector is disconnected.
Test Step 2. Check for Normal Operation
of the Change Oil Lamp Results:
A. Turn the keyswitch to the ON position. Monitor • Result 1 – The lamp turns on and off when the
the change oil lamp. The ECM will illuminate the ECM is bypassed. The circuit for the change oil
lamp for 5 seconds. lamp is OK. Proceed to Test Step 4.
B. Turn the keyswitch to the OFF position. • Result 2 – The change oil lamp does not illuminate
when the ECM is bypassed.
Expected Result:
Repair: The vehicle’s lamp circuit is not functioning
The change oil lamp illuminates for five seconds after properly. The lamp is probably burned out or there
the keyswitch is turned to the ON position. is a problem in the lamp circuit from the cab to the
ECM. Check if the circuit protection for the vehicle
Results: has been tripped. Repair the lamp circuit or send
the vehicle to the OEM dealer for repairs.
• OK – The change oil lamp is operating normally.
STOP.
Repair: There may be an intermittent problem with
the wiring and/or the connectors. Repair the lamp • Result 3 – The change oil lamp remains on while
circuit or send the vehicle to the OEM dealer for the J1/P1 ECM connectors are disconnected.
repairs.
Repair: The circuit between the ECM and the lamp
STOP. is shorted to chassis ground. Repair the circuit or
send the vehicle to the OEM dealer for repairs.
• Not OK – The lamp does not turn on. Proceed to
Test Step 3. STOP.
Test Step 3. Test the Change Oil Lamp Test Step 4. Check the Operation of the
Circuit ECM Output for the Change Oil Lamp
A. Fabricate a jumper wire that can be used to test A. Fabricate a jumper wire with a socket terminal on
the circuit. Crimp connector pins to each end of one end.
the jumper.
B. Remove terminal 30 (change oil lamp) from the P1
B. Disconnect the J1/P1 ECM connectors. connector. Insert the jumper wire (socket terminal)
into P1-30.
C. Insert the jumper into terminal P1-30 (change oil
lamp). C. Connect the J1/P1 ECM connector.
D. Insert the other end of the jumper wire into D. Connect one lead of a test lamp to the jumper
terminal P1-52 (-Battery). wire. Connect the other lead of the test lamp to
the positive terminal of the vehicle’s battery.
E. While the lamp is being watched, insert the jumper
wire and remove the jumper wire from terminal E. Connect Caterpillar Electronic Technician (ET) to
P1-65. the service tool connector.
F. Remove the jumper wire from the ECM connector. F. Turn the keyswitch to the ON position.
G. Access the “Change Oil Lamp” test in the special

test menu.
156 RENR1367-11
H. Activate the “Change Oil Lamp” test. Observe the The check engine lamp is used to provide the
test lamp. The lamp should turn on when the test following functions:
is active. Also, the lamp should turn off when the
test is inactive. • Indicate the existence of an active diagnostic code.
I. Turn the keyswitch to the OFF position. • Indicate driver alert status of the idle shutdown
timer.
J. Return the wiring to the original configuration.
• Read diagnostic flash codes.
Expected Result:
Power Up Lamp Check
The test lamp turns on and the test lamp turns off
per the above description. At powerup, the lamp will turn ON for five seconds.
The lamp will continue to flash if there is an active
Results: diagnostic code.
• OK – The test lamp illuminated during the “Change Operation with an Active Diagnostic Code
Oil Lamp” test.
While the engine is operating, the lamp will turn on
Repair: The lamp circuit and the ECM appear for a minimum of five seconds when certain fault
to be functioning properly. There may be an conditions exist. If certain fault conditions exist, the
intermittent problem. Return the vehicle to service. lamp will operate in the following manner:
If the problem persists, retest the circuit or send
the vehicle to the OEM dealer for repairs. • The check engine lamp will turn on for five seconds.
STOP. • The check engine lamp will turn off for a short time.
• Not OK – The test lamp did not illuminate during • The check engine lamp will turn on for another
the “Change Oil Lamp” test. five seconds.
Repair: Temporarily connect a test ECM. Check The check engine lamp will continue to operate in
the output circuit of the ECM that supplies power to this manner while the fault condition exists.
the change oil lamp when the test ECM is installed.
If the problem is resolved with the test ECM, Indication of the Driver Alert Status of the Idle
reconnect the suspect ECM. If the problem returns Shutdown Timer
with the suspect ECM, replace the ECM.
During the final 90 seconds of the operation of the
STOP. idle shutdown timer, the check engine lamp will
begin to flash. The flashing of the check engine lamp
indicates that an engine shutdown is near.
i02301219
Check Engine Lamp Circuit - Flashing Out Diagnostic Flash Codes
Test The flash codes are two-digit representations of

diagnostic codes. The PID-FMI diagnostic code
SMCS Code: 7431-038 should be used for troubleshooting. The PID is the
parameter identifier. The FMI is the failure mode
System Operation Description: identifier. A 110-03 is an example of a PID-FMI
diagnostic code. Flash codes provide an indication of
Use this procedure under the following situation: a failure. Flash codes are not as specific as diagnostic
codes. Flash codes only indicate that a failure has
Use the following information in order to determine if occurred. Flash codes do not indicate the specific
the check engine lamp is operating incorrectly: type of failure. For example, the flash code (27) is
used for a 110-03 fault code and a 110-04 fault code.
The check engine lamp is the only standard lamp that Flash codes should not be used for troubleshooting.
is used. All other lamps are optional.
Diagnostic flash codes that are active can be viewed
The following background information is related at any time. Turn the cruise control on/off switch to the
to the following procedure: OFF position. Hold the set/resume switch in either the
SET position or the RESUME position until the lamp
Check Engine Lamp begins to flash. Then release the set/resume switch.
RENR1367-11 157
The flash code is determined by the blinking of the Test Step 1. Inspect the Electrical
check engine lamp. The lamp will blink for the first Connectors and the Wiring
digit of the flash code, and the lamp will pause for
five seconds. Then, the lamp will blink for the second A. Turn the keyswitch to the OFF position.
digit.
Some vehicles are equipped with a diagnostic enable

switch. The diagnostic enable switch is used to
flash the diagnostic codes by grounding the input
of the diagnostic enable switch from terminal 46
to terminal 5 (sensor common). The customer
parameter “Diagnostic Enable” must be programmed
to “J1/P1:46” to use terminal 46 as an input for a
diagnostic enable switch. A switch does not need to
be connected to an ECM input in order to be used
as a diagnostic enable switch. The switch position
is transmitted over the J1939 data link to the ECM.
When the ECM receives the message over the
J1939 data link, the output (J1/P1:28) will illuminate
the check engine lamp. The customer parameter
“Diagnostic Enable” must be programmed to “J1939
Body Controller”, “J1939 Cab Controller”, or “J1939
Instrument Cluster” in order to use a J1939 data link
communication to control the check engine lamp. If a
problem is suspected with the J1939 data link, refer
to Troubleshooting, “Powertrain Data Link Circuit - g01146374
Illustration 40
Test”.
Note: The check engine lamp should not continuously (1) J1/P1 ECM connectors
flash the diagnostic flash codes. If the set switch, the
resume switch, or the diagnostic enable switch has B. Thoroughly inspect connector (1). Also inspect
not been used, then the circuit is probably shorted to the harness for the check engine lamp. Refer to
ground. Troubleshooting, “Electrical Connectors - Inspect”
for details.
Electrical Connection of the Check Engine Lamp
One terminal of the check engine lamp must be

connected to battery voltage through the vehicle
wiring. The other terminal is connected to the
Engine Control Module (ECM) at the vehicle harness
connector J1/P1-28 (check engine lamp).
The ECM provides a path to ground in order to turn

the lamp ON.
g01152462
Illustration 39
158 RENR1367-11
• Not OK – The connectors and/or wiring are in

need of repair.
Repair: Repair the connectors or wiring and/or

STOP.

of the Check Engine Lamp
A. Turn the keyswitch to the ON position. Monitor the
check engine lamp. The ECM will illuminate the
lamp for five seconds.
B. Turn the keyswitch to the OFF position.
Expected Result:
The check engine lamp illuminates for five seconds

after the keyswitch is turned to the ON position.
Results:
• OK – The check engine lamp is operating normally.

Repair: There may be an intermittent problem with
the wiring and/or the connectors. Repair the lamp
circuit or send the vehicle to the OEM dealer for
repairs.
g01152407
Illustration 41
P1 connector STOP.
(28) Check engine lamp
(52) +Battery • Not OK – The check engine lamp does not turn
(65) -Battery on. Proceed to Test Step 3.
C. Perform a 45 N (10 lb) pull test on each of the Test Step 3. Test the Check Engine Lamp
wires in the ECM connector that are associated Circuit
with the check engine lamp.
A. Fabricate a jumper wire that can be used to test
D. Check the allen head screw on the ECM the circuit. Crimp connector pins to each end of
connectors for the proper torque. Refer to the jumper.
for the correct torque value. B. Disconnect the J1/P1 ECM connectors.
E. Check the harness and wiring for abrasion and C. Insert the jumper into terminal P1-28 (change oil
pinch points from the battery to the ECM. lamp).
Expected Result: D. Insert the other end of the jumper wire into
terminal P1-52 (-Battery).
coupled and/or inserted and the harness and wiring E. While the lamp is being watched, insert the jumper
are free of corrosion, of abrasion or of pinch points. wire and remove the jumper wire from terminal
P1-65.
Results:
F. Remove the jumper wire from the ECM connector.
• OK – The connectors and wiring appear to be OK.
RENR1367-11 159
Result 1 The check engine lamp turns on while the The test lamp turns on and the test lamp turns off
jumper is connected. Also, the check engine lamp per the above description.
turns off when the jumper is removed.
Results:
Result 2 The check engine lamp does not turn on
while the jumper is connected to both sockets. • OK – The test lamp illuminated when the keyswitch
was turned to the ON position.
Result 3 The check engine lamp remains on while
the ECM connector is disconnected. Repair: The lamp circuit and the ECM appear
to be functioning properly. There may be an
Results: intermittent problem. Return the vehicle to service.
If the problem persists, retest the circuit or send
• Result 1 – The lamp turns on and off when the the vehicle to the OEM dealer for repairs.
ECM is bypassed. The circuit for the check engine
lamp is OK. Proceed to Test Step 4. STOP.
• Result 2 – The check engine lamp does not • Not OK – The test lamp did not illuminate when
illuminate when the ECM is bypassed. the keyswitch was turned to the ON position.
Repair: The vehicle’s lamp circuit is not functioning Repair: Temporarily connect a test ECM. Check
properly. The lamp is probably burned out or there the output circuit of the ECM that supplies power
is a problem in the lamp circuit from the cab to the to the check engine lamp when the test ECM is
ECM. Check if the circuit protection for the vehicle installed. If the problem is resolved with the test
has been tripped. Repair the lamp circuit or send ECM, reconnect the suspect ECM. If the problem
the vehicle to the OEM dealer for repairs. returns with the suspect ECM, replace the ECM.
STOP. STOP.
• Result 3 – The check engine lamp remains on i01857608

while the J1/P1 ECM connectors are disconnected.
Repair: The circuit between the ECM and the lamp

Clutch Pedal Position Switch
is shorted to chassis ground. Repair the circuit or Circuit - Test
SMCS Code: 1435-038-P9
STOP.
Test Step 4. Check the Operation of the
ECM Output for the Check Engine Lamp Use this procedure under the following situation:
A. Fabricate a jumper wire with a socket terminal on Use this procedure to determine if the clutch pedal
one end. position switch is preventing normal operation of
cruise control, fast idle, idle set speed, or PTO
B. Remove terminal P1-28 (change oil lamp) from operation:
the ECM connector. Insert the jumper wire (socket
terminal) into P1-28. The following switch circuits can also prevent the
correct operation of the cruise control, idle set speed
C. Connect the J1/P1 ECM connector. or PTO operation:
D. Connect one lead of a test lamp to the jumper • service brake pedal position (switch 1)
wire. Connect the other lead of the test lamp to
the positive terminal of the vehicle’s battery. • service brake pedal position (switch 2)
E. Turn the keyswitch to the ON position. • neutral switch
F. Observe the test lamp. The lamp should turn on • cruise control set/resume switch
for five seconds. The lamp should then turn off.
• cruise control on/off switch
G. Turn the keyswitch to the OFF position.
• PTO on/off switch
H. Return the wiring to the original configuration.
160 RENR1367-11
• cruise control pause switch The operation of the Caterpillar electronic engine
cruise control is similar to the operation of the
The switches are described in the respective circuit cruise controls that are installed in automobiles. The
tests in Troubleshooting. operation of fast idle, idle and PTO are similar to the
operation of cruise except that the idle and the PTO
All of the following Customer Programmable govern engine rpm instead of vehicle speed.
Parameters can affect cruise control, fast idle, idle
set speed, and PTO operation: Note: Idle in this procedure is an engine idle rpm
above the programmed low idle rpm. Idle is set
• “Low Cruise Control Speed Set Limit” by using the cruise control on/off switch and the
set/resume switch. Refer to Troubleshooting, “PTO
• “High Cruise Control Speed Set Limit” Switch Circuit - Test” for additional information
regarding the programmable options for the
• “Idle Vehicle Speed Limit” Dedicated PTO.
• “Fast Idle RPM #1” Note: Fast idle in this procedure is an engine idle
rpm above the programmed low idle rpm. Fast idle is
• “Fast Idle RPM #2” set by using a dedicated fast idle switch.
• “Cruise/Idle/PTO Switch Configuration” Cruise Control On/Off Switch
• “Idle/PTO Bump rpm” This switch must be on before cruise control or

controlled idle can be activated. This switch is on
• “Idle/PTO rpm Ramp Rate” when the switch is closed. When the switch is closed
the following terminals are connected:
• “PTO Vehicle Speed Limit”
• ECM connector J1/P1 terminal 59 (cruise control
• “Cruise Pause Switch” on/off switch)
The vehicle speed calibration can also affect the • Terminal 5 (AP sensor/switch sensor common)
cruise control, the idle set speed, and the PTO if the
vehicle speed calibration is incorrectly programmed. Note: If the vehicle is programmed to use the
Refer to Troubleshooting, “Customer Specified “Dedicated PTO”, the PTO on/off switch overrides the
Parameters”. cruise control on/off switch. The PTO on/off switch
overrides the cruise control on/off switch when the
Clutch Switch vehicle speed is within the range of the “PTO Vehicle
Speed Limit” that is programmed.
The clutch pedal position switch is normally closed
when the pedal is released. Depressing the clutch Set/Resume Switch
pedal should open the circuit. This switch is OEM
supplied. The clutch pedal position switch is typically With the cruise control on/off switch in the ON
a limit switch that is mounted near the pedal. The position and the vehicle speed within the range of
clutch pedal position switch is usually adjustable. the programmed “Low Cruise Control Speed Set
Limit” and the “High Cruise Control Speed Set Limit”,
This switch may not be connected to an input on the momentarily pressing the set switch will activate
ECM. The parameter “Clutch Pedal Position Switch” cruise control, and the ECM will maintain the current
determines the input to the ECM. If the parameter is speed.
programmed to J1/P1:22 a switch must be connected
to terminal 22. If the parameter is programmed to After a speed has been set and the speed is then
one of the J1939 options, the switch position will be disengaged by using the brake, the clutch, the cruise
transmitted to the ECM over the J1939 data link. If a control pause switch, or the on/off switch, the ECM
problem is suspected with the J1939 data link, refer will seek the previous set speed when the resume
to Troubleshooting, “Powertrain Data Link Circuit - switch is toggled. This assumes that the vehicle
Test”. speed is above the “Low Cruise Control Speed Set
Limit” for cruise control or the vehicle speed is below
The following background information is related the “Idle/PTO Vehicle Speed Limit” for the idle and
to this procedure: the PTO.
The kickout switch refers to the switch that is used to

exit the cruise control, the fast idle, the PTO, or the
idle set speed.
RENR1367-11 161
After a speed has been set, pressing and holding the Table 146
set/resume switch in position will cause the engine Switch Usage.
to establish a new set speed. The system’s reaction Setting For
depends on the programming of the “Cruise/Idle/PTO Transmission Service Service
Switch Configuration”. Style Brake Brake
Clutch Neutral
When the set/resume switch is momentarily pressed, 1 2
the cruise set point will change one mph. The rate of “Manual
change is dependent on the programmed “Idle/PTO X X
Option 1”
Bump rpm” when the engine is setting on idle speed.
“Manual
X X X
Option 2”
“Automatic
X
The cruise control pause switch is not a switch that Option 1”
is wired to an input. The switch position is broadcast “Automatic
over a J1939 data link. The parameter “Cruise Pause X X
Option 2”
Switch” must be programmed to use a cruise control
pause switch. After a speed has been set and the “Automatic
X X X
speed is then disengaged by using the cruise control Option 3”
pause switch, the ECM will seek the previous set “Automatic
speed when the resume switch is toggled. This X X
Option 4”
assumes that the vehicle speed is above the “Low
Cruise Control Speed Set Limit” for cruise control “AT/MT/HT
X
Option 1”
or the vehicle speed is below the “Idle/PTO Vehicle
Speed Limit” for the idle and the PTO. “AT/MT/HT
X X
Option 2”
Kickout Switches
“AT/MT/HT
X X X
Option 3”
The brake pedal position switches, the neutral switch,
the cruise control pause switch, and the clutch pedal “AT/MT/HT
X X
position switch are used in the cruise control mode, Option 4”
the PTO mode, the fast idle mode, and the idle mode “Universal
to discontinue cruise operation, PTO operation, fast X X X
Option”
idle operation, or idle operation. The capability to
override the idle shutdown timer is determined by the
“Allow Idle Shutdown Override” parameter setting. If the “Transmission Style” parameter is programmed
The “Allow Idle Shutdown Override” is a Customer to one of the following options, the input for the clutch
Parameter. pedal position switch is not used:
Usage of Transmission Style Switches • “Automatic Options 1”

The “Transmission Style” parameter determines the • “Automatic Option 2”
switches that will be used. The following switches
can be used. • “Automatic Option 3”
• clutch pedal position • “Automatic Option 4”
• neutral • “AT/MT/HT Option 1”
• service brake pedal position (switch 1) • “AT/MT/HT Option 2”
• service brake pedal position (switch 2) • “AT/MT/HT Option 3”

Refer to Table 146 for additional information. • “AT/MT/HT Option 4”
162 RENR1367-11
A service brake pedal position (switch 1) is required • “Cruise Kickout”

for all configurations. The service brake pedal
position (switch 1) connects to the ECM through • “Idle Kickout”
connector P1 terminal 45. The service brake pedal
position (switch 2) connects to the ECM through • “PTO Kickout”
connector P1 terminal 64. The clutch pedal position
switch connects to the ECM through connector P1 • “Fast Idle Kickout”
terminal 22. The neutral switch connects to the ECM
through connector P1 terminal 62. This parameter is blank when the ECM is first
powered up. If this parameter is blank, “No
Some engines that were built before JULY 1999 Occurrence” is indicated. This parameter remains
may have a Basic ECM. The Basic ECM was used blank until the ECM detects the use of the
only on General Motors chassis. Other chassis used cruise/idle/PTO mode. Also, this parameter remains
engines that were built with a Full Feature ECM. blank until the ECM detects the disengagement of
Basic ECM software does not have the parameter the cruise/idle/PTO mode. Refer to Tables 147 and
for “Transmission Style”. For these systems, a 148 in order to interpret the status screen kickout
jumper wire must be installed between the clutch status parameter.
switch input and the sensor common when an
automatic transmission is installed. When the jumper
wire is installed, the “Clutch Switch” status will
always indicate “OFF”. Engines that were built after
JULY 1999 use only one type of ECM that can be
configured for “Basic” or “Full Feature” operation. A
new parameter was added in order to provide this
flexibility. The “Truck Manufacturer” parameter was
added in order to allow the configuration of the “GM
Basic” operation or the “Other Full Feature” operation.
This parameter is programmed at Caterpillar when
the engine is built. The parameter for “Transmission
Style” is not available for engines that have software
that is dated prior to SEP00 and the parameter for
“Truck Manufacturer” is programmed to “GM”. SEP00
and newer engines that are programmed to “GM”
use the “Transmission Style” parameter. The factory
default for the “GM” setting is the “Universal” option.
The “Universal” option provides identical features as
the “Basic” system that is described above. If the
“Transmission Style” parameter is programmed to the
“Universal” option, a jumper wire must be installed
between the clutch switch input and the sensor
common when an automatic transmission is installed.
Otherwise, the “Transmission Style” parameter can
be programmed to match the specific arrangement
of the vehicle.
If the problem is with undetermined

Cruise/Idle/PTO kickouts use the following
procedure:
Operate the vehicle in Cruise/Idle/PTO mode.
After the kickout, review the status screen on an

electronic service tool. The status screen for the
parameter indicates the cause of the kickout. This
must be performed before the ignition key switch
is turned off. It is important to remember that the
parameter will only indicate the last kickout since the
ECM has been powered by the ignition key switch.
The following kickout status parameters are available:

RENR1367-11 163
Table 147
Cruise Control Kickout Status Table
Electronic Service Tool Meaning or Possible Cause Troubleshooting
Intermittent vehicle speed signal or lost Refer to Troubleshooting, “Vehicle Speed
“Vehicle Speed >=Limit”
vehicle speed signal. Circuit - Test”.
The cruise/idle on/off switch is turned off Refer to Troubleshooting, “Cruise Control
“Switch Turned Off” or the switch circuit has an open circuit Switch Circuit - Test”.
condition.
The cruise control pause switch is Refer to Troubleshooting, “Powertrain Data
“Cruise Control PAUSE
depressed or there is an illegal message Link Circuit - Test”.
Switch”
on the J1939 data link.
The service brake pedal is depressed or Refer to Troubleshooting, “Service Brake
“Brake Pedal Depressed” the service brake switch circuit has an open Pedal Position (Switch 1) Circuit - Test”.
circuit condition.
The clutch pedal is depressed or the Proceed with the test procedure.
clutch pedal switch circuit has an open
“ClutchPedal Depressed”
circuit condition. Also, the switch could be
incorrectly adjusted.
The transmission is not in gear or the Refer to Troubleshooting, “Neutral Switch
“Neutral” transmission switch circuit has a short Circuit - Test”.
circuit condition.
Vehicle speed signal is erratic or Refer to Troubleshooting, “Vehicle Speed
“Bad Vehicle Speed” intermittent. Circuit - Test” if a problem with the signal
exists.
The PTO on/off switch is turned on or the Refer to Troubleshooting, “PTO Switch
“PTO Switch On” circuit for the PTO on/off switch has a short Circuit - Test”.
circuit condition.
The set/resume switch was held in the SET Cruise control cannot be set until the cruise
position for more than 15 seconds (Basic) control on/off switch is turned to the OFF
Set Switch Timeout or there is a short circuit in the switch circuit. position and then turned back to the ON
position. If the circuit for the set switch is
suspected, proceed with this test procedure.
Resume Switch Timeout or there is a short circuit in the switch circuit. position and then turned back to the ON
position. If the circuit for the resume switch is
“No Occurrence” Cruise control has not been enabled since Drive the vehicle in cruise in order to create
or the ECM has been powered up. the problem again.
“Not Kicked Out”
164 RENR1367-11
Table 148
Idle Kickout Status Table
ET Meaning or Possible Cause Troubleshooting
Intermittent engine speed signal or lost Refer to Troubleshooting, “Engine
“No Engine Speed”
engine speed signal. Speed/Timing Circuit - Test”.
condition.
depressed or there is an illegal message on Link Circuit - Test”.
Switch”
the J1939 data link.
circuit condition.
“Clutch Pedal Depressed”
The vehicle speed has exceeded the Idle Refer to Troubleshooting, “Vehicle Speed
“Vehicle Speed ≥ Limit” Vehicle Speed Limit or the vehicle speed Circuit - Test” if a problem with the signal
signal is erratic or intermittent. exists.
The transmission is not in neutral or the Refer to Troubleshooting, “Neutral Switch
“Neutral” transmission neutral switch circuit has an Circuit - Test”.
open circuit condition.
circuit condition.
“No Occurrence” Idle set speed has not been enabled since Operate the vehicle in the Idle mode in order
or the ECM has been powered up. to create the problem again.
RENR1367-11 165
Table 149
Fast Idle Kickout Status Table
The fast idle on/off switch is turned off or the Refer to Troubleshooting, “Cruise Control
“Switch Turned Off”
switch circuit has an open circuit condition. Switch Circuit - Test”.
Switch”
circuit condition.
“No Occurrence” Fast idle set speed has not been exited Operate the vehicle in the Idle mode in order
or since the ECM has been powered up. to create the problem again.
166 RENR1367-11
Table 150
Table For The PTO Kickout Status Screen On The Electronic Service Tool
Intermittent engine speed signal or lost Refer to Troubleshooting, “Speed/Timing
No Engine Speed
engine speed signal. Circuit - Test”.
The PTO On/Off switch is turned OFF or the Refer to Troubleshooting, “Cruise Control
Switch Turned Off
Switch”
“Brake Pedal Depressed” the service brake switch circuit has an open Pedal Position Switch 1 Circuit - Test”.
circuit condition.
The vehicle speed has exceeded the PTO Refer to Troubleshooting, “Vehicle Speed
Vehicle Speed ≥ Limit Vehicle Speed Limit or the vehicle speed Circuit - Test” if a problem with the signal
Neutral transmission neutral switch circuit has an Circuit - Test”.
“No Occurrence” The PTO has not been enabled since the Operate the vehicle in the PTO mode in
or ECM has been powered up. order to create the problem again.
g00643881
Illustration 42
Schematic for cruise control switch, service brake pedal position switch 1 and clutch pedal position switch
Test Step 1. Determine the Type of C. If the vehicle will not allow setting a cruise speed,
Problem. an idle speed or a PTO speed, check the following
Customer Parameters:
A. Connect the electronic service tool.
RENR1367-11 167
• “Low Cruise Control Speed Set Limit” Test Step 2. Inspect Electrical Connectors
and Wiring.
• “High Cruise Control Speed Set Limit”
Idle Parameters
• “Fast Idle RPM #1”

• “Idle Vehicle Speed Limit”
• “Idle RPM Limit”
• “Top Engine Limit” (TEL)
PTO Parameters
• “PTO Configuration”
• “PTO Kickout Vehicle Speed Limit”
D. Ensure that the vehicle is not experiencing
a problem due to one of these parameters.
Parameters” for a description of the parameters, if
necessary.
E. Check the status screen that indicates the last

cause of a kickout for one of the following modes:
• Cruise Kickout
• Idle Kickout
• Fast Idle Kickout
g00773080
Illustration 43
• PTO Kickout
Refer to Tables 147, 148, 149, and 150 for the A. Thoroughly inspect ECM vehicle harness
meaning of the status screen. connector J1/P1, the firewall bulkhead connector
and the terminals for the following switches in the
Expected Result: connectors:
The problem is due to a parameter setting or the • clutch pedal position switch (terminal 22)
problem is due to a normal kickout.
• AP sensor/switch sensor common (terminal 5)
Results:
Refer to Troubleshooting, “ Electrical Connectors -
• Yes – Explain the proper operation of system to Inspect” for details.
the driver. STOP.
• No wires in the ECM connector that are associated
with the switches.
Repair: Refer to Tables 147, 148, 149, and 150 for
recommended troubleshooting. Refer to Illustration 43.
If a problem is still suspected with the clutch switch C. Check the ECM connector (allen head screw) for
circuit perform the following procedure: the proper torque of 6.0 N·m (55 lb in).
Proceed to Test Step 2. D. Check the harness and wiring for abrasion and
pinch points from the sensor to the ECM.
168 RENR1367-11
Expected Result: Test Step 4. Operate the Vehicle and

Check the Kickout Status Parameter.
All connectors, pins and sockets should be completely
coupled and/or inserted and the harness and wiring A. For an intermittent Cruise Control Kickout, talk
should be free of corrosion, abrasion or pinch points. to the driver in order to determine the conditions
when the kickout occurs. Topics of examination
Results: could be the following examples:
• OK – Proceed to Test Step 3. • specific speed

• Not OK • road conditions
Repair: Repair the connectors or wiring and/or • weather conditions
the seals are properly in place and ensure that the Take the vehicle for a road test in order to
connectors are completely coupled. duplicate these conditions and set the cruise
control. Operate the vehicle in cruise control until
Verify that the repair eliminates the problem. the problem reoccurs.
STOP. B. For an intermittent idle kickout, talk to the driver

in order to determine the conditions when the
Test Step 3. Check Clutch Switch Status kickout occurs. A topic of examination could be
on the Electronic Service Tool. the following example:
Table 151 • specific engine rpm

Clutch Pedal Position Status Table
Start the engine. Duplicate these conditions and
Switch Position or Pedal Status Circuit set the idle rpm. Operate the vehicle in idle until
Position the problem reoccurs.
The Clutch Pedal is ON Open
DEPRESSED. Note: The status screen will only indicate the last
kickout. The status screen will lose this information if
The Clutch Pedal is OFF Closed the ignition key switch is turned off.
RELEASED.
C. Connect the electronic service tool and check the
A. Access the status screen on the electronic service status screen for the last cause of the kickout.
tool. Refer to Tables 147 and 148 for an explanation
of the status parameter.
D. If the status screen is blank, then either there was
C. Depress the clutch pedal while the status of the no kickout of the cruise control, or the power to the
clutch pedal position switch is being observed. ECM was turned off before the information could
Also, release the clutch pedal while the status of be read. Repeat this test step.
the clutch pedal position switch is being observed.
Note: A status screen that is blank indicates “No
Expected Result: Occurrence” or “Not Kicked Out”.
The switch status changes per the information in Expected Result:

Table 151.
RESULT 1 The status screen displays the following
Results: result:
• Yes – The switch is operating normally. STOP. • “Clutch Pedal Depressed”

• Intermittent Problem Suspected – Proceed to Test RESULT 2 The status screen displays the following
Step 4. result:
• No – The ECM is not reading the switch status • “Switch Turned Off”
change. Proceed to Test Step 5.
result:
RENR1367-11 169
• “Cruise Control PAUSE Switch” Repair: Perform the following diagnostic

procedure:
result: Troubleshooting, “Service Brake Pedal Position
(Switch 1) Circuit - Test”
• “Brake Pedal Depressed”
STOP.
result: • Result 5
• “Vehicle Speed < Limit” Repair: Perform the following diagnostic
procedure:
• “Bad Vehicle Speed”
• “Vehicle Speed ≥ Limit” Circuit - Test”
RESULT 6 The status screen displays the following STOP.

result:
• Result 6
• “PTO Switch ON”
RESULT 7 The status screen displays the following procedure:
result:
Troubleshooting, “PTO Switch Circuit - Test”
• “Neutral”
STOP.
• “No Engine Speed” Repair: Perform the following diagnostic
procedure:
result: Troubleshooting, “Neutral Switch Circuit - Test”
• “Set Switch Timeout” STOP.
• “Resume Switch Timeout” • Result 8

Results: Repair: Perform the following diagnostic
procedure:
Troubleshooting, “Engine Speed/Timing Sensor
• Result 2 Circuit - Test”
Repair: Perform the following diagnostic STOP.

procedure:
• Result 9
Test” Repair: Perform the following diagnostic
procedure:
STOP.
• Result 3 Test”

procedure:
Troubleshooting, “Powertrain Data Link Circuit -

Test”
STOP.
• Result 4
170 RENR1367-11
Test Step 5. Check the Switch Circuit for 2. Remove all jumpers and replace all connectors.
the ECM.
3. Recheck the system for active diagnostic codes.
Table 152
Clutch Switch Input Status Table 4. Repeat the test step.
Condition of Switch 5. If the problem is resolved with the test ECM,
Switch Status Circuit
Circuit reconnect the suspect ECM.
Terminal 22 is Open. ON Open
Terminal 22 connected replace the ECM.
OFF Closed
to terminal 5.
7. Verify that the repair eliminates the problem.
STOP.
B. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wires. Test Step 6. Insert A Jumper At The
Clutch Switch.
C. Disconnect vehicle harness connector P1 from
the ECM. Table 153
Clutch Switch Input Status Table

D. Connect a 70-Termial breakout T to ECM
connector J1 and connect P1 to the breakout T. Switch
Condition of Switch Circuit Circuit
Status
E. Install the jumper into terminal 22 (clutch pedal Clutch Pedal Position Switch
ON Open
position switch) of the breakout T. Connect Wires are Disconnected.
the other end of the jumper to terminal 5 AP
Clutch Pedal Position Switch
sensor/switch sensor common of the ECM OFF Closed
Wires are Connected.
connector P1 of the breakout T.
F. Turn the ignition key switch to the ON position. A. Turn the ignition key switch to the OFF position.
G. Connect the electronic service tool to the cab data B. Ensure that ECM vehicle harness connector J1/P1
link connector. is connected.
H. Access the status screen. C. Find the clutch switch in the vehicle.
I. While the clutch switch status is being monitored D. Disconnect the wires from the clutch switch
on the status screen slowly remove the jumper terminals.
from terminal 5 AP sensor/switch sensor common.
Now, slowly insert the jumper into terminal 5 AP E. Turn the ignition key switch to the ON position.
sensor/switch sensor common.
F. Connect the electronic service tool to the cab data
Refer to Table 152. link connector.
Expected Result: G. Access the status screen.
The switch status changes per the information in H. While the switch status is being monitored on the
Table 152. status screen slowly connect the switch wires and
slowly disconnect the switch wires.
Results:
Refer to Table 153.
• Yes – The ECM is functioning properly. Proceed
to Test Step 6. Expected Result:
• No – The ECM is NOT functioning properly. The switch status changes per the information in
Table 153.
Results:
1. Temporarily connect a test ECM.
• Yes
RENR1367-11 171
Repair: Perform the following repair: Repair: Perform the following repair:
Replace the faulty switch. Inspect the vehicle wiring and repair the vehicle
wiring, as required. If the problem still exists with
Verify that the repair eliminates the problem. the wiring, send the vehicle to the OEM dealer.
STOP. STOP.
• No – There is a problem in the harness between • No – The problem is in the vehicle wiring between
the switch and the ECM. Proceed to Test Step 7. the bulkhead connector and the ECM.
Test Step 7. Insert a Jumper at the Repair: Perform the following repair:
Bulkhead Connector.
Inspect the vehicle wiring and repair the vehicle
Table 154 wiring, as required. If the problem still exists with
Clutch Switch Input Status Table the wiring, send the vehicle to the OEM dealer.
Condition of Switch Switch STOP.
Circuit
Circuit Status
Bulkhead Wires are
ON Open i02303749
Disconnected.
Bulkhead Wires are
OFF Closed
Coolant Level Sensor Circuit
Connected. - Test
A. Turn the ignition key switch to the OFF position. SMCS Code: 5574-038-CLT
B. Fabricate a jumper wire 100 mm (4 inch) long. System Operation Description:

Crimp a Deutsch pin to each end of the wires.
C. Find the terminal for the clutch switch. Also, find
the terminal for the sensor common for the AP Use this procedure if any of the following diagnostic
sensor/switch. Look for the terminals in the engine codes are active or easily repeatable:
side of the bulkhead connector for the vehicle
harness. • 111-02 Coolant Level signal invalid (12)
D. Insert the jumper wire between the two terminals • 111-03 Coolant Level voltage high (12)
in the engine side of the bulkhead connector.
• 111-04 Coolant Level voltage low (12)
Do not use this procedure for either of the following
F. Connect the electronic service tool to the cab data diagnostic codes:
link connector.
• 111-01 Low Coolant Level Warning (62)
G. Access the status screen.
• 111-11 Very Low Coolant Level (62)
H. While the switch status is being monitored on the
status screen alternately remove the jumper wire • 111-14 Low Coolant Level Warning
between the two terminals, and alternately insert
the jumper wire between the two terminals. These diagnostic codes indicate a low coolant level
but not an electrical system malfunction. Refer
Refer to Table 154. to Troubleshooting, “111-01 Low Coolant Level
Warning”, Troubleshooting, “111-11 Very Low Coolant
Expected Result: Level” or Troubleshooting, “111-14 Low Coolant Level
Warning” for the proper troubleshooting procedure.
The switch status changes per the information in
Table 154. The following background information is related
to this procedure:
Results:
• Yes – The problem is in the vehicle wiring between

the bulkhead connector and the switch.
172 RENR1367-11
The coolant level sensor is installed by the vehicle’s To use a 2-wire float sensor, the parameter “Coolant
Original Equipment Manufacturer (OEM). This Level Sensor” must be programmed to “2-wire float
sensor is an optional sensor for “Engine Monitoring”. sensor”. The sensor is connected to P1/J1-26 (sensor
Engine monitoring is a programmable feature of the input) and to P1/J1-5 (AP sensor/switch common).
Caterpillar Engine Control Module (ECM). The sensor The sensor will provide information to the ECM at
is selectable through a customer programmable P1/J1-26 that will enable the ECM to determine if the
parameter and the customer programmable coolant level is normal, low, or extremely low.
parameter may be protected by customer passwords.
Some OEM installed coolant level sensors are not If this parameter is set and a sensor is not installed,
connected to the ECM. Do not confuse an OEM 111-02 diagnostic code will be logged.
installed coolant level sensor that is independent of
engine monitoring with the coolant level sensor that “2-Pin Switch” (GMT-560)
is used for engine monitoring.
The “2-pin switch” is a switch that is provided by the
The customer programmable parameter for the OEM for the vehicle. The switch is also installed by
coolant level sensor can be programmed to “4-Pin”, the OEM. This coolant level switch is available only
“2-wire float sensor”, or “2-pin switch”. Also, the for the GMT-560 application.
customer programmable parameter for the coolant
level sensor can be programmed to “NO” if the option The ECM detects closed contacts for a coolant level
for the coolant level sensor is not being used. that is present “2-pin switch” and open contacts when
a coolant level is not present. Terminals J1/P1-49
If the parameter “Coolant Level Sensor” is and J1/P1-3 are used for the “2-pin switch”.
programmed to “NO”, the coolant level sensor is
ignored by the ECM. Conversely, if the parameter Refer to OEM information for the proper
is set, then a sensor must be installed. The coolant troubleshooting procedure for the “2-Pin Switch”.
level is monitored by the engine monitoring system
when the parameter “Coolant Level Sensor” is Test Step 1. Use Caterpillar Electronic
programmed to “4-Pin” or “2-wire float sensor”. Technician (ET) to Check for an Active
Coolant Level Sensor Fault
4-Pin Sensor
The sensor indicates the presence or the absence
of coolant at the sensor probe. A sensor with a B. Turn the keyswitch to the ON position.
4-pin connector that requires a +5 VDC connection
to a power supply must be used. The sensor is C. Access the active diagnostic screen on Cat ET.
powered from the ECM through the ECM vehicle
harness connector J1/P1 terminal 2 (+5 VDC). The D. Verify that a diagnostic code that is related to the
ECM vehicle harness connector has 70 terminals. coolant level switch is active.
The signal wires for the coolant level sensor are
connected at J1/P1-54 (coolant level low) and at Expected Result:
J1/P1-49 (coolant level normal). The common wire for
the sensor is connected to the J1/P1 ECM connector Result 1 111-02 diagnostic code is active. This fault
through terminal 5 (AP sensor/switch common). indicates that a problem exists with the 4-pin sensor.
Ensure that the vehicle is equipped with a 4-pin
Note: If both parameters are set and a sensor is not sensor.
installed, 111-02 diagnostic code will be logged.
Result 2 111-03 diagnostic code or 111-04 diagnostic
Table 155 code is active. These faults indicate that a problem
ECM Output for the 4-Pin Sensor exists with the 2-wire float sensor. Ensure that the
vehicle is equipped with a 2-wire float sensor.
Engine coolant Engine coolant
Pin location
level normal level low Result 3 111-01, 111-11, or 111-14 diagnostic code
J1-49 5 VDC 0 VDC is active.
J1-54 0 VDC 5 VDC Results:
2-Wire Float Sensor • Result 1 – Proceed to Test Step 2.

• Result 3
RENR1367-11 173
Repair: Refer to Troubleshooting, “111-01 Low

Coolant Level Warning”, Troubleshooting, “111-11
Very Low Coolant Level” or Troubleshooting,
“111-14 Low Coolant Level Warning” for the proper
troubleshooting procedure.
STOP.

and Wiring for the 4-Pin Sensor
g01118000
Illustration 44
This is a typical schematic for the 4-pin sensor.
174 RENR1367-11


Expected Result:

Results:

• Not OK
Verify that the repair eliminates the problem. Clear

all diagnostic codes.
STOP.
Test Step 3. Disconnect the Coolant Level

g01153498 Sensor and Check the Supply Voltage
Illustration 45
(+5 VDC)
Pin locations on ECM connector
(P1-2) +5V supply A. Turn the keyswitch to the OFF position.
(P1-5) AP sensor/switch common
(P1-49) Coolant level normal
(P1-54) Coolant level low B. Disconnect the coolant level sensor from the
harness.
A. Thoroughly inspect J1/P1 ECM connector, the
connector for the extension harness for the C. Use a multimeter to measure the voltage at the
coolant level and the terminals for the coolant level harness connector from terminal C (+ 5 VDC) to
sensor in the connectors. The connector for the terminal B (AP sensor/switch common).
extension harness for the coolant level connects
the coolant level sensor to the vehicle harness in D. Turn the keyswitch to the ON position.
the engine compartment of some chassis. Refer to
Troubleshooting, “Electrical Connectors - Inspect” Expected Result:
for details.
The measured voltage is 5.0 ± 0.2 VDC.
wires in the ECM connector that are associated Results:
with the following connections:
• P1-2 +5V supply
• Not OK – Proceed to Test Step 5.
• P1-5 AP sensor/switch common
• P1-49 Coolant level normal
• P1-54 Coolant level low
RENR1367-11 175
Test Step 4. Disconnect the Coolant Test Step 5. Disconnect the Terminal for
Level Sensor and Check the Coolant the Sensor Supply (+5 VDC) from the
Level Harness ECM Connector
g00651005
Illustration 46
Jumper wire
B. Disconnect the coolant level sensor from the

harness. Illustration 47
g01118013
Breakout T
C. Use a jumper wire in order to connect terminal
D (coolant level normal) to terminal B (AP (2) +5V supply
(5) AP sensor/switch common
sensor/switch common) at the harness connector.
Refer to Illustration 46. A. Turn the keyswitch to the OFF position.
D. Turn the keyswitch to the ON position. B. Disconnect the J1/P1 ECM connector.
E. While the jumper wire is in place, access the status C. Install a breakout T between the J1 and the P1
screen that indicates the coolant level status. ECM connector.
F. Wait for 30 seconds. Read the status and record D. Turn the keyswitch to the ON position.
the status.
E. Measure the voltage at the breakout T from
Expected Result: terminal 2 to terminal 5.
The coolant level status indicates “LOW” with the Refer to Illustration 47.
jumper in place.
Expected Result:
Results:
The measured voltage is 5.0 ± 0.2 VDC.
• OK – Leave the jumper wire in place. If a breakout Results:
T is installed, leave the breakout T in place also.
• OK – The problem is located in the harness wiring.
• Not OK – Proceed to Test Step 7. Repair: Repair the wiring or replace the wiring,
as required.
STOP.
• Not OK – The problem is on the ECM side.

176 RENR1367-11
Repair: Temporarily connect a test ECM. Ensure Repair: Remove the jumpers. Replace the sensor
that the “Coolant Level Sensor” is programmed and ensure that 111-02 diagnostic code disappears
to match the old ECM. Check the test ECM by with the new sensor.
measuring the voltage at the breakout T from
terminal 2 to terminal 5 again. If the problem is Verify that the repair eliminates the problem. Clear
resolved with the test ECM, reconnect the suspect all diagnostic codes.
ECM. If the problem returns with the suspect ECM,
replace the ECM. STOP.
STOP. • Not OK – Proceed to Test Step 7.

Test Step 6. Check the Wire Harness for Test Step 7. Check the ECM
the Coolant Level Low
g00651008
Illustration 48
Jumper wires
B. Use two jumper wires to connect terminal A g01118015

Illustration 49
(coolant level low) and terminal D (coolant level
normal) to terminal B (sensor common) at the Breakout T
harness connector. (5) AP sensor/switch common
(18) Input sensor common 1
(49) Coolant level normal
Refer to Illustration 48. (54) Coolant level low
C. Turn the keyswitch to the ON position. A. Turn the keyswitch to the OFF position.
D. While the jumper wires are in place, access the B. Fabricate two jumper wires 100 mm (4 inch) long.
active diagnostic code screen on Cat ET. Crimp a Deutsch pin to both ends of each wire.
E. Verify that 111-02 diagnostic code is active. C. Turn the keyswitch to the ON position.
Note: Wait for 30 seconds for the activation of the D. Observe the coolant level sensor status on Cat
diagnostic code. ET. Install the jumper into the breakout T in order
to connect terminal 49 (coolant level normal) to
Expected Result: terminal 5 (AP sensor/switch common).
111-02 diagnostic code is active while the jumper E. Monitor the coolant level sensor status while the
wires are in place. jumper is being inserted and removed. Wait for
30 seconds between the insertion of the jumper
Results: and the removal of the jumper. Waiting for 30
seconds allows the ECM to acknowledge the
• OK – The harness and the ECM are working change. While the jumper remains in place, a
correctly. 111-01 diagnostic code should be active.
F. Record the result.

RENR1367-11 177
G. Leave the jumper installed in the breakout T.
H. Install a jumper wire from 54 coolant level low to

18 input sensor common 1 of the breakout T.
I. While both jumper wires are in place, access the

active diagnostic code screen. Verify that 111-02
Wait for 30 seconds for the activation of the

diagnostic code.
Expected Result:
The coolant level sensor status behaves in the

following manner:
• The Coolant Level Sensor Status indicates “OK”

before the jumper wire is installed between terminal
49 and terminal 5. 111-02 diagnostic code may be
active.
• The coolant level sensor status changes to “LOW”

after the jumper wire is installed between terminal
49 and terminal 5. Also, the diagnostic code 111-01
is active.
111-02 diagnostic code is active when both jumper

wires are installed.
Results:
• OK – The ECM is functioning properly.

Repair: Repair the harness or replace the harness,
as required.

STOP.
• Not OK
Repair: Temporarily connect a test ECM. Ensure
that the “Coolant Level Sensor” is programmed to
match the old ECM. If the problem is resolved with
the test ECM, reconnect the suspect ECM. If the
problem returns with the suspect ECM, replace the
ECM.
STOP.
178 RENR1367-11

and Wiring for the 2-Wire Float Sensor
g00882602
Illustration 50
This is a typical schematic for the 2-wire float sensor.
• P1-5 AP sensor/switch common



Expected Result:

Results:

• Not OK

g01153501
Illustration 51
STOP.
Pin locations on ECM connector
(P1-5) AP sensor/switch common Test Step 9. Disconnect the Coolant Level
(P1-26) Coolant level input Sensor and Check the Supply Voltage
(+5 VDC)
A. Thoroughly inspect the J1/P1 ECM connector,
the connector for the coolant level sensor and A. Turn the keyswitch to the OFF position.
the terminals for the coolant level sensor in the
connectors. Refer to Troubleshooting, “Electrical B. Disconnect the coolant level sensor from the
Connectors - Inspect” for details. harness.
B. Perform a 45 N (10 lb) pull test on each of the C. Use a multimeter to measure the voltage at the
wires in the ECM connector that are associated harness connector.
• P1-26 coolant level input
RENR1367-11 179
Expected Result: Results:
The measured voltage is 5.0 ± 0.2 VDC. • OK – The problem is located in the harness wiring.
Results: Repair: Repair the wiring or replace the wiring,
as required.
• OK – The correct voltage is reaching the sensor.
Repair: Replace the sensor.
STOP.
STOP.
• Not OK – The problem is on the ECM side.
• Not OK – Proceed to Test Step 10.
Test Step 10. Disconnect the Terminal for that the “Coolant Level Sensor” is programmed
the Sensor Supply (+5 VDC) From the to match the old ECM. Check the test ECM by
ECM Connector measuring the voltage at the breakout T from
terminal 26 to terminal 5 again. If the problem is
resolved with the test ECM, reconnect the suspect
ECM. If the problem returns with the suspect ECM,
replace the ECM.
STOP.
i01857652
Cooling Fan Circuit and A/C

Compressor Clutch Circuit -
Test
SMCS Code: 1356-038; 1802-038-CL

g01118029
Illustration 52 A/C compressor clutch is operating correctly. This
Breakout T circuit can be connected to J1/P1:41 Input #11 or to
(5) AP sensor/switch common J1/P1:62 Input #12.
(26) Coolant level input
Note: Not all vehicle manufacturers, or all trucks for
A. Turn the keyswitch to the OFF position. a manufacturer use the Caterpillar cooling fan circuit.
Prior to troubleshooting, determine if the vehicle is
B. Disconnect the J1/P1 ECM connector. using the ECM cooling fan circuit.
C. Install a breakout T between the J1 and P1 ECM Check the following items in order to determine if a
connector. vehicle is using the ECM cooling fan circuit:
D. Turn the keyswitch to the ON position. • The “Fan Control Type” parameter must be
programmed to “On/Off” or one of the variable
E. Measure the voltage at the breakout T from speed options. The Caterpillar factory default is
terminal 26 to terminal 5. None.
Refer to Illustration 52. • “A/C Fan On Time” is programmed between one

second and 600 seconds.
Expected Result:
• A wire is present in the ECM vehicle harness
The measured voltage is 5.0 ± 0.2 VDC. connector J1/P1 (terminal 11) which is Output #5
(cooling fan solenoid).
180 RENR1367-11
• Perform the special test for the “On/Off Cooling • The coolant temperature is greater than 96 °C
Fan”. Access each menu in the order that follows: (205 °F).
“Diagnostics”, “Diagnostic Tests”, and “Special
Test”. Activating and then deactivating the circuit • Active diagnostic code for the coolant temperature
should cause the solenoid to click if the circuit is sensor
working properly.
• The inlet manifold air temperature is greater than
The following background information is related 87 °C (189 °F).
to this procedure:
Cooling Fan 72 °C (162 °F) while the boost pressure is greater
than 70 kPa (10 psi).
The signal for the cooling fan is provided by the ECM
in order to control the cooling fan. An input from one • The manual fan override switch is on.
of the following items may cause the fan to turn ON:
• The “Fan with Exhaust Brake ON” is programmed
• A/C compressor clutch to “YES” and the exhaust brake has been on at
least two seconds.
• Engine coolant temperature sensor
• The “A/C Switch Fan On-Time” is programmed to
• Air inlet temperature sensor a value above 0 and the A/C high pressure switch
is open.
• Exhaust brake
• The ECM is counting after the A/C high pressure
• PTO on/off switch switch has closed.
• OEM installed A/C high pressure switch • The “PTO Activates Cooling Fan” parameter is
programmed to “Continuous” and the PTO on/off
• Manual fan override switch switch is on.
The output for the cooling fan is intended to connect • The “A/C Fan Request Switch” is programmed to
directly to the circuit for the cooling fan solenoid. “J1/P1:41” or “J1/P1:62” and the A/C compressor
Program the “Fan Control Type” parameter to clutch is activated.
“ON/OFF”. The fan will be off when the ECM output
is ON (energized). When the ECM activates the fan, The last five items in the previous list are dependent
the fan will remain on for a minimum of 30 seconds upon the programming of the Customer Parameters.
except for the following conditions:
Note: The ECM will turn off the cooling fan for 10
• Engine start-up seconds during engine shutdown.
• The “A/C Pressure Switch Fan On Time” is Cooling Fan Off Conditions
programmed to less than 30 seconds.
The cooling fan will be turned off by the ECM if engine
During engine start-up, the ECM will keep the fan rpm exceeds 2800 rpm or when all the following
on for two seconds after the engine has reached the circumstances are met:
programmed low idle (700 to 800 rpm). The fan will be
on continuously if the electrical circuit to the cooling • The coolant temperature is less than 92 °C
fan solenoid has an open circuit or if the circuit for the (198 °F).
ECM cooling fan relay has an open circuit.
• The fan has been on for at least 30 seconds.
Cooling Fan ON Conditions
• The inlet manifold air temperature is less than
The ECM will turn on the cooling fan under any of 53 °C (127 °F).
the following circumstances if engine speed is less
than 2750 rpm: • The strategy for the exhaust brake is not active
and the “Fan with Exhaust Brake ON” parameter is
• The engine is not running. programmed to “YES”.
• Engine cranking • The A/C high pressure switch is not active.

RENR1367-11 181
• The PTO on/off switch is in the OFF position and

the “PTO Activates Cooling Fan” parameter is
programmed to “Continious”.
• The A/C compressor clutch is not active.

• The manual fan override switch is off.
The Cooling Fan Control can be Operated
Independently of the ECM.
Operation of the cooling fan control can be controlled

independently of the ECM. The OEM installed air
conditioning high pressure switch may be used for
independent cooling fan control. A cab mounted
override switch in the solenoid circuit can also
operate the cooling fan.
g00840480
Illustration 53
Cooling fan circuit
182 RENR1367-11
Table 156
The following conditions will turn the Fan ON for Illustration 53.
Circuit Condition that will turn the Fan ON
Coolant temperature sensor The coolant temperature is greater than 96 °C (205 °F).
A diagnostic code for the coolant temperature sensor is
active.
Exhaust brake The “Fan with Exhaust Brake ON” parameter is programmed
to “YES”.
The exhaust brake is on at least two seconds.
OEM installed A/C high pressure switch The “A/C Switch Fan On-Time” is programmed to a value
above 0.
The switch circuit is open or on.
The external timer is counting or the timer in the ECM is
counting.
OEM installed A/C compressor clutch circuit The “A/C Fan Request” is programmed to “J1/P1:41” or
“J1/P162”.
The A/C compressor clutch is engaged.
The engine rpm is less than 2750 rpm. The engine is cranking. The engine has been running two
seconds or the ignition key is ON and the engine OFF.
Air inlet temperature sensor The temperature in the air inlet manifold is greater than 87 °C
(189 °F).
The temperature in the air inlet manifold is greater than 72 °C
(162 °F) while the boost pressure is greater than 70 kPa
(10 psi).
OEM installed manual fan override switch There is an open circuit in the switch or the switch is ON.
OEM installed cooling fan air solenoid valve Open solenoid circuit
Circuit breaker for the cooling fan Tripped breaker or open circuit
Dedicated PTO on/off switch The “PTO Configuration” is programmed.
The “PTO Activates Cooling Fan” is programmed.
There is a short circuit in the switch or the switch is on.
RENR1367-11 183

and Wiring.
g00840659
Illustration 54
Terminal locations for the ECM connector (P1)
A. Thoroughly inspect the ECM vehicle harness E. Ensure that the cooling fan on the vehicle is wired
connector J1/P1, the connector on the clutch to the ECM. Check for wires that are connected
for the A/C compressor, the connections to the to terminal 11 (output 5), terminal 62 (input 12) or
cooling fan solenoid, and the firewall bulkhead terminal 41 (input 11).
connectors. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details. Refer to Illustration 54 for terminal locations for
the ECM.
wires in the ECM connector that are associated Expected Result:
All connectors, pins, and sockets are completely
• Cooling fan coupled and/or inserted, and the harness and wiring
should be free of corrosion, abrasion or pinch points.
• circuit for the clutch of the A/C compressor
Results:
the proper torque of 6.0 N·m (55 lb in). • OK – Proceed to Test Step 2.
D. Check the harness and the wiring for abrasion and • Not OK
pinch points from the battery to the ECM. Then,
check from the ignition key switch to the ECM.
184 RENR1367-11
Repair: Repair the wiring or replace the wiring, if Ensure that the “A/C Fan Request” parameter
necessary. Repair the connectors or replace the is programmed to “J1/P1:41” or “J1/P1:62”. If
connectors, if necessary. Ensure that all of the the “A/C Fan Request” is not programmed to
seals are in the proper place. Ensure that all of the “J1/P1:41” or “J1/P1:62”, the A/C compressor
connectors are connected properly. clutch will not turn on the fan .
Verify that the repair eliminates the problem. Ensure that the “A/C Switch Fan On-Time”
parameter is programmed to a value that is
STOP. between “0” and “600”. If this parameter is
programmed to “0”, Input #11 is not used.
• ECM not wired to fan or switch – If the cooling fan
on the vehicle is not wired to the ECM then the Note: If the “Fan Control Type” parameter indicates
ECM is not being used for fan control. STOP. “None”, then the cooling fan driver is not used.
Test Step 2. Check the Programming of Expected Result:

the “Fan Control Type” Parameter.
All three parameters are programmed correctly.
A. Connect an electronic service tool to the cab data
link connector. Results:
B. Check the “Fan Control Type” parameter. Ensure • Yes – The parameters are programmed correctly.
that the parameter is programmed to“On-Off”, Proceed to Test Step 4.
if the ECM is used to control the fan. If the
parameter is programmed to “None” and the ECM • No – Change the parameters to the correct
is connected to the fan, then the fan will always settings. Proceed to Test Step 4.
be ON.
Test Step 4. Use the Electronic Service
Expected Result: Tool to Check Active Codes or Logged
Codes.
The “Fan Control Type” parameter is programmed to
match the vehicle wiring. This is determined in the A. Connect the electronic service tool to the cab data
previous step. link connector.
Results: B. Turn the ignition key switch to the ON position.
• Yes – Proceed to Test Step 3. C. Access the logged diagnostic codes and the active
diagnostic codes onthe electronic service tool.
• No – Program the “Fan Control Type” to the correct
setting and then recheck the system. If conditions D. Check for the following diagnostic codes.
are not resolved, then proceed to Test Step 3.
• 110-00 High Coolant Temperature Warning
Test Step 3. Use the Electronic Service
Tool to Verify that the Parameters are • 110-11 Very High Coolant Temperature
Correctly Programmed.
• 110-03 Coolant Temp Sensor Open Circuit
A. Connect the electronic service tool to the cab data
link connector. • 110-04 Coolant Temp Sensor Short Circuit
B. Turn the ignition key switch to the ON position. Record any logged diagnostic codes. Record any
active diagnostic codes.
C. View the following Customer Specified
Parameters. Expected Result:
• “Fan Control Type” Result 1 None of the diagnostic codes that are listed
are logged or active.
• “A/C Fan Request”
Result 2 Diagnostic Code 110-00, or 110-11 is
• “A/C Switch Fan On-Time” logged or active.
Result 3 Diagnostic Code 110-03 or 110-04 is logged

or active.
RENR1367-11 185
Results: c. The resistance should measure 10 Ohms or

less.
C. If the A/C compressor clutch switch is connected
• Result 2 – The cooling fan is ON because of a to P1:62 (Input #12), use the following steps to
high coolant temperature. check the switch circuit.
Repair: Perform the following diagnostic a. Disconnect the wire at terminal P1:62 (Input
procedure: Troubleshooting, “110-11 Very High #12).
Coolant Temperature”
b. Connect a voltage test lamp between the wire
STOP. that was removed from terminal P1:62 and
terminal 67 (- Battery).
• Result 3 – The cooling fan is ON because of a
coolant temperature sensor fault. c. Turn the keyswitch to the ON position. The A/C
compressor clutch must be engaged in order to
Repair: Perform the following diagnostic check the A/C compressor clutch switch.
procedure: Troubleshooting, “Engine Temperature
Sensor Open or Short Circuit - Test” d. The test lamp should illuminate when the A/C
compressor clutch is engaged.
STOP.
Expected Result:
Test Step 5. Check the A/C Compressor
Clutch Switch. The circuit behaved in the manner that was described
in the instructions above.
Results:
• Yes – The A/C compressor clutch switch and the

wiring are electrically OK. Proceed to Test Step 6.
• No
Repair: Replace the A/C compressor clutch switch
and/or the related wiring.
STOP.
Test Step 6. Use the Electronic

Service Tool to Check Inlet Manifold
Air Temperature and the Coolant
Temperature.
Illustration 55
g00841499 A. Connect the electronic service tool to the cab data
link connector.
Pin locations on P1 connector

C. Access the status screen. Locate the “Coolant
B. If the A/C compressor clutch switch is connected
Temperature” and the “Inlet Manifold Air
to P1:41 Input #11, use the following steps to
Temperature” status screen. Monitor the status
check the switch circuit.
screen for a few minutes in order to verify that the
temperatures are changing as the engine warms
a. Disconnect the wires at terminals P1:41 and
up.
P1:5.
Expected Result:
b. Connect a multimeter and measure the
resistance between the two terminals of
The “Coolant Temperature” and the “Inlet Manifold
the A/C compressor clutch switch. The A/C
Air Temperature” appear to have the correct reading.
compressor clutch must be engaged in order to
check the resistance.
186 RENR1367-11
Results: Verify that the repair eliminates the problem.
• Yes – Proceed to Test Step 7. STOP.
• No • No – Proceed to Test Step 8.

Repair: Temporarily connect another sensor. Test Test Step 8. Use the “Cooling Fan
the new sensor by checking “Inlet Manifold Air Solenoid Special Test” on the Electronic
Temperature” and “Coolant Temperature” again. Service Tool to Check the ECM.
If the problem is resolved with the new sensor,
then reconnect the old sensor in order to verify that
the problem returns. If the problem returns, then
replace the old sensor.
STOP.
Test Step 7. Use the “Cooling Fan

Solenoid Special Test” on the Electronic
Service Tool to Check the Circuit.
link connector.
C. Access the “Cooling Fan Solenoid Special Test”.

Access each menu in the order that follows:
• Diagnostics Illustration 56
g00841548
• Diagnostic Tests A. Turn the ignition key switch to the OFF position.
• Special Test B. Disconnect the ECM vehicle harness connector
J1/P1.
Note: If any override switches are installed, the
switch must be in the OFF position. C. Remove terminal 11 (Output 5) from the vehicle
harness connector P1.
D. Cycle the test to the ON position and to the OFF
position. Listen for the solenoid to click. You may D. Connect a Breakout T to the ECM connector J1
need to be near the engine in order to hear the and vehicle harness connector P1.
click of the solenoid.
E. Connect a voltage test lamp between terminal
Expected Result: 11 (Output 5) and terminal 67 (negative battery)
of the breakout T.
An audible clicking is heard, and the solenoid
appears to be operating properly. F. Turn the ignition key switch to the ON position.
Results: G. Access the “Cooling Fan” test on the electronic
service tool.
• Yes – The cooling fan circuit from the ECM to the
solenoid is functioning properly at this time. Start the “Cooling Fan” test and stop the “Cooling
Fan” test. At the same time, watch the voltage
Repair: If a problem still exists, then the problem is test lamp.
in the wiring that was installed by the OEM. Repair
the problem or send the vehicle to the OEM dealer Note: A multimeter can not be used in place of the
for repair. voltage test lamp when the ECM output is tested.
RENR1367-11 187
Expected Result: • “A/C Fan On Time” is programmed between one

second and 600 seconds.
The voltage test lamp turns on when the test is
active. The voltage test lamp turns off when the test • A wire is present in the ECM vehicle harness
is not active. connector J1/P1 (terminal 11) which is output 5
(cooling fan solenoid). This occurs if an On/Off
Results: type of fan is used.
• Yes – The output for the ECM cooling fan relay • Perform the Special Test for the “On/Off Cooling
is functioning properly. Fan”. Access each menu in the order that follows:
“Diagnostics”, “Diagnostic Tests”, and “Special
Repair: If a problem still exists, then the problem is Test”. Activating and then deactivating the circuit
in the wiring that was installed by the OEM. Repair should cause the air solenoid to click if the circuit
the problem or send the vehicle to the OEM dealer is working properly.
for repair.
Verify that the repair eliminates the problem. to this procedure:
STOP. Cooling Fan
• No The signal for the cooling fan is provided by the ECM

in order to control the cooling fan. An input from one
Repair: Temporarily connect a test ECM. Use of the following items may cause the fan to turn ON:
the special test on the electronic service tool to
check the ECM cooling fan circuit. If the problem • Engine coolant temperature sensor
is resolved with the test ECM, install the suspect
ECM. If the problem returns with the suspect ECM, • Air inlet temperature sensor
replace the ECM.
• Exhaust brake
• PTO on/off switch
STOP.
• OEM installed A/C high pressure switch
i01606147
• Manual fan override switch
Cooling Fan Circuit and A/C A control unit for the A/C may be connected to the
High Pressure Switch Circuit A/C high pressure switch (input 11) instead of a
- Test switch.
SMCS Code: 1356-038; 1435-038-PX The output for the cooling fan is intended to connect
directly to the circuit for the cooling fan solenoid.
Program the “Fan Control Type” parameter to
“ON/OFF”. The fan will be off when the ECM output
is ON (energized). When the ECM activates the fan,
the fan will remain on for a minimum of 30 seconds
Use this procedure to determine if the cooling fan except for the following conditions:
(output 5) or the A/C high pressure switch (input 11)
is operating correctly. • Engine start-up
Note: Not all vehicle manufacturers, or all trucks for • The “A/C Pressure Switch Fan On Time” is
programmed to less than 30 seconds.
a manufacturer use the Caterpillar cooling fan circuit.
Prior to troubleshooting, determine if the vehicle is
During engine start-up, the ECM will keep the fan
using the ECM cooling fan circuit.
ON for two seconds after the engine has reached
Check the following items in order to determine if a the programmed low idle (700 to 800 rpm). The fan
will be ON continuously if the electrical circuit to the
vehicle is using the ECM cooling fan circuit:
cooling fan air solenoid valve has an open circuit or if
the ECM Fan Relay circuit is opened.
• The “Fan Control Type” parameter must be
programmed to “On/Off” or one of the variable
Cooling Fan ON Conditions
speed options. The Caterpillar factory default is
None.
188 RENR1367-11
The ECM will turn the cooling fan ON under any of • The A/C high pressure switch is not active.
the following circumstances if engine speed is less
than 2750 rpm: • The PTO on/off switch is in the OFF position and
the “PTO Activates Cooling Fan” parameter is
• The engine is not running. programmed to “Continious”.
• Engine cranking • The manual fan override switch is OFF.

• The coolant temperature is greater than 96 °C A/C High Pressure Switch Input Connected to
(205 °F). A/C Control Unit.
• Active diagnostic code for the coolant temperature A control unit for the A/C that is supplied by the OEM
sensor may be used. The control unit for the A/C determines
when the cooling fan should operate. This is based
• The inlet manifold air temperature is greater than on the following input information:
87 °C (189 °F).
• A/C high pressure switch
72 °C (162 °F) while the boost pressure is greater • low pressure switch
than 70 kPa (10 psi).
• evaporator thermostat
• The manual fan override switch is on.
The output for the fan for the control unit to the A/C
• The “Fan with Exhaust Brake ON” is programmed is designed to interface with the ECM. The output
to “YES” and the exhaust brake has been on at for the fan may be connected to the input for the
least two seconds. A/C high pressure switch. The input for the A/C high
pressure switch is Input 11 of the ECM connector
• The “A/C Switch Fan On-Time” is programmed to J1/P1 terminal 41. The fan is in the ON position when
a value above 0 and the A/C high pressure switch the A/C high pressure switch is in the OPEN position.
is open. This type of control has a time delay. Typically, the
“A/C Switch Fan On-Time” is programmed to one
• The ECM is counting after the A/C high pressure second since the control unit for the A/C provides
switch has closed. an additional time delay.
• The “PTO Activates Cooling Fan” parameter is The Cooling Fan Control can be Operated
programmed to “Continuous” and the PTO on/off Independently of the ECM.
switch is on.
Operation of the cooling fan control can be controlled
The last four items in the previous list are dependent independently of the ECM. The OEM installed air
upon the programming of the Customer Parameters. conditioning high pressure switch may be used for
independent cooling fan control. A cab mounted
Note: The ECM will turn OFF the cooling fan for 10 override switch in the solenoid circuit can also
seconds during engine shutdown. operate the cooling fan.
Cooling Fan OFF Conditions Troubleshooting
The cooling fan will be turned OFF by the ECM Before troubleshooting the cooling fan circuit,
if engine rpm exceeds 2800 rpm or when all the determine the type of fan drive system that is used.
following circumstances are met: The fan drive can use the following controls in order
to control the fan:
• The coolant temperature is less than 92 °C
(198 °F). • normally open with a pneumatic air solenoid
• The fan has been ON for at least 30 seconds. • normally closed with a pneumatic air solenoid
• The inlet manifold air temperature is less than • normally open with an electrically controlled
53 °C (127 °F). solenoid
• The strategy for the exhaust brake is not active • normally closed with an electrically controlled
and the “Fan with Exhaust Brake ON” parameter is solenoid
programmed to “YES”.
RENR1367-11 189
The following OEM installed components may affect

the operation of the cooling fan in some applications:
• OEM installed, normally open relay

• The a/c high pressure switch is connected to the
ECM or the a/c high pressure switch is independent
of the ECM.
• Cab mounted manual override switch

• A timer that keeps the fan in the ON position
• Cooling fan air solenoid valve
g00766507
Illustration 57
This schematic represents the on/off fan with a direct solenoid connection to the ECM and the A/C pressure switch connected to the ECM input.
190 RENR1367-11
Table 157
active.
to “YES”.
OEM installed A/C high pressure switch The “A/C Switch Fan On-Time” is programmed to a value
above 0.
The switch circuit is open or on.
The external timer is counting or the ECM timer is counting.
seconds or the ignition key is ON and the engine OFF.
(189 °F).
(10 psi).
OEM installed manual fan override switch There is an open circuit in the switch or the switch is ON.
g00766679
Illustration 58
This schematic represents an on/off fan with a direct solenoid connection to the ECM and the A/C high pressure switch is not connected to
the ECM input.
RENR1367-11 191
Table 158
active.
to “YES”.
OEM installed A/C high pressure switch The switch circuit is open or ON.
The engine rpm is less than 2750 rpm. The engine is cranking. The engine has been running for
two seconds or the ignition key is in the ON position and the
engine off.
(189 °F).
(10 psi).
There is a short circuit in the switch or the switch is ON.
g00675587
Illustration 59
This schematic represents the on/off fan with a direct solenoid connection to the ECM and the control unit for the A/C connected to the
ECM input.
192 RENR1367-11
Table 159
active.
to “YES”.
OEM installed A/C control unit The “A/C Switch Fan On-Time” parameter is programmed
to a value above 0 seconds.
The A/C control unit circuit is open.
The engine rpm is greater than 2750 rpm. The engine is cranking. The engine has been running two
seconds or the ignition key is on the ON position and the
engine off.
(189 °F).
(10 psi).
OEM installed manual fan override switch There is an open circuit in the switch or the switch is on.
g00766689
Illustration 60
This schematic represents the on/off fan with a normally closed relay and the A/C high pressure switch that is not connected to the ECM input.
RENR1367-11 193
Table 160
active.
to “YES”.
OEM installed A/C high pressure switch The circuit for the switch is closed or the switch is on.
engine off.
(189 °F).
(10 psi).
OEM installed cooling fan air solenoid valve The solenoid is energized.
OEM installed cooling fan relay There is an open circuit on the coil side of the relay.
g00845731
Illustration 61
This schematic represents the on/off fan with a normally open relay connection and an A/C high pressure switch connected to the ECM input.
194 RENR1367-11
Table 161
active.
to “YES”.
OEM installed A/C high pressure switch The “A/C Switch Fan On-Time” parameter is programmed
The switch circuit is open or the switch is on.
engine off.
(189 °F).
(10 psi).
OEM installed cooling fan relay Open circuit in either coil or contact side of relay
g00845732
Illustration 62
This schematic represents the on/off fan with a normally open relay connection and an A/C high pressure switch connected between the
solenoid and the relay.
RENR1367-11 195
Table 162
active.
to “YES”.
OEM installed A/C high pressure switch The switch circuit is open or the switch is ON.
engine off.
(189 °F).
(10 psi).
OEM installed cooling fan relay Open circuit in either coil or contact side of relay
g00675642
Illustration 63
This schematic represents the on/off fan with a normally closed relay connection and an A/C high pressure switch connected to the ECM input.
196 RENR1367-11
Table 163
active.
to “YES”.
OEM installed A/C high pressure switch The “A/C Switch Fan On-Time” parameter is programmed
The switch circuit is open or the switch is on.
engine off.
(189 °F).
(10 psi).
OEM installed manual fan override switch There is a short circuit in the switch or the switch is on.
OEM installed cooling fan air solenoid valve The solenoid is energized.
OEM installed Cooling Fan Relay Open circuit in coil side of relay
RENR1367-11 197

and Wiring.
g00675876
Illustration 64
Terminal locations for the ECM
A. Thoroughly inspect the ECM vehicle harness Refer to Illustration 64 for terminal locations for
connector J1/P1, the A/C high pressure switch the ECM.
connector, the connections to the cooling fan
solenoid, and the firewall bulkhead connectors. Expected Result:
Inspect” for details. All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring
B. Perform a 45 N (10 lb) pull test on each of the should be free of corrosion, abrasion or pinch points.
with the following connections: Results:
• Cooling fan • OK – Proceed to Test Step 2.

• A/C high pressure switch • Not OK
C. Check the ECM connector (allen head screw) for Repair: Repair the wiring or replace the wiring, if
the proper torque of 6.0 N·m (55 lb in). necessary. Repair the connectors or replace the
connectors, if necessary. Ensure that all of the
D. Check the harness and the wiring for abrasion and seals are in the proper place. Ensure that all of the
pinch points from the battery to the ECM. Then, connectors are connected properly.
E. Ensure that the ECM is wired to the cooling fan on
the vehicle and/or the A/C high pressure switch. STOP.
Check for wires that are connected to terminal
11 (output 5) and for wires that are connected • ECM not wired to fan or switch – If the ECM is
to terminal 41. Input 11 is the A/C high pressure not wired to the cooling fan on the vehicle and/or
switch of vehicle harness connector P1. the A/C high pressure switch, then the ECM is not
being used for fan control. STOP.
198 RENR1367-11
Test Step 2. Check the Programming of • No – The status of the A/C high pressure switch
the “Fan Control Type” Parameter. is “Unavailable”. The ECM is not programmed to
use the A/C high pressure switch. Proceed to Test
A. Connect ET to the cab data link connector. Step 5.
B. Check the “Fan Control Type” parameter. Ensure Test Step 4. Use ET to Check the
that the parameter is programmed to“On-Off”, Operation of the A/C Pressure Switch.
if the ECM is used to control the fan. If the
parameter is programmed to “None” and the ECM A. Connect ET to the cab data link connector.
is connected to the fan, then the fan will always
be ON. B. Turn the ignition key switch to the ON position.
Expected Result: C. Access the “A/C High Pressure Switch” status

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

the vehicle harness at the switch and use the
• Yes – Proceed to Test Step 3. jumper wire to short the two terminals in the
harness connector together.
• No – Program the “Fan Control Type” to the correct
setting and then recheck the system. If conditions F. Remove the jumper wire and then insert the
are not resolved, then proceed to Test Step 3. jumper wire. At the same time, view the “A/C High
Pressure Switch” status on the service tool status
Test Step 3. Use ET to Check the A/C screen.
Pressure Switch.
Expected Result:
A. Connect ET at the cab data link connector.
The status screen indicates that the “A/C High
B. Turn the ignition key switch to the ON position. Pressure Switch” is turning to the ON position. Then,
the “A/C High Pressure Switch” is turning to the OFF
C. View the following Customer Specified position.
Parameters.
Results:
• “Fan Control Type”
• Yes – The A/C high pressure switch harness is
• “A/C Switch Fan On-Time” OK. Proceed to Test Step 6.
Ensure that the “A/C Switch Fan On-Time” is • No – Proceed to Test Step 7.
programmed to a greater value than “0”. If the
“A/C Switch Fan On-Time” is programmed to “0”, Test Step 5. Use ET to Check Active
then the “A/C High Pressure Switch Input” (Input Codes or Logged Codes.
11) is not used.
A. Connect ET to the cab data link connector.
Note: If the “Fan Control Type” parameter indicates
“None”, then the cooling fan driver is not used. B. Turn the ignition key switch to the ON position.
View the “A/C High Pressure Switch” status on ET. C. Access the “Logged Diagnostic Codes” and the
“Active Diagnostic Codes” on ET.
Expected Result:
D. Check for the following diagnostic codes.
The status of the A/C high pressure switch indicates
ON or OFF. • 110-00 High Coolant Temperature Warning
Results: • 110-11 Very High Coolant Temperature
• Yes – The status of the A/C high pressure switch • 110-03 Coolant Temp Sensor Open Circuit
is ON or OFF. Proceed to Test Step 4.
• 110-04 Coolant Temp Sensor Short Circuit
RENR1367-11 199
Record any logged diagnostic codes. Record any Repair: Check the A/C pressure or send the
active diagnostic codes. vehicle to the OEM dealer for repairs.
Result 1 None of the diagnostic codes that are listed • No

are logged or active.
Repair: Replace the A/C high pressure switch.
Result 2 Diagnostic code 110-00, or 110-11 is logged
or active. Verify that the repair eliminates the problem.
Result 3 Diagnostic code 110-03 or 110-04 is logged STOP.

or active.
Results:

high coolant temperature.
Repair: Perform either of the following diagnostic

procedures: Troubleshooting, “0110-00 High
Coolant Temperature Warning” Troubleshooting,
“0110-11 Very High Coolant Temperature”
STOP.

coolant temperature sensor fault.

procedure: Troubleshooting, “Engine Temperature
Sensor Open or Short Circuit - Test”
STOP.
Test Step 6. Use a Voltmeter to Check the

A/C Pressure Switch.
B. Turn the ignition key switch to the OFF position.
C. Ensure that the A/C high pressure switch is

disconnected from the vehicle harness at the
switch terminals.
D. Connect a multimeter and measure the resistance

between the two terminals of the A/C high
pressure switch. The switch must be closed in
order to check the resistance.
Expected Result:
The resistance measures 10 Ohms or less.
Results:
• Yes – The ECM, the A/C high pressure switch,

and the wiring are electrically OK.
200 RENR1367-11
Test Step 7. Use ET to Check the ECM.
g00676088
Illustration 65
Connector for the Breakout T
A. Connect ET to the cab data link connector. Repair: If a problem still exists, then the problem
is in the OEM Wiring. Repair the problem or send
B. Turn the ignition key switch to the OFF position. the vehicle to the OEM dealer for repair. Verify that
the repair eliminates the problem.
C. Disconnect the ECM vehicle harness connector
J1/P1. STOP.
D. Remove terminal 41 (output 11) from the vehicle • No

E. Install a breakout T between connectors J1 and that the “A/C Pressure Switch Fan On-Time”
P1. parameter is programmed in the same manner as
the suspect ECM. Use ET to check the ECM. If
F. Fabricate a jumper wire 100 mm (4 inch) long. the problem is resolved with the test ECM, install
Crimp a Deutsch pin to both ends of the wire. the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM.
G. Connect the jumper wire to terminal 5 (ap
sensor/switch common) and to terminal 41 (input Verify that the repair eliminates the problem.
11) of the breakout T.
STOP.
Refer to illustration 65.
Test Step 8. Use ET to Check Inlet
H. Turn the ignition key switch to the ON position. Manifold Air Temperature and the
Coolant Temperature.
I. Access the “A/C High Pressure Switch” status
screen on ET. A. Connect ET to the cab data link connector.
J. Remove the jumper wire and then insert the B. Turn the ignition key switch to the ON position.
jumper wire. At the same time, watch the “A/C
High Pressure Switch” status on ET. C. Access the status screen. Locate the “Coolant
Temperature” and the “Inlet Manifold Air
Expected Result: Temperature” status screen. Monitor the status
screen for a few minutes in order to verify that the
The status screen indicates that the “A/C High temperatures are changing as the engine warms
Pressure Switch” status is OFF when the jumper wire up.
is in place. The status screen indicates ON when the
jumper wire is removed. Expected Result:
Results: The “Coolant Temperature” and the “Inlet Manifold

Air Temperature” appear to have the correct reading.
• Yes – The ECM is OK.
RENR1367-11 201
Results:
• Yes – Proceed to Test Step 9.

• No
Repair: Temporarily connect another sensor. Test
the new sensor by checking “Inlet Manifold Air
Temperature” and “Coolant Temperature” again.
If the problem is resolved with the new sensor,
then install the old sensor in order to verify that
the problem returns. If the problem returns, then
replace the old sensor.
STOP.
Test Step 9. Use the “Cooling Fan

Solenoid Special Test” on ET to Check
the Circuit.
g00676097
Illustration 66
Connector for the Breakout T
A. Connect ET to the cab data link connector. Expected Result:
B. Turn the ignition key switch to the ON position. An audible clicking is heard, and the solenoid
appears to be operating properly.
C. Access the “Cooling Fan Special Test”. Access
each menu in the order that follows: Results:
• Diagnostics • Yes – The cooling fan circuit from the ECM to the
Solenoid is functioning properly at this time.
• Diagnostic Tests
Repair: If a problem still exists, then the problem is
• Special Test in the OEM Wiring. Repair the problem or send the
vehicle to the OEM dealer for repair.
NOTE: If any override switches are installed, the
switch must be in the OFF position. Verify that the repair eliminates the problem.
D. Cycle the “Special Test” to the ON position and to STOP.

the OFF position. Listen for the solenoid to click.
You may need to be near the engine in order to • No – Proceed to Test Step10.
hear the click of the solenoid.
202 RENR1367-11
Test Step 10. Use the “Cooling Fan i01604160

Solenoid Special Test” on ET to Check
the ECM. Cruise Control Switch Circuit
- Test
SMCS Code: 7332-038
B. Disconnect the ECM vehicle harness connector
J1/P1. System Operation Description:
C. Remove terminal 11 (Output 5) from the vehicle Use this procedure under the following situation:
Use this procedure to determine if one of the
D. Connect a breakout T to the ECM connector J1 following switches is preventing normal operation of
and vehicle harness connector P1. cruise control, fast idle, idle set speed, extended idle,
or PTO operation:
E. Connect a voltage test lamp between terminal
11 (Output 5) and terminal 67 (negative battery) • Cruise control on/off switch
of the breakout T.
• Cruise control set/resume switch
F. Turn the ignition key switch to the ON position.
The following switch circuits can also prevent the
G. Access the “Cooling Fan Special Test” on ET. correct operation of the cruise control, idle set speed,
fast idle, extended idle, or PTO operation:
Cycle the “Cooling Fan Special Test” to the ON
position and to the OFF position. At the same • Service brake pedal position (switch 1)
time, watch the voltage test lamp.
• Service brake pedal position (switch 2)
Note: A multimeter can not be used in place of the
voltage test lamp when the ECM output is tested. • Clutch switch
Expected Result: • Neutral switch
The voltage test lamp turns to the ON position when • Cruise control set/resume switch
the test is “Active”. The voltage test lamp turns to the
OFF when the test is “NOT Active”. • Cruise control on/off switch
Results: • PTO on/off switch
• Yes – The output for the ECM cooling fan relay • Cruise control pause switch
is functioning properly.
The switches are described in the respective circuit
Repair: If a problem still exists, then the problem is tests in Troubleshooting.
in the OEM Wiring. Repair the problem or send the
vehicle to the OEM dealer for repair. All of the following Customer Programmable
Parameters can affect cruise control, fast idle, idle
Verify that the repair eliminates the problem. set speed, extended idle, and PTO operation:
STOP. • “Low Cruise Control Speed Set Limit”
• No • “High Cruise Control Speed Set Limit”
Repair: Temporarily connect a test ECM. Use the • “Idle Vehicle Speed Limit”
special test on ET to check the ECM cooling fan
circuit. If the problem is resolved with the test ECM, • “Idle RPM Limit”
install the suspect ECM. If the problem returns with
the suspect ECM, replace the ECM. • “Fast Idle RPM #1”
Verify that the repair eliminates the problem. • “Fast Idle RPM #2”
STOP. • “Cruise/Idle/PTO Switch Configuration”
RENR1367-11 203
• “Idle/PTO Bump rpm” After a speed has been set, pressing and holding the
set/resume switch in position will cause the engine
• “Idle/PTO rpm Ramp Rate” to establish a new set speed. The system’s reaction
depends on the programming of the “Cruise/Idle/PTO
• “PTO Vehicle Speed Limit” Switch Configuration”.
The vehicle speed calibration can also affect the When the set/resume switch is momentarily pressed,
cruise control, the fast idle, the idle set speed, the cruise set point will change one mph. The rate of
extended idle, and the PTO if the vehicle speed change is dependent on the programmed “Idle/PTO
calibration is incorrectly programmed. Refer to Bump RPM” when an idle speed is set.
Troubleshooting, “Customer Specified Parameters”.
The cruise control pause switch is not a switch that
This switch must be ON before cruise control or is wired to an input. The switch position is broadcast
controlled idle can be activated. This switch is ON over a J1939 data link. The parameter “Cruise Pause
when the switch is closed. When the switch is closed Switch” must be programmed to use a cruise control
the following terminals are connected: pause switch. After a speed has been set and the
speed is then disengaged by using the cruise control
• ECM connector J1/P1 terminal 59 (cruise control pause switch, the ECM will seek the previous set
on/off switch) speed when the resume switch is toggled. This
• Terminal 5 (ap sensor/switch sensor common) Cruise Control Speed Set Limit” for cruise control
This switch may not be connected to an input on the Speed Limit” for the idle and the PTO.
ECM. The parameter “Cruise Control On/Off Switch”
determines the input to the ECM. If the parameter is The following background information is related
programmed to J1/P1:59 a switch must be connected to this procedure:
to terminal 59. If the parameter is programmed to
one of the J1939 options, the switch position will be The kickout switch refers to the switch that is used to
transmitted to the ECM over the J1939 data link. If a exit the cruise control, the PTO, the fast idle, or the
problem is suspected with the J1939 data link, refer idle set speed.
to Troubleshooting, “Powertrain Data Link Circuit -
Test”. The operation of the Caterpillar Electronic Engine
Note: If the vehicle is programmed to use the cruise controls that are installed in automobiles. The
dedicated PTO, the PTO on/off switch overrides the operation of idle fast idle, and PTO are similar to the
cruise control on/off switch. The PTO on/off switch operation of cruise except that the idle, fast idle, and
overrides the cruise control on/off switch when the the PTO govern engine rpm instead of vehicle speed.
Speed Limit” that is programmed. Note: Idle in this procedure is an engine idle rpm
Set/Resume Switch by using the cruise control on/off switch and the
With the cruise control on/off switch in the ON Switch Circuit - Test” for additional information
position and the vehicle speed within the range of regarding the programmable options for the
the programmed “Low Cruise Control Speed Set dedicated PTO.
Limit” and the “High Cruise Control Speed Set Limit”,
momentarily pressing the set switch will activate the Kickout Switches
cruise or controlled idle, and the ECM will maintain
the current speed. The service brake pedal position switches, the neutral
switch and the clutch pedal position switch are used
After a speed has been set and the speed is then in the cruise control mode, the PTO mode, the fast
disengaged by using the brake, the clutch, the cruise idle mode, and the idle mode in order to discontinue
control pause switch, or the on/off switch, the ECM cruise operation, PTO operation, fast idle operation,
will seek the previous set speed when the resume or idle operation. The capability to override the idle
switch is toggled. This assumes that the vehicle shutdown timer is determined by the “Allow Idle
speed is above the “Low Cruise Control Speed Set Shutdown Override” parameter setting. The “Allow
Limit” for cruise control or the vehicle speed is below Idle Shutdown Override” is a Customer Parameter.
the “Idle/PTO Vehicle Speed Limit” for the idle and
the PTO. Usage of Transmission Style Switches
204 RENR1367-11
The “Transmission Style” parameter determines the • “AT/MT/HT Option 1”

can be used with being dependent on the parameter • “AT/MT/HT Option 2”
setting:
• “AT/MT/HT Option 3”
• clutch pedal position
• neutral
A service brake pedal position (switch 1) is required
• service brake pedal position (switch 1) for all configurations. The service brake pedal
position (switch 1) connects to the ECM through
• service brake pedal position (switch 2) connector P1 terminal 45. The service brake pedal
Refer to Table 164 for additional information. connector P1 terminal 64. The clutch pedal position
switch connects to the ECM through connector P1
Table 164 terminal 22. The neutral switch connects to the ECM
Switch Usage. through connector P1 terminal 62.
Setting For
Transmission Service Service Some engines that were built before JULY 1999
Style Brake Brake may have a Basic ECM. The Basic ECM was used
Clutch Neutral
only on General Motors chassis. Other chassis used
1 2
engines that were built with a Full Feature ECM.
“Manual
X X
Basic ECM software does not have the parameter
Option 1” for “Transmission Style”. For these systems, a
“Manual jumper wire must be installed between the clutch
X X X switch input and the sensor common when an
Option 2”
“Automatic wire is installed, the “Clutch Switch” status will
X
Option 1” always indicate “OFF”. Engines that were built after
“Automatic JULY 1999 use only one type of ECM that can be
X X configured for “Basic” or “Full Feature” operation. A
Option 2”
“Automatic flexibility. The “Truck Manufacturer” parameter was
X X X
Option 3”
“Automatic Basic” operation or the “Other Full Feature” operation.
X X
Option 4” This parameter is programmed at Caterpillar when
“AT/MT/HT
Option 1”
X Style” is not available for engines that have software
“AT/MT/HT “Truck Manufacturer” is programmed to “GM”. SEP00
X X
Option 2” and newer engines that are programmed to “GM”
“AT/MT/HT use the “Transmission Style” parameter. The factory
X X X default for the “GM” setting is the “Universal” option.
Option 3”
“AT/MT/HT the “Basic” system that is described above. If the
X X
Option 4” “Transmission Style” parameter is programmed to the
“Universal “Universal” option, a jumper wire must be installed
X X X between the clutch switch input and the sensor
Option”
If the “Transmission Style” parameter is programmed be programmed to match the specific arrangement
to one of the following options, the input for the clutch of the vehicle.
pedal position switch is not used.
• “Automatic Option 1” Cruise/Idle/PTO kickouts use the following
procedure:
• “Automatic Option 2”
Operate the vehicle in “Cruise/Idle/PTO” mode.
RENR1367-11 205
After the kickout, review the status parameter on ET.

The status parameter on ET indicates the cause.
This must be performed before the ignition key switch
is turned OFF. It is important to remember that the
parameter will only indicate the last kickout since the
ECM has been powered by the input for the ignition
key switch.
The following kickout status parameters are available:
• “Cruise Kickout”
• “Idle Kickout”
• “PTO Kickout”
• “Fast Idle Kickout”
This parameter is blank when the ECM is first
Occurrence” is indicated. This parameter remains
blank until the ECM detects the use of the
Cruise/Idle/PTO Mode. Also, this parameter remains
blank until the ECM detects the disengagement of
the Cruise/Idle/PTO Mode. Refer to Tables 165, 166,
167, and 168 in order to interpret the status screen
kickout status parameter.
206 RENR1367-11
Table 165
The cruise/idle on/off switch is turned off Proceed with the test procedure.
“Switch Turned Off” or the switch circuit has an open circuit
condition.
Switch”
circuit condition.
The clutch pedal is depressed or the Refer to Troubleshooting, “Cutch Pedal
clutch pedal switch circuit has an open Position Switch Circuit - Test”.
circuit condition.
exists.
circuit condition.
RENR1367-11 207
Table 166
The cruise/idle on/off switch is turned off Proceed with the test procedure.
“Switch Turned Off” or the switch circuit has an open circuit
condition.
Switch”
circuit condition.
circuit condition.
208 RENR1367-11
Table 167
The fast idle on/off switch is turned off or the Proceed with the test procedure.
switch circuit has an open circuit condition.
Switch”
circuit condition.
RENR1367-11 209
Table 168
Table For The PTO Kickout Status Screen On ET
No Engine Speed
The PTO On/Off switch is turned OFF or the Proceed with the test procedure.
Switch Turned Off
Switch”
circuit condition.
g00643881
Illustration 67
Schematic for cruise control switch, service brake pedal position switch 1 and clutch pedal position switch
Test Step 1. Determine the Type of C. If the vehicle will not allow setting a cruise speed,
Problem. an idle speed or a PTO speed, check the following
A. Connect ET.
• “Low Cruise Control Speed Set Limit”
210 RENR1367-11

Idle Parameters

• “Idle rpm Limit”
• “Top Engine Limit (TEL)”
PTO Parameters
necessary.

cause of a kickout for one of the following items:
• Cruise Control Kickout

• Idle Kickout
• PTO Kickout
Refer to Tables 165, 166, 167, and 168 for the
meaning of the cause of the kickout.
Expected Result:
The problem is due to a parameter setting or the

Results:
• Yes – Explain the proper operation of system to

the driver. STOP.
• No
recommended troubleshooting.
If a problem is still suspected with the cruise control

on/off switch or the set/resume switch, perform the
following procedure:

RENR1367-11 211

and Wiring.
g00703076
Illustration 68
A. Thoroughly inspect ECM vehicle harness Results:

connector J1/P1, the firewall bulkhead connector
and the terminals for the following switches in the • OK – Proceed to Test Step 3.
connectors:
• Not OK
• AP sensor/switch sensor common (terminal 5)
• set/resume switch (terminals 35 and 44) replace the connectors or wiring. Ensure that all of
• cruise control on/off switch (terminal 59) connectors are completely coupled.
Refer to Troubleshooting, “Electrical Connectors - Verify that the repair eliminates the problem.
STOP.
with the switches.

the proper torque of 6.0 N·m (55 lb in).

Expected Result:

212 RENR1367-11
Test Step 3. Check the Cruise Control Test Step 4. Operate the Vehicle and
Switch Status on ET. Check the Kickout Status Parameter.
Table 169 A. For an intermittent cruise control kickout, talk to
Table for Cruise Control Switch Status the driver in order to determine the conditions
Switch Position Switch Status Circuit could be the following examples:
The Cruise/Idle On/Off
ON Closed • specific speed
Switch is turned ON.
The Cruise/Idle On/Off
Switch is turned OFF.
OFF Open • road conditions
The Set/Resume Switch
Set Switch ON Closed
• weather conditions
is in the SET position.
Take the vehicle for a road test in order to
The Set/Resume Switch
is in the RESUME
Resume Switch
Closed
duplicate these conditions and set the cruise
ON control. Operate the vehicle in cruise control until
position.
the problem reoccurs.
A. Access the status screen on ET. B. For an intermittent idle kickout, talk to the driver
B. Turn the ignition key switch to the ON position. kickout occurs. A topic of examination could be
the following example:
C. Operate the cruise control on/off switch while the
status of the cruise/idle on/off switch is being • specific engine rpm
observed.
D. Leave the cruise control on. set the idle rpm. Operate the vehicle in idle until
E. Operate the set switch while the status of the
set/resume switch is being observed. The status Note: The status screen will only indicate the last
screen should indicate “Set Switch ON” when the kickout. The status screen will lose this information if
set switch is held in the SET position. The status the ignition key switch is turned OFF.
screen should indicate “Off” when the set switch
is released. C. Connect ET and check the status screen for the
last cause of the kickout. Refer to Tables 165,
F. Operate the resume switch while the status of 166, 167, and 168 for an explanation of the status
the resume switch is being observed. The status parameter.
screen should indicate “Resume Switch ON”
when the resume switch is held in the RESUME D. If the status screen is blank, then either there was
position. The status screen should indicate “Off” no kickout of the cruise control, or the power to
when the resume switch is released. the ECM was turned OFF before the information
could be read. Repeat this test step.
Expected Result:
Note: A status screen that is blank indicates No
The switch status changes per the information in Occurrence.
Table 169.
Expected Result:
Results:
• Yes – The switches are operating normally. STOP. result:
• Intermittent Problem Suspected – Proceed to Test • “Switch Turned Off”

Step 4.
• No – The ECM is not reading the switch status result:
• “Cruise Control PAUSE Switch”
results:
RENR1367-11 213
• “Vehicle Speed < Limit” Repair: Perform the following diagnostic

procedure:
• “Vehicle Speed ≥ Limit”
STOP.
• “PTO Switch ON” Repair: Perform the following diagnostic
procedures:
result: Troubleshooting, “Neutral Switch Circuit - Test”.
• “Neutral” STOP.
RESULT 6 The status screen displays the following • Result 6

result:
• “Brake” procedure:
RESULT 7 The status screen displays the following Troubleshooting, “Service Brake Pedal Position
result: (Switch 1) Circuit - Test”
• “Clutch” STOP.
RESULT 8 The status screen displays the following • Result 7

result:
• “No Engine Speed” procedure:
RESULT 9 The status screen displays the following Troubleshooting, “Clutch Pedal Position Switch
result: Circuit - Test”
• “Set Switch Timeout” STOP.
• “Resume Switch Timeout” • Result 8

Results: Repair: Perform the following diagnostic
procedure:
• RESULT 1 – Proceed to Test Step 5.
Troubleshooting, “Engine Speed/Timing Switch
• Result 2 Circuit - Test”

procedure:
• Result 9
Test” Repair: Perform the following diagnostic
procedure:
STOP.
• Result 3 Test”

procedure:
Troubleshooting, “Vehicle Speed Circuit - Test”
STOP.
• Result 4
214 RENR1367-11
Test Step 5. Check the Switch Circuit.

Table 170
Table for Status of the Cruise Control Switch Input
Condition of Switch Circuit Switch Status Circuit
Terminal 59 Cruise/Idle On/Off Switch is Open. OFF Open
Terminal 59 Cruise/Idle On/Off Switch is connected to
ON Shorted
terminal 5.
Set Switch Terminal 35 is Open. OFF Open
Set Switch Terminal 35 connected to terminal 5. Set Switch ON Shorted
Resume Switch (Terminal 44) is Open. OFF Open
Resume Switch (Terminal 44) connected to terminal 5. Resume Switch ON Shorted
A. Turn the ignition key switch to the OFF position. 2. Remove all jumpers and replace all connectors.
B. Fabricate a jumper wire 100 mm (4 inch) long. 3. Recheck the system for active diagnostic codes.
Crimp a Deutsch pin to both ends of the wires.
4. Repeat the test step.
the ECM. 5. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
D. Connect a breakout T to ECM connector J1 and
connect P1 to the breakout T. 6. If the problem returns with the suspect ECM,
replace the ECM.
E. Install the jumper into the suspect switch socket
of the breakout T. Connect the other end of the 7. Verify that the repair eliminates the problem.
jumper to ECM connector P1 terminal 5 (ap
sensor/switch sensor common) of the breakout T. STOP.
G. Connect ET to the cab data link connector.
H. Access the status screen.
I. While the switch status is being monitored on

the status screen slowly remove the jumper from
terminal 5 and slowly insert the jumper from
terminal 5 (ap sensor/switch sensor common).
Refer to Table 170.
Expected Result:

Table 170.
Results:

to Test Step 6.
• No – The ECM is not functioning properly.


RENR1367-11 215
Test Step 6. Insert a Jumper at the

Suspect Switch.
Table 171
The wires for the Cruise/Idle On/Off Switch are
OFF Open
disconnected.
ON Shorted
connected.
Set Switch wires are disconnected. OFF Open
Set Switch wires are connected. Set Switch ON Shorted
The Resume Switch wires are disconnected. OFF Open
The Resume Switch wires are connected. Resume Switch ON Shorted
B. Ensure that ECM vehicle harness connector J1/P1

is connected.
C. Find the suspect switch in the vehicle.
D. Disconnect the wires from the suspect switch

terminals.
F. Connect ET to the cab data link connector.

status screen slowly connect the suspect switch
wires and slowly disconnect the suspect switch
wires.
Refer to Table 171.
Expected Result:

Table 171.
Results:
• Yes
Replace the faulty switch.
STOP.
• No – There is a problem in the harness between

the switch and the ECM. Proceed to Test Step 7.
216 RENR1367-11

Bulkhead Connector.
Table 172
OFF Open
disconnected.
ON Shorted
connected.
The Set Switch wires are disconnected. OFF Open
The Set Switch wires are connected. Set Switch ON Shorted
The Resume Switch wires are disconnected. OFF Open
The Resume Switch wires are connected. Resume Switch ON Shorted
A. Turn the ignition key switch to the OFF position. Inspect the vehicle wiring and repair the vehicle
B. Fabricate a jumper wire 100 mm (4 inch) long. the wiring, send the vehicle to the OEM dealer.
STOP.
C. Find the suspect switch terminal and the ap
sensor/switch sensor Common terminal in the • No – The problem is in the vehicle wiring between
engine side of the bulkhead connector for the the bulkhead connector and the ECM.
vehicle harness.
D. Insert the jumper wire between the two terminals
in the engine side of the bulkhead connector. Inspect the vehicle wiring and repair the vehicle
E. Turn the ignition key switch to the ON position. the wiring, send the vehicle to the OEM dealer.
F. Connect ET to the cab data link connector. STOP.

i01631916

status screen alternately remove the jumper wire
ECM Memory - Test
between the two terminals, and alternately insert SMCS Code: 1901-038
the jumper wire between the two terminals.
Refer to Table 172.
Expected Result:
Use this procedure if one of the following diagnostic
The switch status changes per the information in codes is present:
Table 172.
Results:
• 252-11 Incorrect Engine Software (59)
• 253-02 Check Customer or System Parameters
• Yes – The problem is in the vehicle wiring between (56)

• 253-14 Truck Manufacturer Parameter Not
Programmed (56)
RENR1367-11 217
Also, use this procedure if the integrity of the

Customer Parameters or the System Parameters in
the ECM is questionable. Also, use this procedure if
the data for the Engine Lifetime Totals is questionable.

to this procedure:
The Engine Control Module (ECM) is the computer

which controls the Caterpillar electronic truck engine.
The Personality Module contains the software that
controls the operation of the computer (ECM).
The Personality Module software is the instructions

that are used by the ECM to control the engine. For
this reason, updating the Personality Module to a
different version may cause some engine functions
to behave in a different manner.
Performance Maps
Performance Maps define characteristics for various Illustration 69

g00772334
operating conditions. These characteristics are used ECM and harness connectors
to achieve optimum performance while emissions
requirements are being met. Examples of these Logged Diagnostics
characteristics are included in the following list:
Logged diagnostics are stored by the ECM into
• Fuel rate memory so a permanent record of the diagnostic
code is retained. Logged faults that are not critical
• Timing are automatically cleared after 100 hours.
These characteristics are programmed into the Input Circuits
Personality Module at the factory only.
Input circuits filter electrical noise for sensor signals.
Microprocessor Also, input circuits protect internal circuits from
potentially damaging voltage levels.
The ECM uses a microprocessor to perform the
computing that is required to perform the following Output Circuits
functions:
Output circuits provide the voltage or current that is
• Governing required to energize components that are connected
to the ECM.
• Controlling timing
Power Circuits
• Generating diagnostic codes
Power circuits provide clean stable electrical power
• Communicating with service tools to internal circuits and external sensors.
The microprocessor reads the instructions from the Test Step 1. Inspect Electrical Connectors
software in the Personality Module. and Wiring.
Programmable Parameters A. Thoroughly inspect ECM vehicle harness
connector J1/P1 and the battery connections.
Programmable Parameters are stored in permanent Refer to Troubleshooting, “Electrical Connectors -
memory. This includes both Customer Specified Inspect” for details.
Parameters and System Configuration Parameters.
Refer to Troubleshooting, “Customer Specified B. Perform a 45 N (10 lb) pull test on each of the
Parameters” for details on Customer Specified following wires in the ECM connector:
Parameters and refer to Troubleshooting, “System
Configuration Parameters” for details on System
Configuration Parameters. • Ignition key switch (terminal 70)
• +Battery (terminals 52 and 53)
218 RENR1367-11
• −Battery (terminals 65 and 67) • Result 2 – Proceed to Test Step 4.

• ATA data link (terminals 8 and 9) • Result 3 – Proceed to Test Step 5.
C. Check the ECM connector (allen head screw) for • Result 4 – Proceed to Test Step 6.
Test Step 3. Use ET To Check The Part
D. Check the harness and wiring for abrasion and Number Of The ECM Personality Module.
pinch points from the data link connectors back
to the ECM. A. Connect ET at the cab data link connector.
Expected Result: B. Turn the ignition key switch to the ON position.
All connectors, pins and sockets should be completely C. Read the Customer Specified Parameters. Refer
coupled and/or inserted and the harness and wiring to Troubleshooting, “Programming Parameters”.
D. Ensure that the Personality Module Part Number
Results: agrees with the original engine arrangement.
• OK – Proceed to Test Step 2. Expected Result:
• Not OK The correct Personality Module is installed in the

ECM for the engine.
replace the connectors or wiring. Ensure that all of Results:
connectors are completely coupled. • Yes
Verify that the repair eliminates the problem. Repair: The diagnostic code 252-11 must be
cleared if the correct Personality Module has been
STOP. installed. Clearing this diagnostic code requires
Factory Passwords and resetting the Personality
Test Step 2. Check for Diagnostic Codes. Module Code to zero.
Connect ET and check for diagnostic codes. STOP.
Expected Result: • No
Result 1 The following diagnostic code requires Repair: Reprogram the ECM with the correct
troubleshooting: Personality Module. Refer to Troubleshooting,
“Flash Programming”.
• 252-11 Incorrect Engine Software (59)
Result 2 The following diagnostic code requires
troubleshooting: STOP.
• 253-02 Check Customer or System Parameters Test Step 4. Use ET to Determine

(56) Parameters that Require Programming.
Result 3 Scrambled parameters or data require A. Connect ET at the cab data link connector.
troubleshooting.
Result 4 The following diagnostic code requires
troubleshooting: C. Check the active diagnostic codes. Note any
parameters that are listed in the following active
• 253-14 Truck Manufacturer Programmed Not diagnostic code:
Programmed (6)
• 253-02 Check Customer or System Parameters
Results: (56)

RENR1367-11 219
Expected Result: Verify that the repair eliminates the problem.
The ECM allows the parameters that are listed under STOP.
the following active diagnostic code in the “Active
Diagnostic Code” screen to be programmed: • No – The ECM is OK. STOP.
• 253-02 Check Customer or System Parameters Test Step 6. Use ET to Determine
(56) Programming Requirements
Results: A. Connect ET to the cab data link connector.
• Yes B. Turn the ignition key switch to the ON position.
Repair: Ensure that the cause of all diagnostic C. Check for active diagnostic codes.
codes is repaired.
Note: If the diagnostic code 253-14 is active,
STOP. the “Truck Manufacturer” parameter must be
programmed.
• No
D. Determine the type of chassis. If the engine is
Repair: Temporarily connect a test ECM. Ensure installed in a General Motors chassis, program the
that the test ECM will allow the programming of “Truck Manufacturer” parameter to GM. For any
the Parameters. If the test ECM does not allow other chassis, program the parameter to “Other”.
the programming of the Parameters, the old ECM
is OK. Something is wrong in the vehicle wiring. Note: ET will indicate that the communication to the
Check the battery supply circuit to the ECM and ECM must be reestablished in order for the change
repair, as required. in the parameter to take effect.
Verify that the repair eliminates the problem. Expected Result:
STOP. There are no active diagnostic codes.
Test Step 5. Use ET to Review Parameters Results:

and Data.
• Yes – Diagnostic codes are active. Proceed to
A. Turn the ignition key switch to the ON position. the appropriate troubleshooting procedure for the
active diagnostic code. STOP.
B. Check the active diagnostic codes and the logged
diagnostic codes by using ET. • No – The ECM has been properly programmed.
STOP.
C. Review the Customer and System Parameters.
i02378207
D. Review the Engine Lifetime Totals.
Expected Result:
Electrical Connectors - Inspect
SMCS Code: 7553-040-WW
The parameters and totals are scrambled.
Results:
Most electrical problems are caused by poor
• Yes connections. The following procedure will assist in
detecting problems with connectors and with wiring.
Repair: Try to reprogram the suspect parameter If a problem is found correct the condition and verify
or parameters. If the ECM does not maintain that the problem is resolved.
the parameters, temporarily connect a test
ECM. Ensure that the test ECM will allow the
programming of the parameters. If the test ECM
does not allow the programming of the parameters,
the old ECM is OK. Something is wrong in the
vehicle wiring. Check the battery supply circuit to
the ECM and repair, as required.
220 RENR1367-11
Intermittent electrical problems are sometimes Test Step 1. Check Connectors for
resolved by disconnecting and reconnecting Moisture and Corrosion
connectors. It is very important to check for diagnostic
codes immediately before disconnecting a connector.
Also check for diagnostic codes after reconnecting
the connector. If the status of a diagnostic code is
changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
likely reasons are loose terminals, improperly crimped
terminals, moisture, corrosion, and inadequate
mating of a connection.
Follow these guidelines:
• Always use a 1U-5804 Crimp Tool to service

Deutsch HD and DT connectors. Never solder the
terminals onto the wires. Refer to “SEHS9615,
Servicing Deutsch HD and DT Style Connectors”.
• Always use a 147-6456 Wedge Removal Tool to

remove wedges from DT connectors. Never use a
screwdriver to pry a wedge from a connector.
• Always use a breakout harness for a voltmeter Illustration 70

g01131211
probe or a test light. Never break the insulation
Leaky seal at the connector (typical example)
of a wire in order to access to a circuit for
measurements.
A. Inspect all wiring harnesses. Ensure that the
routing of the wiring harness allows the wires to
• If a wire is cut, always install a new terminal for enter the face of each connector at a perpendicular
the repair.
angle. Otherwise, the wire will deform the seal
bore. Refer to Illustration 70. This will create a
path for the entrance of moisture. Verify that the
seals for the wires are sealing correctly.
The connection of any electrical equipment and
the disconnection of any electrical equipment may
cause an explosion hazard which may result in in-
jury or death. Do not connect any electrical equip-
ment or disconnect any electrical equipment in an
explosive atmosphere.
g01131276
Illustration 71
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
RENR1367-11 221
B. Ensure that the sealing plugs are in place. If any If moisture or corrosion is evident in the connector,
of the plugs are missing, replace the plug. Ensure the source of the moisture entry must be found and
that the plugs are inserted correctly into the the source of the moisture entry must be repaired.
connector. Refer to Illustration 71. If the source of the moisture entry is not repaired,
the problem will recur. Simply drying the connector
will not fix the problem. Check the following items
for the possible moisture entry path:
• Missing seals
• Improperly installed seals
• Nicks in exposed insulation
• Improperly mated connectors
Moisture can also travel to a connector through
the inside of a wire. If moisture is found in a
g01131019
connector, thoroughly check the connector’s
Illustration 72 harness for damage. Also check other connectors
Seal for a three-pin connector (typical example) that share the harness for moisture.
Note: The ECM is a sealed unit. If moisture is found

in an ECM connector, the ECM is not the source of
the moisture. Do not replace the ECM.
Expected Result:
The harness wiring, connectors, and seals are in

good condition. There is no evidence of moisture in
the connectors.
Results:
• OK – The harness wiring, connectors, and seals

are in good condition. Proceed to Test Step 2.
• Not OK – A problem has been found with the

harness or the connectors.
Repair: Repair the connectors or the wiring, as

required. Ensure that all of the seals are properly
Illustration 73
g01131165 in place. Ensure that the connectors have been
reattached.
Seal for ECM connector (typical example)
If corrosion is evident on the pins, sockets or the

C. Disconnect the suspect connector and inspect the connector, use only denatured alcohol to remove
connector seal. Ensure that the seals are in good the corrosion. Use a cotton swab or a soft brush
condition. If necessary, replace the connector. to remove the corrosion.
D. Thoroughly inspect the connectors for evidence If moisture was found in the connectors, run the
of moisture entry. engine for several minutes and check again for
moisture. If moisture reappears, the moisture is
Note: It is normal to see some minor seal abrasion wicking into the connector. Even if the moisture
on connector seals. Minor seal abrasion will not allow entry path is repaired, it may be necessary to
the entry of moisture. replace the wires.
STOP.
222 RENR1367-11
Test Step 2. Check the Wires for Damage Repair: Repair the terminals and/or replace the
to the Insulation terminals, as required.
A. Carefully inspect each wire for signs of abrasion, Verify that the repair eliminates the problem.
of nicks, and of cuts.
STOP.
Inspect the wires for the following conditions:
Test Step 4. Perform a Pull Test on Each
• Exposed insulation Wire Terminal Connection
• Rubbing of a wire against the engine
• Rubbing of a wire against a sharp point
B. Check all of the wiring harness fasteners in order
to verify that the harness is properly secured. Also
check all of the fasteners in order to verify that the
harness is not compressed. Pull back the harness
sleeves in order to check for a flattened portion
of wire. A fastener that has been overtightened
flattens the harness. This damages the wires that
are inside the harness.
Expected Result: g01131435

Illustration 74
The wires are free of abrasion, of nicks, and of cuts Receptacle lock wedge (typical example)
and the harness is properly clamped.
A. Ensure that the locking wedge for the connector
Results: is installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not
• OK – The harness is OK. Proceed to Test Step 3. installed properly.
• Not OK – There is damage to the harness. B. Perform the 45 N (10 lb) pull test on each wire.
Each terminal and each connector should easily
Repair: Repair the wires or replace the wires, withstand 45 N (10 lb) of tension and each wire
as required. Verify that the repair eliminates the should remain in the connector body. This test
problem. checks whether the wire was properly crimped
in the terminal and whether the terminal was
STOP. properly inserted into the connector.
Test Step 3. Inspect the Connector Expected Result:

Terminals
Each terminal and each connector easily withstands
A. Visually inspect each terminal in the connector. 45 N (10 lb) of pull and each wire remains in the
Verify that the terminals are not damaged. connector body.
Verify that the terminals are properly aligned in
the connector and verify that the terminals are Results:
properly located in the connector.
• OK – All terminals pass the pull test. Proceed to
Expected Result: Test Step 5.
The terminals are properly aligned and the terminals • Not OK – A wire has been pulled from a terminal
appear undamaged. or a terminal has been pulled from the connector.
Results: Repair: Use the 1U-5804 Crimp Tool to replace

the terminal. Replace damaged connectors, as
• OK – The terminals are OK. Proceed to Test Step required. Verify that the repair eliminates the
4. problem.
• Not OK – The terminals of the connector are STOP.

damaged.
RENR1367-11 223
Test Step 5. Check Individual Pin • Not OK – The connector’s locking mechanism is
Retention into the Socket damaged or missing.
Repair: Repair the connector or replace the

connector, as required. Verify that the repair
eliminates the problem.
STOP.
Test Step 7. Check the Allen Head Screws

on the Connectors
Visually inspect the allen head screws for the ECM
connectors. Ensure that the threads on each allen
head screw are not damaged.
g01131604
A. Connect the ECM connectors.
Illustration 75
Diagram for testing pin retention (typical example)
A. Verify that the sockets provide good retention for

the pins. Insert a new pin into each socket one
at a time in order to check for a good grip on the
pin by the socket.
Expected Result:
The sockets provide good retention for the new pin.
Results:
• OK – The terminals are OK. Proceed to Test Step g01132827

6. Illustration 76
Allen head screw for the 120 pin ECM connector (typical example)
• Not OK – Terminals are damaged.
a. Torque the allen head bolt for the 120 pin ECM
Repair: Use the 1U-5804 Crimp Tool to replace connector to 7.0 ± 0.5 N·m (60 ± 4 lb in).
the damaged terminals. Verify that the repair
STOP.
Test Step 6. Check the Locking

Mechanism of the Connectors
A. Ensure that the connectors lock properly. After
locking the connectors, ensure that the two halves
cannot be pulled apart.
B. Verify that the latch tab of the connector is

properly latched. Also verify that the latch tab of
the connector returns to the locked position.
g01132849
Illustration 77
Expected Result: Allen head screw for the 70 pin ECM connector (typical example)
The connector will securely lock. The connector and b. Torque the allen head screw for the 70
the locking mechanism are without cracks or breaks. pin ECM connector to 6.0 + 1.5 - 0.5 N·m
(55 + 13 - 4 lb in).
Results:
• OK – The connectors are in good repair. Proceed

to Test Step 7.
224 RENR1367-11
Repair: Repair the connector or replace the

connector, as required. Verify that the repair
STOP.
Test Step 8. Perform the “Wiggle Test” on

the Caterpillar Electronic Technician (ET)
A. Select the “Wiggle Test” from the diagnostic tests
on Cat ET.
B. Choose the appropriate group of parameters to

monitor.
g01132863
Illustration 78 C. Press the “Start” button. Wiggle the wiring harness
Allen head screw for the 40 pin ECM connector (typical example) in order to reproduce intermittent problems.
c. Torque the allen head screw for the 40 pin ECM If an intermittent problem exists, the status will be
connector to 2.25 ± 0.25 N·m (20 ± 2 lb in). highlighted and an audible beep will be heard.
Expected Result:
No intermittent problems were indicated during the

“Wiggle Test”.
Results:
• OK – No intermittent problems were found. The

harness and connectors appear to be OK. If you
were sent from another procedure, return to the
procedure and continue testing. If this test has
resolved the problem, return the engine to service.
STOP.
g01133047
Illustration 79 • Not OK – At least one intermittent problem was
Allen head screw for the 40 pin customer connector and the 70 pin indicated.
customer connector (typical example)
Repair: Repair the harness or the connector. Verify
B. Connect the customer connector. that the repair eliminates the problem.
Torque the allen head screw for the 40 pin STOP.
customer connector and the 70 pin customer
connector to 2.25 ± 0.25 N·m (20 ± 2 lb in).
i02301263
Expected Result:
Engine Pressure Sensor Open
The ECM connector is secure and the allen head or Short Circuit - Test
screws are properly torqued.
SMCS Code: 1917-038; 1923-038; 1924-038
Results:
• OK – The ECM connectors and the customer
connector is properly connected. Proceed to Test Use this procedure to troubleshoot the system only
Step 8. when there is an active diagnostic code or when
a diagnostic code can easily be activated. This
• Not OK – The allen head screws for the ECM procedure covers diagnostic codes for the following
connector or the customer connector is damaged. sensors:
• Boost pressure sensor

RENR1367-11 225
• Oil pressure sensor

• Barometric pressure sensor
• Injection actuation pressure sensor
Use this procedure for the following diagnostic
codes:
• 100-03 Engine Oil Pressure voltage high

• 100-04 Engine Oil Pressure voltage low
• 102-03 Boost Pressure Sensor voltage high
• 102-04 Boost Pressure Sensor voltage low
• 102-07 Boost Pressure not responding
• 108-03 Barometric Pressure Sensor voltage high
• 108-04 Barometric Pressure Sensor voltage low
• 164-03 Injection Actuation Pressure voltage high
• 164-04 Injection Actuation Pressure voltage low
The troubleshooting procedures for the diagnostic
codes of each pressure sensor are identical. The
Engine Control Module (ECM) sends a +5 V supply
to terminal A for each sensor. The sensor common
connection is connected to terminal B of each sensor.
The signal voltage from terminal C of each sensor is
sent to the J2 ECM connector.
Pull-up Voltage
The ECM continuously outputs a pull-up voltage on

the circuit for the sensor signal wire. The ECM uses
this pull-up voltage in order to detect an open in the
signal circuit. When the ECM detects the presence of
a voltage that is above a threshold on the signal wire,
the ECM will generate a -03 diagnostic code.
If the sensor is disconnected at the sensor connector,

the presence of pull-up voltage at the sensor
connector indicates that the signal wire and the return
wire from the sensor connector to the ECM are good.
If the sensor is disconnected at the sensor connector,

the absence of pull-up voltage at the sensor
connector indicates an open in the signal wire, an
open in the return wire, or a short to ground.
If the sensor is disconnected at the sensor connector

and the voltage on the signal wire at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.
226 RENR1367-11
g01151304
Illustration 80
Schematic for the engine pressure sensors
Test Step 1. Inspect the Electrical B. Thoroughly inspect ECM connector (5). Also
Connectors and the Wiring inspect the connectors for pressure sensors
(1), (2), (3), and (4). Refer to Troubleshooting,
A. Turn the keyswitch to the OFF position. “Electrical Connectors - Inspect” for details.
g01151317
Illustration 81
(1) Injection actuation pressure sensor
(2) Atmospheric pressure sensor
(3) Boost pressure sensor
(4) Engine oil pressure sensor (option)
(5) J2/P2 ECM connector
RENR1367-11 227
g01123211
Illustration 83
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal

wires in the ECM connector and the sensor
connectors that are associated with the active
diagnostic code.
g01152507 D. Check the torque of the allen head screw on

Illustration 82
the ECM connectors. Refer to Troubleshooting,
P1 ECM connector “Electrical Connectors - Inspect” for the correct
(P2-2) +5 V pressure sensor supply torque values.
(P2-3) Sensor return
(P2-14) Barometric pressure
(P2-24) Engine oil pressure E. Check the harness and wiring for abrasions and
(P2-27) Injection actuation pressure for pinch points from the sensors back to the ECM.
(P2-40) Boost pressure
(P2-41) +5 V oil pressure sensor supply Expected Result:
(P2-42) Oil pressure sensor return
Results:
• OK – The harness and wiring are OK. Proceed

to Test Step 2.
• Not OK
Repair: Repair the wiring and/or the connectors.
Replace parts, if necessary. Ensure that all of the
Verify that the problem is resolved.
STOP.
228 RENR1367-11
Test Step 2. Check the Voltage on the +5 B. Turn the keyswitch to the ON position. Wait at
V Supply Wire least 15 seconds for activation of the diagnostic
codes.
C. Use Cat ET to check for active diagnostic codes.
B. Disconnect the harness connectors for the Wait at least 15 seconds so that any codes may
following sensors: become active. Look for an active diagnostic code
for an engine pressure sensor.
• 100-03 Engine Oil Pressure voltage high
D. Determine if the problem is related to a -03
• 100-04 Engine Oil Pressure voltage low diagnostic code or to a -04 diagnostic code.
• 102-03 Boost Pressure Sensor voltage high Expected Result:
• 102-04 Boost Pressure Sensor voltage low No diagnostic codes are active.
• 102-07 Boost Pressure not responding Results:
• 108-03 Barometric Pressure Sensor voltage • OK – No diagnostic codes are active for the engine
high pressure sensors.
• 108-04 Barometric Pressure Sensor voltage low Repair: If any of the above codes are logged
and the engine is not running properly, refer to
• 164-03 Injection Actuation Pressure voltage Troubleshooting, “Troubleshooting Without a
high Diagnostic Code”.
• 164-04 Injection Actuation Pressure voltage low If the engine is running properly at this time, there
may be an intermittent problem in a harness
C. Turn the keyswitch to the ON position. that is causing the codes to be logged. Refer to
D. Measure the voltage between terminals A (supply)
and B (return) at each sensor connector on the STOP.
engine harness.
• Active -04 Code – An -04 diagnostic code is active.
E. Turn the keyswitch to the OFF position. Proceed to Test Step 4.
F. Connect all of the sensors. • Active -03 code – An -03 diagnostic code is active.
Expected Result:
Test Step 4. Disconnect the Suspect
Each voltage measurement is 5.0 ± 0.2 VDC. Sensor in Order to Create an Open Circuit
Results: A. Turn the keyswitch to the OFF position.
• OK – Each voltage measurement is 5.0 ± 0.2 B. Disconnect the harness connector of the sensor
VDC. Proceed to Test Step 3. with the -04 diagnostic code.
• Not OK – At least one voltage measurement is C. Turn the keyswitch to the ON position. Wait at
not 5.0 ± 0.2 VDC. least 15 seconds for activation of the diagnostic
codes.
Repair: Refer to Troubleshooting, “Engine
Pressure Sensor Supply Circuit - Test”. D. Use Cat ET to check for active diagnostic codes.
Check for an active -03 diagnostic code for the
STOP. disconnected sensor.
Test Step 3. Check for Active Diagnostic E. Turn the keyswitch to the OFF position.
Codes
Expected Result:
(ET) to the service tool connector. Refer to A -03 diagnostic code is now active for the
Troubleshooting, “Electronic Service Tools”. disconnected sensor.
RENR1367-11 229
Results: C. Disconnect the harness connector for the suspect

sensor.
• OK – A -04 diagnostic code was active before you
disconnected the sensor. A -03 diagnostic code D. Identify the terminal for the signal wire on the
became active after the sensor was disconnected. ECM connector that is appropriate for the suspect
sensor. Measure the resistance between the
Repair: Temporarily connect a new sensor to the appropriate terminal and the remaining terminals
harness, but do not install the new sensor in the on both ECM connectors.
engine. Verify that there are no active diagnostic
codes for the sensor. If there are no active E. Measure the resistance between the appropriate
diagnostic codes for the sensor, permanently terminal and the engine ground.
install the new sensor. Clear any logged diagnostic
codes. F. Connect the J1/P1 and J2/P2 connectors. Connect
the connectors for the suspect sensor.
STOP.
Expected Result:
• Not OK – A -04 diagnostic code was active before
you disconnected the sensor. The -04 diagnostic Each resistance measurement indicates an open
code remained after the sensor was disconnected. circuit.
Leave the sensor disconnected. Proceed to Test
Step 8. Results:
Test Step 5. Check the Pull-up Voltage at • OK – Each resistance measurement indicates an
the Sensor Connector open circuit. Proceed to Test Step 7.
A. Turn the keyswitch to the ON position. • Not OK – At least one resistance measurement
does not indicate an open circuit. There is a
B. Disconnect the suspect sensor. problem in the wiring for the sensor. There may be
a problem with a connector.
C. Measure the voltage between terminals C (signal)
and B (return) at the harness connector for the Repair: Repair the wiring and/or the connector.
suspect sensor. Replace parts, if necessary.
D. Turn the keyswitch to the OFF position. Verify that the problem is resolved.
The voltage is 11 ± 2 VDC. Test Step 7. Create a Short at the Harness

Connector
Results:
• OK – The voltage is 11 ± 2 VDC. The signal wire
to the ECM from the sensor connector is OK. B. Install a jumper wire with Deutsch sockets on each
end between terminals B (return) and C (signal)
Repair: The open circuit is in the sensor or the on the harness connector for the suspect sensor.
wire between the sensor and the sensor connector.
Temporarily connect a new sensor to the engine C. Turn the keyswitch to the ON position.
harness. Do not install the sensor in the engine.
Verify that no diagnostic codes are active for the Note: Monitor Cat ET for diagnostic codes before
new sensor before you permanently install the installing the jumper wire and after installing the
sensor. jumper wire.
STOP. D. Use Cat ET to check for active diagnostic codes.

Wait at least 15 seconds so that any codes may
• Not OK – The voltage is not 11 ± 2 VDC. Proceed become active. Look for a -04 diagnostic code.
to Test Step 6.
E. Remove the jumper wire.
Test Step 6. Check the Signal Wire for a
Short Circuit F. Turn the keyswitch to the OFF position.
B. Disconnect the J1/P1 and J2/P2 connectors.

230 RENR1367-11
Expected Result: A -03 diagnostic code should be active for the

suspect sensor.
A -04 diagnostic code was active when the jumper
wire was installed. A -03 diagnostic code became E. Turn the keyswitch to the OFF position.
active when the jumper wire was removed.
F. Check the operation of the ECM by creating a
Results: short circuit at the ECM:
• OK – A -04 diagnostic code was active when the a. Disconnect the J2/P2 connectors.
jumper wire was installed. A -03 diagnostic code
became active when the jumper wire was removed. b. Install a jumper wire between the terminal for
The engine harness and the ECM are OK. the sensor’s signal wire and the return wire at
the P2 ECM connector.
Repair: Temporarily connect a new sensor to the
harness, but do not install the new sensor in the c. Connect the J2/P2 connectors.
engine. Verify that there are no active diagnostic
codes for the sensor. If there are no active G. Turn the keyswitch to the ON position.
diagnostic codes for the new sensor, permanently
install the new sensor. Clear any logged diagnostic H. Monitor Cat ET for active diagnostic codes. Wait at
codes. least 15 seconds so that any codes may become
active.
A -04 diagnostic code should be active when the
STOP. wire jumper is installed.
• Not OK – A -04 diagnostic code was active when I. Turn the keyswitch to the OFF position.
the jumper wire was installed. The -04 code
remained when the jumper wire was removed. J. Remove the jumper wire. Return the wiring to the
Proceed to Test Step 8. original configuration.
Test Step 8. Check the Operation of the Expected Result:

ECM
A -03 diagnostic code was active when the signal
A. Turn the keyswitch to the OFF position. wire was removed from the ECM connector. A -04
diagnostic code became active when the signal wire
B. Check the operation of the ECM by creating an was connected to the return wire.
open at the ECM:
Results:
a. Disconnect the J2/P2 connectors.
• OK – The ECM is operating properly. There is a
b. Remove the signal wire for the suspect sensor problem in the wiring between the ECM and the
from the ECM connector. sensor connector.
c. Remove the sensor return from the ECM Repair: If the code is active for more than one
connector. sensor, the problem is most likely in the return wire
for the sensor. The problem may be in a connector.
Note: Disconnecting the return wire from the ECM Repair the return wire and/or the connector.
will generate a -03 diagnostic code for all of the Replace parts, if necessary.
sensors. Ignore the additional codes. Troubleshoot
the original diagnostic code and clear the codes If the code is only active for one sensor, the
when you are finished. problem is most likely in the signal wire for the
sensor. Repair the signal wire and/or the connector.
d. Connect the J2/P2 connectors. Replace parts, if necessary.
C. Turn the keyswitch to the ON position. Verify that the problem is resolved.
D. Monitor Cat ET for active diagnostic codes. Wait at STOP.

least 15 seconds so that any codes may become
active.
RENR1367-11 231
• Not OK – One of the following conditions exists:

The -03 diagnostic code is not active when the
signal wire is disconnected. The -04 diagnostic
code is not active when the wire jumper is installed.
Repair: Replace the ECM. Refer to

STOP.
i01606388
Engine Running Output Circuit

- Test
SMCS Code: 1901-038
Use this procedure in order to determine if the circuit

for the Engine Running Output is operating properly.

to this procedure:
Personality Modules that have a Software Date

Code dated earlier than OCT01.
The Engine Running Output is located on ECM

J1/P1:13 (Output 4).
The engine running output comes on when the

engine is running. The engine running output turns
off when the engine rpm equals 0. This can be used
to prevent the engagement of the starter motor while
the engine is running. The ECM can be connected to
a relay that disables the starter. The relay is normally
closed so cranking can be achieved immediately at
powerup. During cranking, the ECM energizes the
engine running output once engine rpm reaches 50
rpm below low idle. The output is de-energized if the
engine speed falls below the programmed low idle
by 100 rpm. The low idle rpm is programmable. The
range for low idle is between 700 rpm and 800 rpm.
232 RENR1367-11
g00832285
Illustration 84
Engine Running Output Circuit

Code dated OCT01.
GMT-560 applications have a programmable

parameter “Engine Running Output” that can be
programmed to “P1/J1:31”. If this parameter is
programmed, the engine running output is located
on ECM J1/P1:31 (Output 9). This feature allows
the ECM to control a relay in order to prevent the
starter motor from being engaged after the engine
has started.
When the ignition key switch is turned to the ON

position, Output 9 is low. The relay is off and the
switch is closed. Current flows to the starter solenoid
and this allows the starter to engage. When the
engine speed reaches 600 rpm the output will go
high. This energizes the relay and the switch opens.
When the switch is open there is no current flow to
the starter solenoid.
g00832209
Illustration 85
Engine Running Output Circuit for GMT-560
RENR1367-11 233
Results:

• Not OK

STOP.
Test Step 2. Use ET to Check the Relay.

A. Turn the ignition key switch to the ON position.
B. Access the special test“Engine Running Output”

on ET. The “Engine Running Output” test will
enable the engine running output when the test
is active.
C. Begin the “Engine Running Output” test and listen

for the relay to “click”. You may need to be near
the engine in order to hear the “click”.
Expected Result:
The relay activates when the special test is enabled.
Illustration 86
g00832305 Results:
Location for the ECM terminal
• Yes – The ECM and vehicle components are
operating correctly. STOP.
and Wiring. • No – Proceed to Test Step 3.
A. Thoroughly inspect ECM vehicle harness Test Step 3. Use ET to Check the ECM.
connector J1/P1, and the firewall bulkhead
connector. A. Connect ET to the cab data link connector.
Refer to Troubleshooting, “Electrical Connectors - B. Turn the ignition key switch to the OFF position.
B. Perform a 45 N (10 lb) pull test on terminal 13 in J1/P1.
the ECM connector.
D. Connect a breakout T between ECM connectorsJ1
C. Check the ECM connector (allen head screw) for and P1.
E. Connect a voltage test lamp to terminal 13 (Output
D. Check the harness and wiring for abrasion and for 4) and terminal 65 (-battery) of the breakout T.
Note: If the vehicle is a GM-560 application, connect
Expected Result: the voltage test lamp to terminal 31 (Output 9) and
terminal 65 (-battery) of the breakout T.
coupled and/or inserted and the harness and wiring F. Turn the ignition key switch to the ON position.
234 RENR1367-11
G. Access the special test “Engine Running Output” The actual timing and duration of each injection
on ET. is based on engine rpm and load. If the engine
is running and the signal from one of the engine
H. Cycle the special test “Engine Running Output” to speed/timing sensors is lost, no noticeable change in
“Active” and to “Not Active” and watch the voltage engine performance will be noticed.
test lamp.
The engine will start and the engine will run when
I. Stop the special test. only one sensor signal is present from either of the
sensors. The loss of the signal from both of the
Note: A multimeter can not be used in place of the sensors during engine operation will result in the
voltage test lamp when the ECM outputs are being termination of injection and the shutting down the
tested. engine by the ECM. The loss of the signal from both
of the sensors during start-up will prevent the engine
Expected Result: from starting.
The voltage test lamp turns ON when the test is Both sensors are magnetic sensors. The two sensors
active. The voltage test lamp turns OFF when the are not interchangeable. Do not switch the positions
test is not active. of the sensors. The two sensors must be replaced as
a pair. If the sensors are replaced, a timing calibration
Results: is not necessary for the engine. Timing calibration
is only necessary after replacing an ECM that will
• Yes – The ECM is OK. The problem is in the not communicate.
vehicle wiring. Inspect the vehicle wiring and then
repair the vehicle wiring. Otherwise, send the If a replacement of the ECM is required, the ECM
vehicle to the OEM dealer for repair. Verify that the parameters and the timing calibration can be
original condition is resolved. STOP. transferred from the suspect ECM to the replacement
ECM. Timing calibration will not be necessary. This
• No – Temporarily connect a test ECM. Use the feature requires the Caterpillar Electronic Technician
“Engine Running Output Special Test” on ET to (Cat ET) and this feature is only possible if the
check the ECM. If the problem is resolved with the existing ECM can communicate with Cat ET. Use the
test ECM, install the suspect ECM. If the problem procedure “Copy Configuration - ECM Replacement”
returns with the suspect ECM, replace the ECM. on Cat ET. Refer to Troubleshooting, “Programming
Verify that the repair eliminates the problem. STOP. Parameters” for more information.
When the sensors are being installed, complete

i01927891
all of the following tasks:
Engine Speed/Timing Sensor
• Lubricate the O-ring with oil.
Circuit - Test
• Ensure that the sensor has a face seal inside the
SMCS Code: 1912-038 connector body. If a seal is damaged or missing,
replace the seal.
• Ensure that the sensor is fully seated into the
The engine uses two engine speed/timing sensors. engine before tightening the bracket bolt.
Both of the engine speed/timing sensors detect the
reference for engine speed and timing from a unique • Ensure that the connector is latched on both sides.
pattern on the camshaft gear. The ECM counts the
time between pulses that is created by the sensor as • Ensure that the harness is properly secured, and
the gear rotates in order to determine rpm. The ECM ensure that the harness is attached to the harness
remembers the pattern of the pulses. The ECM uses clip.
the pattern of the pulses in order to determine the
position of the crankshaft.
When the timing has been established, the ECM

triggers each injector in the correct firing order at the
correct time.
RENR1367-11 235
g00864785
Illustration 87
Left side engine view (typical view)
g00931977
Illustration 88
Schematic
236 RENR1367-11
g00931983
Illustration 89
P2 ECM connector
Test Step 1. Check for Active Diagnostic Note: If the diagnostic code is logged but not active,
Codes and Logged Diagnostic Codes run the engine until the engine is at normal operating
temperature. The problem may only occur when the
A. Connect Cat ET to the data link connector. engine is at the normal operating temperature. If the
engine will not start, monitor the engine rpm from
B. Turn the key switch to the ON position. Cat ET while the engine is being cranked. Cat ET
may need to be powered from another battery while
C. Check for one of the following logged diagnostic the engine is being cranked. This is done in order to
codes or active diagnostic codes: ensure that Cat ET does not reset.
• 64-02 Secondary Engine Speed loss of signal Expected Result:

(34)
One or more of the diagnostic codes that are listed
• 64-11 Secondary Engine Speed no pattern (34) above are logged or active.
• 190-02 Secondary Engine Speed Loss of Signal Note: If you have been directed here from
(34) Troubleshooting, “Troubleshooting without a
Diagnostic Code” for the following reason, select “No
• 190-11 Secondary Engine Speed no pattern Engine rpm”:
(34)
• The engine rpm was not indicated on Cat ET.
RENR1367-11 237
Results: Note: The sensor must not be removed from the

bracket.
• OK – There is an active diagnostic code or a
logged diagnostic code. Proceed to Test Step 3. 3. Ensure that the sensor is properly oriented
and that the harness is secured in the proper
• Not OK – If none of the codes that are listed are location.
active diagnostic codes or logged diagnostic codes
and the engine is not running properly, refer to 4. Verify that the repair eliminates the problem.
the appropriate symptoms in the service manual.
STOP. STOP.
• No Engine rpm – Engine rpm is not indicated on Test Step 3. Measure the Sensor
Cat ET. Proceed to Test Step 2. Resistance Through the Engine Harness
Test Step 2. Check the Installation of the A. Turn the key switch to the OFF position.
Sensors and the Bracket
B. Thoroughly inspect ECM vehicle harness
connector J2/P2. Refer to Troubleshooting,
C. Perform a 45 N (10 lb) pull test on the following

wires in the ECM engine harness connector P2
that are associated with the engine speed/timing
sensors:
g00767308
Illustration 90
Flange of the sensor and mounting bracket • P2:48
A. The flange of the sensor should be flush against • P2:49

the engine in order to ensure proper operation.
• P2:58
B. Inspect the bracket in order to ensure that the
installation allows the flange of the sensor to be • P2:59
flush against the engine.
D. Ensure that the latch tab on the connector is
Verify that the bracket is not bent. properly latched and ensure that the latch tab is
fully latched.
Note: The bracket cannot be replaced separately.
E. Check the ECM connector (allen head screw) for
C. Ensure that one O-ring has been installed on the proper torque of 6.0 N·m (55 lb in).
the sensor, and ensure that the O-ring is free of
damage. F. Repair the harness or repair the connector if a
problem is found.
Note: If the flange of the sensor is bent or if an
obstruction is preventing the sensor from reading a G. Ensure that the wiring harness is correctly routed
good pattern, the engine will not start. and secured at the proper locations.
Results: H. Ensure that the harness wiring is not pulled

too tightly. When the harness wiring is pulled
too tightly, vibrations or movement can cause
• OK – The sensors and the bracket are properly intermittent connections.
installed. Proceed to Test Step 3.
I. Inspect the harness wiring for nicks and abrasions.
• Not OK
Repair: Perform the following procedure in order J. If the harness and the connector are OK,
to properly install the sensors and the bracket: disconnect ECM connector J2/P2.
1. Loosen the bolt that holds the sensor mounting K. Primary engine speed/timing sensor
bracket to the engine.
a. Use a multimeter to measure the resistance
2. Seat the sensor and tighten the bolt. from P2:48 (Primary Engine Speed/Timing +)
to P2:49 (Primary Engine Speed/Timing -).
If the sensor will not seat, repair the sensor or
replace the sensor, as required.
238 RENR1367-11
b. Check for an intermittent open circuit or a. Use a multimeter to measure the sensor
short circuit by moving the harness while the resistance (Ohms) from J401:B (Primary
measurement for resistance is being taken. Engine Speed/Timing +) to J401:A (Primary
Pull the wires that are directly behind the Engine Speed/Timing -).
sensors or shake the wires that are directly
behind the sensors. Resistance ............................. 75 to 230 Ohms
Resistance ............................ 75 to 230 Ohms F. Secondary engine speed/timing sensor
L. Secondary engine speed/timing sensor a. Use a multimeter to measure the sensor

resistance (Ohms) from J402:B (Secondary
a. Use a multimeter to measure the sensor Engine Speed/Timing +) to J402:A (Secondary
resistance (Ohms) from P2: 58 (Secondary Engine Speed/Timing -).
Engine Speed/Timing +) to P2:59 (Secondary
Engine Speed/Timing -). Resistance ........................ 600 to 1800 Ohms
b. Check for an intermittent open circuit or Note: Timing calibration is not necessary following
short circuit by moving the harness while the replacement of the speed/timing sensors. Refer to
measurement for resistance is being taken. the information in the System Operation Section
Pull the wires that are directly behind the regarding the installation of sensors.
sensors or shake the wires that are directly
behind the sensors. Expected Result:
Resistance ........................ 600 to 1800 Ohms The readings agree with the values that are listed
above.
Expected Result:
Results:
The readings agree with the values that are listed
above. • OK – The sensor resistance is correct. Proceed
to Test Step 5.
Results:
• Not OK – The sensor resistance is out of the
• OK – Neither a short circuit nor an open circuit is range.
indicated. Proceed to Test Step 5.
Repair: Perform the following procedure in order
• Not OK – The sensor resistance is not within the to check and install the new sensor:
acceptable range when the sensor resistance is
measured through the engine harness. Proceed 1. Before installing the new sensor, measure the
to Test Step 4. resistance of the new sensor.
Test Step 4. Measure the Resistance of Note: If the new sensor resistance is not in the
the Sensor at the Sensor correct range, inspect the wiring harness for damage.
A. Turn the key switch to the OFF position. If the new sensor resistance is in the correct
range, install the new sensor in the engine, as
B. Check the harness and the wiring for abrasion and follows:
pinch points from the sensor back to the ECM.
a. Loosen the bolt that holds the sensor
C. Disconnect the suspect sensor from the engine mounting bracket to the engine.
harness.
b. Ensure that one O-ring is installed and free
D. Thoroughly inspect ECM engine harness of damage.
connectors for the sensors J401/P401 or
J402/P402. Refer to Troubleshooting, “Electrical c. Seat the sensor and tighten the bolt.
If the sensor will not seat, repair the sensor
E. Primary engine speed/timing sensor or replace the sensor, as required.
Note: The sensor must not be removed from the

bracket.
RENR1367-11 239
d. Ensure that the sensor is properly oriented C. Start the engine. Run the engine in order to repeat
and that the harness is secured in the proper the conditions when the problem occurs.
location.
D. If the problem is resolved with the test ECM,
2. Verify that the repair eliminates the problem. reconnect the suspect ECM.
STOP. E. If the problem returns with the suspect ECM,

replace the ECM.
Test Step 5. Install the Bypass Harness
for the Engine Speed/Timing Sensors Verify that the repair eliminates the problem.
A. Turn the key switch to the OFF position. Expected Result:
B. Disconnect ECM connector J2/P2. The problem remains with the suspect ECM.
C. Install the wiring harness to the P2 ECM Results:

connector. Connect the wiring:
• OK – The problem is resolved with the test ECM
• P2:48 to the white wire and the problem returns with the suspect ECM.
Replace the ECM. Verify that the repair eliminates
• P2:49 to the black wire the problem. STOP.
• P2:58 to the yellow wire • Not OK – The problem was not resolved with a
test ECM.
• P2:59 to the blue wire
Repair: Replace the sensor.
Note: Twisted pair wiring is required. Ensure that the
wires have at least one twist per inch. Verify that the repair eliminates the problem.
D. Reconnect the J2/P2 ECM connector. STOP.
E. Start the engine in order to determine if the bypass

i01857895
harness repairs the problem.
Expected Result:
Engine Temperature Sensor
Open or Short Circuit - Test
The problem is corrected with the installation of the
bypass harness. SMCS Code: 1906-038; 1921-038; 1922-038;
1928-038
Results:
• OK – The bypass harness corrected the problem.
Repair: Permanently install a new section of
harness. Use this procedure to troubleshoot the system only
when there is an active diagnostic code or when
STOP. a diagnostic code can easily be activated. This
procedure covers open circuit diagnostic codes and
• Not OK – The bypass harness did not correct the short circuit diagnostic codes that are associated with
problem. the following sensors:
Repair: Verify that the correct terminals have been • coolant temperature sensor
installed in the correct location of the P2 ECM
connector. If the temporary harness was installed • air inlet temperature sensor
correctly, install the original wiring.
Use this procedure for the following Diagnostic
Proceed to Test Step 6. Codes:
Test Step 6. Check the ECM • 105-03 Inlet Manifold Temp Sensor Open Circuit
(38)
A. Turn the key switch to the OFF position.
• 105-04 Inlet Manifold Temp Sensor Short Circuit
B. Temporarily connect a test ECM. (38)
240 RENR1367-11
• 110-03 Coolant Temp Sensor Open Circuit (27)

• 110-04 Coolant Temp Sensor Short Circuit (27)
to this procedure:
The troubleshooting procedures for the diagnostic

codes of each temperature sensor are identical.
The temperature sensors are passive sensors that
have two terminals. The passive sensors do not
require supply voltage from the ECM. ECM connector
J2/P2 terminal 18 is the common connection for the
engine temperature sensors. The sensor common
connection is shared between all of the temperature
sensors. The common line is connected to each
sensor connector terminal 2. Terminal 1 is the sensor
output. The signal from terminal 1 of each sensor
is supplied to the appropriate terminal at ECM
connector J2/P2.
g00767354
Illustration 91
g00724478
Illustration 92
Schematic for engine temperature sensors
RENR1367-11 241
Test Step 1. Verify All Active Diagnostic

Codes.
A. Connect an electronic service tool to the cab data
link connector.

Wait at least 15 seconds for activation of the
diagnostic codes.
C. Verify if any of the following diagnostic codes are

active:
• 105-03 Inlet Manifold Air Temp Sensor Open

Circuit (38)
• 105-04 Inlet Manifold Air Temp Sensor Short

Circuit (38)
• 110-03 Coolant Temp Sensor Open Circuit (27)

• 110-04 Coolant Temp Sensor Short Circuit (27)
Expected Result:
One or more of the preceding diagnostic codes are

active.
Results:

• No
Repair: If the preceding codes are logged but
not active and the engine is not running properly,
refer to Troubleshooting, “Troubleshooting without
a Diagnostic Code”. If the engine is running
properly at this time, an intermittent condition
may be causing the logged codes. Refer to
STOP.
242 RENR1367-11

and Wiring.
g00724517
Illustration 93
A. Thoroughly inspect ECM engine harness Results:

connector J2/P2 and the suspect sensor
connector. Refer to Troubleshooting, “Electrical • OK – Proceed to Test Step 3.
• Not OK
wires in the sensor connector and the ECM Repair: Repair the connectors or wiring and/or
connector that are associated with the active replace the connectors or wiring. Ensure that all of
diagnostic code. the seals are properly in place and ensure that the
C. Verify that the latch tab of the connector is properly
latched and that the latch tab of the connector has STOP.
returned to the Fully Latching position.
Test Step 3. Verify that the Diagnostic
D. Check the ECM connector (allen head screw) for Code is Still Active.
A. Turn the ignition key switch to the ON position.
E. Check the harness and wiring for abrasion and Wait at least 15 seconds for activation of the
pinch points from the sensor to the ECM. diagnostic codes.
Expected Result: B. Access the “Active Diagnostic Code” screen of the

electronic service tool. Check for active diagnostic
All connectors, pins and sockets should be completely codes.
should be free of corrosion, abrasion or pinch points. C. Determine if the problem is related to an open
circuit diagnostic code or a short circuit diagnostic
code.
RENR1367-11 243
Expected Result: D. Install the jumper on the engine harness

connector. Install one end of the jumper at the
A short circuit diagnostic code or an open circuit sensor signal (terminal 1). Install the other end
diagnostic code is active. of the jumper at the common connection for the
engine temperature sensor (terminal 2). Wait at
Results: least 15 seconds for activation of the short circuit
diagnostic code.
• Short Circuit – A short circuit diagnostic code is
active at this time. Proceed to Test Step 4. Expected Result:
• Open Circuit – An open circuit diagnostic code is A short circuit diagnostic code is active when the
active at this time. Proceed to Test Step 5. jumper is installed. An open circuit diagnostic code is
active when the jumper is removed.
Test Step 4. Disconnect the Sensor in
order to Create an Open Circuit. Results:
A. Turn the ignition key switch to the OFF position. • OK – The engine harness and the ECM are OK.
B. Disconnect the sensor connector of the sensor Repair: Perform the following repair:
with the short circuit diagnostic code.
1. Temporarily connect the suspect sensor.
Wait at least 15 seconds for activation of the 2. If the diagnostic code remains active, replace
diagnostic codes. the sensor.
D. Access the “Active Diagnostic Code” screen on 3. Verify that the repair eliminates the problem.
the electronic service tool. Check for an active
open circuit diagnostic code. 4. Clear all Logged diagnostic codes.
An open circuit diagnostic code for the disconnected • Not OK – The open circuit diagnostic code remains
sensor is now active. active with the jumper in place. The most probable
location for the open is in the sensor common
Results: or the sensor signal wire in the engine harness
between the ECM and the sensor. Remove the
• OK – A short circuit diagnostic code was active jumper. Proceed to Test Step 7.
before disconnecting the sensor. An open circuit
diagnostic code became active after disconnecting Test Step 6. Determine if the Short Circuit
the sensor. Proceed to test step 6. is in the Connector or in the Sensor.
• Not OK – There is a short circuit between the A. Thoroughly inspect the connector for moisture.
sensor harness connector and the ECM. Leave the
sensor disconnected. Proceed to Test Step 7. B. Inspect the seals and reconnect the sensor.
Test Step 5. Create a Short Circuit C. If the short circuit diagnostic code reappears, the
Between the Signal and the Common sensor is the problem.
Terminals at the Sensor Connector.
a. Temporarily connect a new sensor to the
A. Turn the ignition key switch to the ON position. harness, but do not install the new sensor in
the engine.
B. Fabricate a jumper wire150 mm (6 inch) long.
Crimp a Deutsch terminal to both ends of the wire. D. Check for a short circuit diagnostic code while the
new sensor is connected to the harness.
C. Monitor the “Active Diagnostic Code” screen
before installing the jumper wire and after installing Expected Result:
the jumper wire.
The short circuit diagnostic code is not present when
a new sensor is connected.
244 RENR1367-11
Results:
• OK – Verify that the repair eliminates the problem.

Clear the logged diagnostic codes. STOP.
• Not OK
Repair: Repair the engine harness connector.
STOP.
Test Step 7. Check the Operation of the

ECM by Creating Open and Short Circuits
at the ECM Connector.
g00767376
Illustration 94
Engine harness connector
A. Turn the ignition key switch to the OFF position. A short circuit diagnostic code should be active
when the jumper wire is installed.
B. Disconnect the Connector for the ECM harness.
Thoroughly inspect both halves of the connector Note: If access to the ECM connector is limited, it
for signs of corrosion or moisture. may be helpful to connect a breakout T to the ECM
connector. This will allow the jumper wire to be
C. Turn the ignition key switch to the ON position. inserted into the breakout T. Ensure that the jumper
Monitor the “Active Diagnostic Code” screen. Wait wire is inserted into the breakout T and that the full
at least 15 seconds for activation of the code. wiring harness is attached.
An open circuit diagnostic code should be active Refer to Illustration 94 for the engine harness
for the suspect sensor. connector P2.
Note: When the engine harness is disconnected, all Expected Result:

of the open circuit diagnostic codes for the pressure
sensors will be active. This is normal. Disregard the Open circuit diagnostic codes are active when the
diagnostic codes for the pressure sensors. jumper is removed. Short circuit diagnostic codes are
active when the jumper is installed.
D. Turn the ignition key switch to the OFF position.
Results:
E. Fabricate a jumper wire 150 mm (6 inch) long.
Crimp a Deutsch socket to both ends of the wire. • OK – The ECM is working properly. Proceed to
Test Step 8.
F. Install the jumper wire on the ECM pin terminal.
Insert the jumper wire between the terminal for the • Not OK – One of the following conditions exists:
suspect sensor signal and the common connection The open circuit diagnostic code is not active when
for the engine temperature sensor (terminal 18). the harness is disconnected. The short circuit
diagnostic code is not active when the jumper wire
is installed.
RENR1367-11 245
Repair: Perform the following repair: 1. Repair the faulty wiring harness or replace the
faulty wiring harness.
2. Clear all diagnostic codes.
STOP.
• Not OK – Restart this procedure and carefully
5. If the problem is resolved with the test ECM, perform each step. STOP.
i01617893
replace the ECM. Exhaust Brake Circuit - Test
7. Verify that the repair eliminates the problem. SMCS Code: 1093-038
STOP. System Operation Description:
Test Step 8. Bypass the Harness Wiring Use this procedure under the following situation:
Between the ECM and the Sensor
Connector. Use this procedure to determine if the circuit for the
exhaust brake (output 3) is operating correctly.
B. Disconnect the connector for the ECM harness, to this procedure:
and the sensor connector.
The exhaust brake relay circuit is provided by
C. Remove the sensor signal wire from the ECM the ECM. The circuit indicates that conditions
connector. are acceptable for an exhaust brake to operate.
Operation of the exhaust brake is inhibited during
D. Remove the signal wire (terminal 1) from the undesirable engine operating conditions.
sensor connector on the engine harness.
When the cruise control on/off switch is in the
E. Fabricate a jumper wire that is long enough to OFF position, the following conditions exist:
reach from the ECM to the sensor connector with
Deutsch sockets on both ends. All of the following conditions must be met in order to
ensure the proper operation of the exhaust brake:
F. Insert one end of the jumper into the ECM
Connector. Insert the other end of the jumper into • Engine speed is above 1000 rpm.
the sensor connector of the engine harness.
• The accelerator pedal position is less than seven
G. Reconnect the connector for the ECM harness percent.
and the sensor connector.
• The clutch pedal is released.
H. Turn the ignition key switch to the ON position.
• The switch for the exhaust brake is on.
I. Monitor the “Active Diagnostic Code” screen for
either the open circuit diagnostic code for the • The PTO on/off switch is off.
sensor or the short circuit diagnostic code for the
sensor. When the cruise control on/off switch is in the ON
position, the following conditions exist:
Expected Result:
“Exhaust Brake Mode” Parameter
The diagnostic code disappears when the jumper is
installed. When the cruise control on/off switch is on, this
parameter provides two special options that allow the
Results: exhaust brake to be operated only after the driver has
depressed the service brake pedal. The two modes
• OK – There is a problem in the wiring harness. of operation that follow are customer programmable:
246 RENR1367-11
• The “Coast” mode engages the exhaust brake With OCT01 Software, the exhaust brake can be
when the driver depresses the service brake pedal. used to apply a parasitic load to the engine in order
The exhaust brake disengages when the driver to aid engine warm-up. The exhaust brake will help
releases the service brake pedal. the engine achieve normal operating temperatures.
To use this feature, the parameter “Exhaust Brake
• The “Latch” mode engages the exhaust brake Warm Up Configuration” must be programmed to
when the driver depresses the service brake pedal. “Warm Up Only” or “Exhaust Brake & Warm Up”.
The exhaust brake remains engaged until the Also, the on/off switch for the exhaust brake must be
control detects a change in the control input. The in the ON position and the parameter “Exhaust Brake
following actions are examples of a change in a Switch” must be programmed to “J1/P1:16” or one of
control input: the J1939 options. The “Warm Up Mode Idle Speed”
parameter must be programmed to an engine speed
• The throttle is depressed. between 700 rpm and 1400 rpm. If the preceding
conditions are met, the engine will ramp up to the
• The clutch pedal is depressed. engine rpm that is programmed into the “Warm Up
Mode Idle Speed” parameter.
• The engine speed drops below 900 rpm.
Warm up mode will terminate when the engine
The third option for the Exhaust Brake Parameter reaches normal operating temperatures or when one
is “Manual”. The “Manual” mode operates in the of the following conditions are met:
same manner regardless of the position of the cruise
control on/off switch. The driver is not required to • The service brake is depressed.
depress the service brake pedal in order to initiate
the exhaust brake. Depress the service brake pedal • The clutch pedal is depressed.
in order to initiate the exhaust brake in the “Latch”
mode and the “Coast” mode. • The exhaust brake switch is turned off.
Note: The “Latch” mode and the “Coast” mode are • The vehicle is in gear.
customer programmable options. The “Latch” mode
and the “Coast” mode determine the operation of the • The throttle is depressed.
exhaust brake only when the cruise control switch is
in the ON position. The “Latch” mode and the “Coast” • The vehicle speed is greater than one mph.
mode do not determine the operation of the exhaust
brake when the engine is active in cruise control. • The ECM detects an excessive load on the engine.
“Latch” mode and “Coast” mode require the initiation
of the service brake before acting. The action of the • The engine rpm is less than 500 rpm. The engine
service brake disengages the cruise control. rpm is greater than 1450 rpm.
Note: The output for the exhaust brake is disabled Exhaust Brake On/Off Switch
whenever the PTO on/off circuit is on and the
customer parameter “PTO Configuration” is An on/off switch can be used to provide operator
programmed to “Cab Switches”, “Remote Switches”, control of the exhaust brake in order to inhibit
or “Remote Throttle”. operation during undesirable conditions. Two different
methods may be used. An in-line switch can be
Warm-up Mode installed in the output circuit for the exhaust brake
(terminal 12). The switch will turn the brake off by
opening the circuit. This removes power from the
brake relay. Opening the switch does not disable
the output driver. Opening the switch disables the
exhaust brakes.
With NOV99 and newer Personality Modules, an

optional feature was added in order to provide an
input to the ECM. The input is used to connect an
on/off switch for the exhaust brake. The input uses
terminal 16. When the switch is opened, the ECM
will turn off the output circuit for the exhaust brake.
This method allows the ECM to broadcast the correct
status of the exhaust brake over the data link. With
the first method that is described above, the brake
can be disabled but the output remains active.
RENR1367-11 247
Note: If the on/off switch for the exhaust brake is

installed in the output circuit, the “Exhaust Brake
Switch” parameter must be programmed to “NOT
INSTALLED”. If the on/off switch is connected to
the ECM switch input (terminal 16), the “Exhaust
Brake Switch” parameter must be programmed to
“INSTALLED”.
OCT01 Software
Note: If the on/off switch for the exhaust brake is

installed in the output circuit, the “Exhaust Brake
Switch” parameter must be programmed to “NONE”.
If the on/off switch is connected to the ECM switch
input (terminal 16), the “Exhaust Brake Switch”
parameter must be programmed to “J1/P1:16”. If the
J1939 data link is used to transmit the status of the
on/off switch for the exhaust brake, the “Exhaust
Brake Switch” parameter must be programmed to
“Cab Controller”, “Body Controller”, or “Instrument
Cluster”. If the parameter is programmed to one
of the J1939 options, the switch status will be
transmitted to the ECM over the J1939 data link. If a
problem is suspected with the J1939 data link, refer
to Troubleshooting, “Powertrain Data Link Circuit -
Test”.
g00729018
Illustration 95
Schematic for the exhaust brake that is powered by a relay circuit
248 RENR1367-11
g00837623
Illustration 96
Schematic for the on/off switch that is connected to terminal 16
g00837627
Illustration 97
Schematic for the on/off switch that is connected in series with the output circuit
RENR1367-11 249

STOP.
Test Step 2. Connect ET and Check the

Accelerator Pedal Position Sensor and
the Clutch Pedal Position Switch.
A. Ensure that the cruise control on/off switch is OFF.
B. Connect ET at the cab data link connector.
D. Use the following procedure to check the

accelerator pedal position sensor:
a. Monitor the duty cycle of the throttle sensor on

ET. Access the “Accelerator Pedal Position”
display screen.
g00729019
Illustration 98 b. While the duty cycle is being monitored on ET
ECM terminal depress the accelerator pedal and release the
accelerator pedal. Repeat this action several
Test Step 1. Inspect Electrical Connectors times.
and Wiring.
E. If a manual transmission is installed, use the
A. Thoroughly inspect ECM connectors J1/P1 following procedure to check the status of the
and the firewall bulkhead connector. Refer to “Clutch Pedal Position Switch”:
for details. a. Access the status screen onET for the “Clutch
Pedal Position Switch”.
wires in the ECM connector that are associated b. While the status screen is being monitored on
with the connections for the circuit for the exhaust ET, depress the clutch pedal and release the
brakes. clutch pedal. Repeat this action several times.
C. Check the ECM connector (allen head screw) for Expected Result:
The duty cycle of the accelerator pedal position
D. Check the harness and wiring for abrasion and for sensor is between 3 percent and 100 percent. The
pinch points from the sensor to the ECM. status of the “Clutch Pedal Position Switch” on ET
changes from OFF to ON when the clutch pedal is
Expected Result: depressed. The status of the “Clutch Pedal Position
Switch” on ET changes from ON to OFF when the
All connectors, pins, and sockets should be clutch pedal is released.
completely coupled and/or inserted and the harness
and wiring should be free of corrosion, abrasion or Results:
pinch points.
Results:
• Not OK – Incorrect accelerator pedal position
• OK – Proceed to the Test Step 2.
• Not OK procedure:
250 RENR1367-11
Troubleshooting, “Accelerator Pedal (Throttle) Expected Result:

Position Sensor Circuit - Test”.
All of the solenoids and all of the relays are operating.
STOP.
Results:
• Not OK – Clutch switch status is incorrect.
• Yes – The ECM is operating correctly. STOP.
procedure: • No – Proceed to Test Step 4.
Troubleshooting, “Clutch Pedal Position Switch Test Step 4. Use ET to Check the ECM.
Circuit - Test”.
STOP.
B. Disconnect the ECM engine harness connector
Test Step 3. Connect ET and Check the J1/P1.
Solenoids and the Relays.
C. Connect a breakout T to the ECM connector
J1/P1.
D. Connect a voltage test lamp to terminal 12 (Output

3) and terminal 65 (-battery) of the 70-Terminal
breakout T.
F. Access the special test for the “Exhaust Brake

Special Test” on ET.
G. While the voltage test lamp is being observed,

cycle the special test for the exhaust brake to the
ON and OFF positions.
H. Stop the special test.
Expected Result:
The voltage test lamp behaves in the following

g00769913 manner:
Illustration 99
Breakout T
• The voltage test lamp turns on when the test is
active.
• The voltage test lamp turns off when the test is
B. Turn the ignition key switch to the ON position. not active.
C. Turn the switch ON for the exhaust brake. Results:
D. Access the status screen on ET for the “Exhaust • Yes – There is a problem in the harness.
Brake Special Test”.
E. Turn the on/off switch for the exhaust brake to the
ON position. Repair the engine harness or replace the engine
harness. Verify that the repair eliminates the
F. Begin the “Exhaust Brake Special Test” while you problem.
listen for the solenoids to click. You may need to
be closer to the engine in order to hear the click of STOP.
the solenoid.
RENR1367-11 251
• No – Verify that the switch for the exhaust brake is The diagnostic module provides a way to alert
on and verify that the ET status screen reflects this the driver if the exhaust particulate filter becomes
condition. If the ECM is reading the switch status plugged. The module monitors exhaust temperature
change, temporarily connect a test ECM. Repeat and exhaust back pressure. When the temperature
this test step. If the problem is resolved with the test or the pressure reaches a predetermined level, the
ECM, reconnect the suspect ECM. If the problem diagnostic module closes a switch that is connected
returns with the suspect ECM, replace the ECM. to the ECM at J1/P1:7 input 4 and J1/P1:18 input
sensor common 1. When the switch is closed the
Repair: Perform the following repair: ECM derates the engine and a warning light may be
illuminated. When the engine is derated, the engine
1. Temporarily connect a test ECM. speed is limited to 1200 rpm and the vehicle speed
is limited to 72 km/h (45 mph). Refer to System
2. Remove all jumpers and replace all connectors. Operation, Testing and Adjusting, RENR1271 and
Special Instruction, REHS1314, “Johnson Mathey
3. Recheck the system for active diagnostic codes. CRTdm Interface Software Guide” if a problem is
suspected with the diagnostic module.


replace the ECM.
STOP.
i01738942
Exhaust Particulate Filter Illustration 100

g00890690
Circuit - Test Circuit schematic for the diagnostic module
SMCS Code: 1091-038

diagnostic module is operating correctly.

to this procedure:
The ECM can use various inputs in a number of ways.

The inputs depend on the parameter programming.
Certain features are available on several different
inputs. When an exhaust particulate filter is installed,
the parameter “PTO Configuration” is automatically
programmed to “Cab Switches”. This parameter
cannot be reprogrammed.
Diagnostic Module
252 RENR1367-11
D. Check the harness and the wiring for abrasion and

Refer to Illustration 101 for terminal locations for

the ECM.
Expected Result:

Results:

• Not OK
Repair: Repair the wiring and connectors or
replace the wiring or the connectors. Ensure that
all of the seals are properly connected. Verify that
the repair eliminates the problem.
STOP.
Test Step 2. Check the Switch Circuit for

the ECM
g00890806
Illustration 101
Terminal locations for ECM connector P1

and Wiring
A. Thoroughly inspect the ECM vehicle harness
connector J1/P1, the connectors, and the firewall
bulkhead connectors. Refer to Troubleshooting,

with the torque limit switch.
g00890896
The wires are on the following terminals: Illustration 102
• P1:7 A. Turn the ignition key switch to the OFF position.
• P1:18 B. Install a 140-2266 Cable breakout T to the ECM

vehicle harness connector J1/P1.
the proper torque of 6.0 N·m (55 lb in). C. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wire.
RENR1367-11 253
D. Insert the jumper wire into terminal 7 of the F. Alternately remove the jumper wire and then insert
breakout T. Connect the other end of the jumper the jumper wire at the terminals on the diagnostic
wire to terminal 18 in the breakout T. Terminal 18 module. At the same time, watch the status screen
is input sensor common 1. on Cat ET.
E. Connect Caterpillar Electronic Technician (Cat Expected Result:

ET) to the cab data link connector.
The input status changes to “ON” with the jumper
F. Turn the ignition key switch to the ON position. wire in place. The input status changes to “OFF”
when the jumper wire is removed.
G. Alternately remove the jumper wire and then insert
the jumper wire from terminal 18. At the same Results:
time, monitor the status screen on Cat ET.
• OK – The vehicle wiring is OK.
Expected Result:
Repair: Refer to System Operation, Testing and
The input status changes to “ON” with the jumper Adjusting, RENR1271 and Special Instruction,
wire in place. The input status changes to “OFF” REHS1314, “Johnson Mathey CRTdm Interface
when the jumper wire is removed. Software Guide” for troubleshooting the diagnostic
module.
Results:
STOP.
• OK – The ECM is functioning properly at this time.
Proceed to Test Step 3. • Not OK – The problem is in the vehicle wiring
between the ECM and the diagnostic module.
• Not OK – The ECM is not functioning properly.
Repair: Inspect the vehicle wiring and then repair
Repair: Perform the following repair: the vehicle wiring. Otherwise, send the vehicle to
the OEM dealer for repair. Verify that the original
1. Temporarily connect a test ECM. condition is resolved.
2. Remove all jumpers and replace all connectors. STOP.

i01479400
4. Repeat the Test Step. Fast Idle Enable Circuit - Test

5. If the problem is resolved with the test ECM, SMCS Code: 1900-038
replace the ECM. Use this procedure under the following situation:
7. Verify that the repair eliminates the problem. Use this procedure to determine if the fast idle switch
is operating correctly.
STOP.
Test Step 3. Insert a Jumper Wire at the to this procedure:
Diagnostic Module
A fast idle switch (momentary switch) and a fast idle
A. Turn the ignition key switch to the OFF position. lamp can be installed. The operator can use the fast
idle switch in either of the following ways:
B. Reconnect the ECM vehicle harness connector
J1/P1.
• Press and release the fast idle switch in order to
use the engine speed that is programmed into the
C. Fabricate a jumper wire 100 mm (4 inch) long. “Fast Idle RPM #1” parameter.

• Use the accelerator pedal to accelerate the engine
to the desired engine speed. Press and release
at the diagnostic module. the fast idle switch in order to maintain the engine
speed at the desired engine speed.
254 RENR1367-11
A second programmable parameter “Fast Idle RPM

#2” provides a second engine rpm set speed. The
ECM will increase the engine speed from low idle to
the engine speed that is programmed in the “Fast
Idle RPM #1” parameter when the fast idle switch
is pressed and then released. The ECM will set the
engine speed to the rpm that is programmed in the
“Fast Idle RPM #2” parameter when the fast idle
switch is pressed and then released again.
Input 18 (terminal 40) is used as a dedicated switch

input for fast idle operation. This feature does not
require an input selection to be programmed to
enable the switch input. A momentary connection
between terminal 40 and a sensor common will
initiate the fast idle operation. The “Fast Idle RPM
#2” and/or “Fast Idle RPM #1” parameters must be
programmed to the desired engine operating speeds.
The engine rpm set speed will not be maintained if

any of the following actions occur:
g00770407
Illustration 103
• The service brake is depressed.
• The clutch pedal is depressed.
• The neutral switch indicates that the transmission
is in gear.
An optional fast idle lamp can be connected to

output 9 in order to indicate when fast idle is in
operation. When the “Truck Manufacturer” parameter
is configured to “Other”, the “Output #9” parameter
must be programmed to “Fast Idle Lamp” to enable
the lamp operation. If the “Output #9” parameter is
programmed to “Wait to Start Lamp”, the lamp will
turn on when the air inlet heater is active. When the
“Truck Manufacturer” parameter is configured to
“GM”, output 9 can only be used as a fast idle lamp
output, and no programming is necessary.
g00770414
Illustration 104
RENR1367-11 255
Test Step 1. Check The Electrical Expected Result:

Connectors and The Wiring
The status screen should indicate “ON” if the switch
A. Thoroughly inspect the ECM vehicle harness is turned on. The status screen should indicate “OFF”
connector J1/P1, terminal 40, and the firewall if the switch is off.
bulkhead connectors. Refer to Troubleshooting,
“Inspecting Electrical Connectors” for details. Results:
B. Perform a 45 N (10 lb) pull test on each of the • YES – The switch is operating normally. Continue
wires in the ECM connector that are associated troubleshooting if the original condition is not
with the fast idle switch circuit. resolved. STOP.
The wires are on the following terminals: • NO – The ECM is not reading the “Switch Status”
• terminal 40
Test Step 3. Check The Switch Circuit for
• terminal 5 the ECM.


the ECM.
Expected Result:

Results:

• Not OK – Repair the wiring and connectors or Illustration 105
g00770457
all of the seals are properly connected. Verify that A. Turn the ignition key switch to the OFF position.
the repair eliminates the problem. STOP.
B. Install a 70 terminal breakout T to the ECM vehicle
Test Step 2. Check the Status of the Fast harness connector J1/P1.
Idle Switch On The Electronic Service
Tool. C. Fabricate a jumper wire 100 mm (4 inch) long.
A. Connect an Electronic Service Tool at the cab
data link connector. D. Insert the jumper wire into terminal 40 of the
breakout T. Connect the other end of the jumper
B. Turn the ignition key switch to the ON position. wire to terminal 5 in the breakout T. Terminal 5 is
AP sensor/switch common.
C. Operate the switch in the ON position and the
OFF position. E. Connect an Electronic Service Tool at the cab
data link connector.
D. View the “Fast Idle Switch” status on the Electronic
Service Tool. F. Turn the ignition key switch to the ON position.
Note: A fast idle rpm must be programmed in order G. Alternately remove the jumper wire and then insert
to automatically go to a set speed. the jumper wire from terminal 5. At the same time,
monitor the “Status Screen” on the Electronic
Service Tool.
256 RENR1367-11
The “Switch Status” changes to “ON” with the jumper • YES

wire in place. The “Switch Status” changes to “OFF”
when the jumper wire is removed. Repair: Perform the following diagnostic
procedure:
Results:
Replace the fast idle switch.
• Yes – The ECM is functioning properly at this time.
Proceed to Test Step 4. Verify that the repair eliminates the problem.
• No – The ECM is not functioning properly. STOP.
Repair: Perform the following repair: • NO – There is a problem in the wire harness
between the fast idle switch and the ECM. Proceed
1. Temporarily connect a test ECM. to Test Step 5.
2. Remove all jumpers and replace all connectors. Test Step 5. Insert A Jumper Wire At The
Bulkhead Connector.
3. Recheck the system for Active diagnostic codes.
5. If the problem is resolved with the test ECM, Crimp a Deutsch pin to both ends of the wire.
C. Locate the socket for the fast idle switch in the
6. If the problem returns with the suspect ECM, engine side of the bulkhead connector for the
replace the ECM. wiring to the ECM.
7. Verify that the repair eliminates the problem. D. Insert the wire jumper pin between the switch
socket and the sensor common connection. Install
STOP. the jumper wire on the engine side of the bulkhead
connector for the wiring to the ECM.
Test Step 4. Insert a Jumper Wire at the
Switch. E. Turn the ignition key switch to the ON position.
A. Turn the ignition key switch to the OFF position. F. Alternately connect and then disconnect the
jumper wire. At the same time, monitor the “Status
B. Reconnect the ECM vehicle harness connector Screen” on the Electronic Service Tool.
J1/P1.
Expected Result:
C. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wire. The “Switch Status” changes from “ON” with the
jumper wire in place. The “Switch Status” changes to
D. Insert the jumper wire between the two switch “OFF” when the jumper wire is removed.
terminals of the fast idle switch.
Results:
• YES – The problem is in the vehicle wiring
F. Alternately remove the jumper wire and then between the bulkhead connector and the switch.
insert the jumper wire at the switch terminals. At Inspect the vehicle wiring and then repair the
the same time, watch the “Status Screen” on the vehicle wiring. Otherwise, send the vehicle to
Electronic Service Tool. the OEM dealer for repair. Verify that the original
condition is resolved. STOP.
Expected Result:
• NO – The problem is in the vehicle wiring between
The “Switch Status” changes to “ON” with the jumper the bulkhead connector and the ECM. Inspect the
wire in place. The “Switch Status” changes to “OFF” vehicle wiring and then repair the vehicle wiring.
when the jumper wire is removed. Otherwise, send the vehicle to the OEM dealer for
repair. Verify that the original condition is resolved.
STOP.
RENR1367-11 257
i01606728
Fast Idle Lamp Circuit - Test

SMCS Code: 1901-038

Code dated earlier than OCT01.
Use this procedure to determine if the fast idle lamp

(P1:31 output 9) is operating properly.
g00834354
Illustration 107
Output 9 can operate as a fast idle lamp or a wait Schematic for the fast idle enable switch (OCT01 Option)
to start lamp. The “Output #9” parameter defaults to
“Fast Idle Lamp” and the ECM will turn on output 9 Test Step 1. Inspect Electrical Connectors
when the fast idle is active. and Wiring.
Note: For “GM Truck Manufacturer” configurations,
the “Output #9” parameter is unavailable and output
9 functions as an output only for the fast idle lamp.
Electrical Connections of the Lamp
One terminal of the lamp must be connected to

terminal is connected to the ECM at the vehicle
harness connector P1:31.
The ECM provides a path to ground that will turn on

the lamp.
g00832955
Illustration 106
Schematic for the fast idle enable switch
OCT01 Software
OCT01 and newer Personality Module Software also g00834349

offers an alternative output that can be used for a Illustration 108
fast idle lamp. The parameter “Output #9” is not Location of Output 8 and Output 9
used in the OCT01 software. The parameter “Fast
Idle Lamp” has been added. “Fast Idle Lamp” can A. Thoroughly inspect ECM vehicle harness
be programmed to “J1/P1:31” output 9, “J1/P1:21” connector J1/P1, the firewall bulkhead connector,
output 8, or “None”. and the terminals for the fast idle lamp.
258 RENR1367-11
Refer to Troubleshooting, “Electrical Connectors - F. Depress the fast idle switch while the status of
Inspect” for details. the fast idle enable switch is being observed. Also
observe the fast idle lamp. Release the fast idle
B. Perform a 45 N (10 lb) pull test on each of the switch. The fast idle lamp should turn on when the
wires in the ECM connector that are associated fast idle switch is pressed and released.
with the fast idle lamp.
G. Depress the service brake pedal. The fast idle
C. Check the ECM connector (allen head screw) for lamp should turn off when the service brake is
the proper torque of 6.0 N·m (55 lb in). applied.
D. Check the harness and wiring for abrasion and for Expected Result:
The switch status changes per the above information.
Expected Result: The fast idle lamp turns on and the fast idle lamp
turns off per the description above.
All connectors, pins, and sockets should be
completely coupled and/or inserted and the harness Results:
and wiring should be free of corrosion, abrasion or
pinch points. • Yes – The fast idle lamp is operating normally.
STOP.
Results:
• No – The ECM is not reading the switch status
• OK – Proceed to Test Step 2. change. Proceed to Test Step 3.
• Not OK Test Step 3. Test the Fast Idle Lamp

Circuit.
STOP.

of the Fast Idle Lamp.
A. Verify that a fast idle enable switch is installed.
B. Connect ET.
D. Access the ET status screen. Verify that the

following switches indicate the correct status:
• The service brake switch 1 is off. Illustration 109

g00834351
Pin locations
• The service brake switch 2 is off.
• The neutral switch is on.
• The clutch switch is off. Crimp a Deutsch pin to both ends of the wires.
If any of the switches do not display the indicated
status, fast idle will not activate.
the ECM.
E. Use the ET status screen to monitor the fast idle
D. Insert the jumper into P1:31.
switch and the fast idle rpm.
RENR1367-11 259
Note: For OCT01 and newer Personality Module Test Step 4. Check ECM Operation of the
Software, insert the jumper into P1:31 or P1:21. The Fast Idle Lamp.
terminal location depends on the programming of the
“Fast Idle Lamp” parameter.
E. Connect the other end of the jumper wire to P1:65

(−battery).
G. While the lamp is being watched, insert the jumper

wire and remove the jumper wire.
Expected Result:
Result 1 The fast idle lamp turns on while the jumper

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

the jumper is connected to both sockets.
Result 3 The fast idle lamp will stay on while the g00834353
Illustration 110
ECM vehicle harness connector is disconnected.
Pin locations on the Breakout T
Results:
A. Disconnect ECM vehicle harness connector
• Result 1 – The fast idle lamp is functioning J1/P1.
properly. Proceed to Test Step 4.
B. Insert a breakout T between ECM vehicle harness
• Result 2 – The fast idle lamp did not turn on. The connector J1 and ECM vehicle harness connector
vehicle’s lamp circuit is not functioning properly. P1.
The lamp is probably burned out or there is a
problem in the wiring from the cab to either the C. Connect one probe of the voltage test lamp to
ECM or the +battery connection. Repair the lamp P1:65 (-battery). Connect the other probe of the
circuit or send the vehicle to the OEM dealer for voltage test lamp to P1:52 (unswitched +battery)
repairs. STOP. of the breakout T.
• Result 3 D. The test lamp should turn on. If the test lamp does
not turn on, either the test lamp is faulty or the
Repair: Perform the following diagnostic wiring to the ECM is faulty. Continue with this step
procedure: if the lamp turns on.
The circuit between the ECM and the lamp is E. Leave the probe of the test lamp connected to
shorted to chassis ground. Repair the circuit or P1:52 (unswitched +battery).
F. Connect the other probe of the test lamp to P1:31
STOP. (output 9) of the breakout T.
G. Connect an ET. Access the following display

screens in order:
• Diagnostics
• Diagnostic Test
• Special Test
260 RENR1367-11
H. Activate the “Fast Idle Enabled Lamp” test.

Observe the voltage test lamp. The lamp should
turn on when the test is active. Also, the lamp
should turn off when the test is inactive.
Expected Result:
per the above description.
Results:
• Yes – The ECM is operating correctly. There is a

problem in the vehicle wiring or the lamp. STOP.
• No
Repair: Temporarily connect a test ECM. Check
the ECM operation of the fast idle lamp when the
test ECM is installed. If the problem is resolved
with the test ECM, reconnect the suspect ECM. If
the problem returns with the suspect ECM, replace
the ECM.
STOP.
i02336549
Fuel Level Sensor Circuit - Test

SMCS Code: 5574-038
This feature is only available on GMT-560

applications.
Use this procedure to troubleshoot the system only

when there is an active diagnostic code or when a
diagnostic code can easily be activated.
The fuel level sensors are OEM installed components

for the vehicle. The sensors are selectable through a
customer programmable parameter and the customer
programmable parameter may be protected by
customer passwords.
The sensors read the level of fuel in the primary fuel

tank and secondary fuel tank. The sensors require
a +5 VDC supply from the Engine Control Module
(ECM). The customer programmable parameters
“Primary Fuel Tank Size” and “Secondary Fuel Tank
Size” must be programmed to “25”, “35”, or “50” for
this feature to work.
RENR1367-11 261
g00844899
Illustration 111
Typical circuit schematic for the fuel level sensors

pinch points from the sensors to the ECM.
Expected Result:

Results:

• Not OK

Illustration 112
g01151126 all diagnostic codes.
Pin location on ECM connector
STOP.
(P1-3) Sensor common
(P1-15) Primary fuel tank level
(P1-26) Secondary fuel tank level Test Step 2. Determine the Condition that
is Present
and Wiring A. Connect Caterpillar Electronic Technician (ET) to
the data link connector.
A. Thoroughly inspect the J1/P1 ECM connector
and the terminals for the fuel level sensors in the B. Turn the key switch to the ON position. Wait at
connectors. Refer to Troubleshooting, “Electrical least 15 seconds for activation of the diagnostic
Connectors-Inspect” for details. codes.
B. Perform a 45 N (10 lb) pull test on each of the C. Monitor the “Active Diagnostic Code” screen on
wires in the ECM connector that are associated Cat ET for diagnostic codes that are related to the
with the fuel level sensors. fuel level sensors.
C. Check the ECM connector (allen head screw) Expected Result:

“Electrical Connectors - Inspect” for details. A short circuit diagnostic code 04 is active or an open
circuit diagnostic code 03 is active.
262 RENR1367-11
Results: • Not OK – The sensor supply voltage is out of the

acceptable range. Continue testing the sensor
• Voltage Low – A short circuit diagnostic code 04 is supply circuit. Proceed to Test Step 7.
active at this time. Proceed to Test Step 3.
Test Step 5. Determine if the Short Circuit
• Voltage High – An open circuit diagnostic code 03 is in the Connector or in the Sensor
is active at this time. Proceed to Test Step 4.
A. Thoroughly inspect the connector for moisture.
Test Step 3. Disconnect the Sensor in
order to Create an Open Circuit B. Inspect the seals and reconnect the sensor.
A. Turn the key switch to the OFF/RESET position. C. If the short circuit diagnostic code reappears, the
sensor or the harness connector is the problem.
B. Disconnect the connector of the sensor with the
short circuit diagnostic code. a. Temporarily connect a new sensor to the
harness.
C. Turn the key switch to the ON position. Wait at
least 15 seconds for activation of the diagnostic D. Check for a short circuit diagnostic code 04 while
codes. the new sensor is connected to the harness.
D. Monitor the “Active Diagnostic Code” screen on Expected Result:

Cat ET.
The short circuit diagnostic code 04 is not present
Expected Result: when a new sensor is connected.
An open circuit diagnostic code 03 for the Results:

disconnected sensor is now active.
• OK – Verify that the repair eliminates the problem.
Results: Clear the logged diagnostic codes. STOP.
• OK – A short circuit diagnostic code 04 was • Not OK – Repair the engine harness connector.
active before disconnecting the sensor. An open STOP.
circuit diagnostic code 03 became active after
disconnecting the sensor. Proceed to Test Step 5. Test Step 6. Create a Short Circuit at the
Sensor
• Not OK – There is a short circuit between the
sensor harness connector and the ECM. Leave the A. Fabricate a jumper wire 150 mm (6 inch) long.
sensor disconnected. Proceed to Test Step 7.
B. Turn the key switch to the ON position.
Test Step 4. Measure the Sensor Supply
Voltage C. Insert the jumper wire between the two terminals
at the connector for the suspect sensor on the
A. Turn the key switch to the OFF/RESET position. vehicle harness.
B. Disconnect the suspect sensor from the harness D. Monitor the “Active Diagnostic Code” screen
at the fuel tank. before installing the jumper wire and after installing
the jumper wire.
C. Turn the key switch to the ON position.
Expected Result:
D. Measure the voltage between the two terminals
of the fuel level sensor. A short circuit diagnostic code 04 is active when the
jumper is installed. An open circuit diagnostic code
Expected Result: 03 is active when the jumper is removed.
The voltage is 4.5 to 5.5 VDC. Results:
Results: • OK – The engine harness and the ECM are OK.

• OK – The sensor supply voltage is correct. Repair: Perform the following repair:
1. Temporarily connect the suspect sensor.
RENR1367-11 263
2. If the diagnostic code remains active, replace E. Fabricate a jumper wire 150 mm (6 inch) long.
the sensor. Crimp a Deutsch Socket to both ends of the wire.
3. Ensure that the diagnostic code is no longer F. Install the jumper wire at the breakout T. Insert the
active. jumper wire between the terminal for the suspect
sensor supply and the common connection for the
4. Verify that the repair eliminates the problem. sensor.
STOP. A short circuit diagnostic code 04 should be active

when the jumper wire is installed.
• Not OK – The open circuit diagnostic code 03
remains active when the jumper is installed. The Refer to Illustration 113 for the breakout T.
most probable location for the open is in the
sensor common or in the sensor supply in the Expected Result:
vehicle harness between the ECM and the sensor.
Remove the jumper. Proceed to Test Step 7. An open circuit diagnostic code 03 is active when
the jumper wire is removed. A short circuit diagnostic
Test Step 7. Check the ECM code 04 is active when the jumper wire is installed.
Results:
• OK – The ECM is operating properly. There may

be an intermittent problem in the wiring between
the ECM and the suspect sensor. Proceed to Test
Step 8.
• Not OK – One of the following conditions exists:

The open circuit diagnostic code 03 is not active
when the harness is disconnected. The short circuit
diagnostic code 04 is not active when the jumper
wire is installed.

g01151140
Illustration 113
4. Repeat the Test Step.
Breakout T
(3) Sensor common 5. If the problem is resolved with the test ECM,
(15) Secondary fuel tank level reconnect the suspect ECM.
(26) Primary fuel tank level

A. Turn the key switch to the OFF/RESET position.
replace the ECM.
B. Disconnect the J1/P1 ECM connector. Thoroughly
inspect both halves of the J1/P1 ECM connector
for signs of corrosion or moisture.
STOP.
C. Install a 140-2266 Cable (Seventy-Pin Breakout)
between the J1 and P1 ECM connectors.
D. Turn the key switch to the ON position. Monitor

the “Active Diagnostic Code” screen on Cat ET.
Wait at least 15 seconds for activation of the code.
An open circuit diagnostic code 03 should be

active for the suspect sensor.
264 RENR1367-11
Test Step 8. Bypass the Harness Wiring Expected Result:

Between the ECM and the Sensor
Connector The diagnostic code disappears when the jumper is
installed.
Results:
• OK – There is a problem in the wiring harness.

1. Repair the faulty wiring harness or replace the

faulty wiring harness.
2. Clear all diagnostic codes.
STOP.
• Not OK – Restart this procedure and carefully

perform each step. STOP.
i02136394
g01151144
Illustration 114
Pin locations on ECM connector Idle Shutdown Timer - Test
(P1-3) Sensor common
(P1-15) Primary fuel tank level SMCS Code: 1901-038
(P1-26) Secondary fuel tank level
A. Turn the key switch to the OFF/RESET position.
B. Disconnect J1/P1 ECM connector, and the sensor
connector. Use this procedure to determine if the idle shutdown
timer is operating correctly.
C. Remove the wire for the sensor supply and the
wire for the sensor common from the P1 ECM The following background information is related
connector on the harness. to this procedure:
D. Remove the wire for the sensor supply and the Idle Shutdown Timer
wire for the sensor common from the sensor
connector on the vehicle harness. The idle shutdown timer is intended to improve fuel
economy by limiting idling time.
E. Fabricate jumper wires that are long enough to
reach from the ECM to the sensor connector. The idle shutdown timer is a customer specified
parameter that may be programmed for any period
F. Insert the jumper wires into the P1 ECM connector from 3 to 1440 minutes.
on the vehicle harness. Insert the other end of
the wires into the sensor connector of the vehicle The timer is activated when all of the following
harness. conditions are met regardless of the position of the
parking brake:
G. Reconnect the J1/P1 ECM connector and the
sensor connector. • The vehicle speed is zero.
H. Turn the key switch to the ON position. • The engine is not in cold mode or dedicated PTO
mode.
I. Monitor the “Active Diagnostic Code” screen on
Cat ET for diagnostic codes that are related to the • The engine is not under load.
fuel level sensors.
RENR1367-11 265
The timer can be reset by moving the vehicle or Test Step 1. Verify Activation of the Idle
the timer can be reset by quickly depressing the Shutdown Timer
accelerator pedal and releasing the accelerator
pedal. A. Connect Cat ET to the data link connector.
The check engine lamp will begin to rapidly flash 90 B. Access the customer parameters.
seconds before the programmed time expires. During
this 90 second time period, the following conditions a. Access the following display screens in order:
can disable the timer:
• “Service”
• The clutch pedal is depressed.
• “Configuration”
• The service brake pedal is depressed.
b. Record the programmed time for the “Idle
The following event code will be logged when the Shutdown Time”. The “Idle Shutdown Time”
driver overrides the timer by using the clutch pedal or must be between 3 and 1440 minutes. If the
the brake pedal during the 90 second period: “Idle Shutdown Time” is programmed to zero,
then the timer is disabled.
• 71-00 (01)
c. Record the current value of the parameter
If the parameter “Allow Idle Shutdown Override” is “Allow Idle Shutdown Override” and the
programmed to “NO”, the timer can not be overridden parameter “Idle RPM Limit”.
by using the clutch pedal or the brake pedal during
the final 90 second period. The factory default that is C. Start the engine. Allow the engine to warm up until
programmed for “Allow Idle Shutdown Override” is the coolant temperature is 38 °C (100 °F). Allow
“YES”. This setting allows the timer to be overridden. the engine to operate at the programmed low idle.
If the timer is activated and the timer is allowed to D. Ensure that all unnecessary loads are turned OFF.
shut down the engine the following event code will
be generated: a. Park the vehicle.
• 71-01 (47) b. Ensure that “Vehicle Speed” on the Cat ET

status screen is 0 km/h (0 mph).
Code 71-01 records the event and the code does
not indicate an electrical system malfunction or an c. Ensure that “Engine Speed” on the Cat ET
electronic system malfunction. Disable the timer status screen is at “Low Idle”.
by programming “Idle Shutdown Time” to zero
(Caterpillar factory default). d. Ensure that the clutch pedal and the brake
pedal are not depressed.
The Engine Control Module (ECM) will shut down the
engine but not the vehicle electrical system when the e. Ensure that the status of the “PTO On/Off
time that is programmed in “Idle Shutdown Timer” Switch” is OFF.
expires. The “Engine Shutdown Output” can be used
to shut down the vehicle electrical system after the f. Observe the “Idle Shutdown Status”.
time has expired.
Expected Result:
The idle shutdown timer can be temporarily disabled
by using Caterpillar Electronic Technician (ET). The Result 1 The “Idle Shutdown Status” indicates
idle shutdown timer can be temporarily disabled “Counting”.
through the “System Troubleshooting” screen which
can be found by selecting “Diagnostic Tests” under Result 2 The “Idle Shutdown Status” indicates “Not
the “Diagnostics” menu. Select “Idle Shutdown Timer” Active”.
and click the “Change” icon. When the dialog box
appears, change the value to “OFF”. Temporarily Results:
disabling this feature avoids engine shutdowns when
you are troubleshooting other systems. Using this • Result 1 – The ECM is reading the proper
method eliminates the need to temporarily alter the conditions for the activation of the “Idle Shutdown
customer specified parameter “Idle Shutdown Timer”. Timer”. Proceed to Test Step 2.
Note: If the following diagnostic code is active, the • Result 2 – The ECM is not reading the proper
idle shutdown timer will not operate. conditions for activation of the “Idle Shutdown
Timer”. Proceed to Test Step 3.
• 84-08 (36)
266 RENR1367-11
Test Step 2. Verify the Driver Alert Result 2 The check engine lamp did not flash during
Function for Idle Shutdown and the the alert.
Override Function for Idle Shutdown.
Result 3 The ECM did not sense a change in the
A. Verify that Cat ET is connected to the data link status of the service brake.
connector.
Result 4 The ECM did not sense a change in the
B. Access the customer parameters on Cat ET. status of the clutch.
a. Access the following display screens in order: Results:
• “Service” • Result 1 – The idle shutdown timer is operating

properly. STOP.
• Result 2 – The check engine lamp did not flash
b. Record the programmed time for the “Idle during the alert.
Shutdown Time”. The “Idle Shutdown Time”
must be between 3 and 1440 minutes. If the Repair: Perform the following diagnostic
“Idle Shutdown Time” is programmed to zero, procedure: Troubleshooting, “Check Engine Lamp
the timer is disabled. Circuit - Test”
c. Reprogram the “Idle Shutdown Time” to three STOP.

minutes for this test.
• Result 3 – The ECM did not sense a change in the
C. Observe the following items during the 90 second status of the service brake.
period before the programmed shutdown time:
• Check engine lamp procedure: Troubleshooting, “Service Brake Pedal
Position (Switch 1) Circuit - Test”
• “Idle Shutdown Status”
STOP.
D. If the customer parameter of “Allow Idle Shutdown
Override” is programmed to “YES”, perform either • Result 4 – The ECM did not sense a change in
of the following actions in order to override the the status of the clutch.
shutdown:
• Press the clutch pedal. procedure: Troubleshooting, “Clutch Pedal Position
Switch Circuit - Test”
• Press the service brake pedal.
STOP.
Note: The pedals must be pressed while the check
engine lamp is flashing. The check engine lamp Test Step 3. Check the State of the
flashes during the 90 second period before the Related Conditions When the Vehicle is
programmed shutdown time. Parked.
E. Reprogram the “Idle Shutdown Time” to the value A. Check the state of the following related conditions
that was recorded earlier for this test. when the vehicle is parked:
Expected Result: • Ensure that the vehicle speed is 0 km/h (0 mph)

on Cat ET or the dash display.
During the 90 second period before the scheduled
shutdown, the status should change from “Counting” • Ensure that the engine is not in cold mode. (The
to “Driver Alert” and the check engine lamp should Cat ET status screen will indicate that “Cold
flash rapidly. If the “Allow Idle Shutdown Override” is Mode” is “Active” in the corner of the display
programmed to “YES”, the “Idle Shutdown Status” screen.)
should change to “Override” after the pedals are
depressed. • Ensure that the PTO on/off switch is OFF.
Result 1 The idle shutdown timer behaves in the • Ensure that the engine is at low idle.
manner that is described above.
RENR1367-11 267
Expected Result: This procedure tests whether proper voltage is

supplied by vehicle wiring. Use this procedure if any
Result 1 Vehicle speed is not indicated as 0 km/h one of the following diagnostic codes are logged
(0 mph). several times:
Result 2 The Cat ET status screen indicates that the • 168-02 Intermittent Battery (51)
engine is in cold mode.
• 43-02 Ignition Key Switch Fault (71)
Result 3 The status of the PTO on/off switch is not
“OFF”. Also, use this procedure if you suspect that the ECM
is not receiving the battery supply voltage.
Result 4 The engine is not at low idle.
Note: This code can be generated by rapidly cycling
Results: the ignition key switch. Some control modules on the
vehicle require this action in order to prompt flash
• Result 1 – Vehicle speed is not indicated as 0 km/h codes. If this occurs, clear the logged diagnostic
(0 mph). codes in order to prevent future confusion or an
incorrect diagnosis.
procedure: Troubleshooting, “Vehicle Speed and The following background information is related
Speedometer Circuit - Test” to this procedure:
STOP. The ECM receives electrical power (battery voltage)

through the wiring that is supplied by the vehicle
• Result 2 – The status screen on Cat ET indicates manufacturer. The ECM input at connector P1
that the engine is in cold mode. terminal 70 (ignition key switch) receives battery
voltage from the ignition key switch when the ignition
Repair: The engine must not be in “Cold Mode” key switch is in the ON position or the START
operation while this test procedure is being position. When the ECM detects battery voltage at
performed. Allow the engine to run until the coolant this input, the ECM will power up. When battery
temperature exceeds 20 °C (68 °F). Troubleshoot voltage is removed from this input, the ECM will
and repair any related conditions. power down.
STOP. The cause of an intermittent power supply to the ECM

can occur on either the positive side (unswitched
• Result 3 – The status of the PTO on/off switch is +battery) or the negative side (−battery). Both sides
not “OFF”. are routed from the ECM to the battery. The two
unswitched +battery connections should be routed
Repair: Perform the following diagnostic through a dedicated protection circuit.
procedure: Troubleshooting, “PTO Switch Circuit -
Test” Some vehicles may be equipped with an engine
protection shutdown system or an idle timer shutdown
STOP. system that interrupts electrical power to the ECM
in order to shut down the engine. Also, some
• Result 4 – The engine is not at low idle. vehicles may be equipped with an engine protection
shutdown system or an idle timer shutdown system
Repair: Return the engine to Low Idle. Perform that interrupts electrical power to the ignition key
the test procedure again. switch. The engine protection shutdown system can
be an aftermarket device and the idle timer shutdown
STOP. system can be external to the ECM. Some of these
systems will not supply power to the ECM until one
of the following conditions is met:
i01632013
Ignition Key Switch Circuit and • The engine is cranked.

Battery Supply Circuit - Test • The engine oil pressure achieves acceptable limits.
SMCS Code: 1401-038; 1553-038 • An override button is pressed.
System Operation Description: Keep in mind that these devices may be the cause
of intermittent power to the ECM.
268 RENR1367-11
Usually, battery power to the cab data link connector

is available and the battery power to the cab data link
connector is independent of the ignition key switch.
Therefore, you will be able to power up ET, but you
may not be able to communicate with the engine
ECM. The engine ECM requires the ignition key
switch to be in the ON position in order to maintain
communications. The ECM may power down a
short time after connecting ET if the ignition key
switch is in the OFF position. This is normal. Refer
to Troubleshooting, “ATA (SAE J1587 / J1708) Data
Link Circuit - Test”.
For intermittent problems such as intermittent

shutdowns that could be caused by vehicle wiring,
temporarily bypassing the vehicle wiring may be
an effective means of determining the root cause.
If the symptoms disappear with the bypass wiring,
the vehicle wiring is the cause of the problem. A
means of bypassing vehicle wiring is explained in
this test procedure. This is especially important for
vehicles that do not provide dedicated circuits for
the unswitched battery and the ignition key switch
connections.
g00742658
Illustration 115
Schematic for ECM battery circuit
RENR1367-11 269
g00640974
Illustration 116
Terminal locations for ECM
Test Step 1. Inspect Electrical Connectors Results:

and Wiring.
• OK, Troubleshooting a 43-02 Code – Proceed to
A. Thoroughly inspect ECM vehicle harness Test Step 2.
connector J1/P1, the battery connections and the
connections to the ignition key switch. Refer to • OK, Troubleshooting a 168-02 Code – Proceed
Troubleshooting, “Electrical Connectors - Inspect” to Test Step 3.
for details.
• Not OK – There is a problem with the connectors
B. Perform a 45 N (10 lb) pull test on each of the or wiring.
with the following connections: Repair: Repair the connectors or wiring and/or
• Unswitched +battery (terminals 52 and 53) the seals are properly in place and ensure that the
• −Battery (terminals 65 and 67)
STOP.
• Ignition Key Switch (terminal 70)
Test Step 2. Use ET to Check the Ignition
C. Check the ECM connector (allen head screw) for Key Switch.
pinch points from the battery to the ECM, and from B. Connect ET to the cab data link connector and
the ignition key switch to the ECM. access the status screen that shows the status of
the ignition key switch.
Expected Result:
C. Monitor the status of the ignition key switch while
All connectors, pins and sockets should be completely the ignition key switch is being cycled slowly from
coupled and/or inserted and the harness and wiring the ON position to the OFF position.
270 RENR1367-11
Note: ET may indicate that a new ECM has

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

may cause additional 43-02 faults to be logged. This
is normal. Clear any logged faults.
Expected Result:
The status of the ignition key switch changes from

“On” with the ignition key switch in the ON position to
“Off” with the ignition key switch in the OFF position.
Results:
• YES – The input for the ignition key switch is

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

- Inspect”. Excessive cycling of the ignition key
switch can cause this fault to be logged. This is
normal. Clear any logged faults.
STOP.
• NO – Proceed to Test Step 3.

Test Step 3. Check the Battery Voltage at
the ECM.
Perform Steps A, B, and C if the following
diagnostic code is active or logged:
• 168-02 Intermittent Battery (51)

A. Disconnect vehicle harness connector P1 from
ECM connector J1 and insert a breakout T.
B. Measure the voltage between vehicle harness

connector P1 terminal 52 (unswitched +battery)
and terminal 65 (-battery).
g00640981
Illustration 117
ECM Breakout T-connector
RENR1367-11 271
C. Measure the voltage from vehicle harness Test Step 4. Check the Batteries.
connector P1 terminal 53 (unswitched +battery)
and terminal 67 (-battery). A. Measure no-load battery voltage at the battery
posts.
Refer to Illustration 117 for the ECM breakout
T-connector. B. Load test the batteries. Use the 4C-4911
Battery Load Tester. Refer to Special Instruction,
Perform Steps D, E, and F if the following SEHS9249, “Use of 4C-4911 Battery Load Tester
diagnostic code is active or logged: for 6, 8 and 12 Volt Lead Acid Batteries” and
Special Instruction, SEHS7633, “Battery Test
• 43-02 Ignition Key Switch Fault (71) Procedure”.
D. Disconnect vehicle harness connector P1 from Expected Result:

ECM connector J1 and insert a breakout T.
The batteries pass the load test. For 12 Volt Systems,
E. Turn the ignition key switch to the ON position. the measured voltage is at least 11.0. For 24 Volt
Systems, the measured voltage is at least 22.0.
F. Measure the voltage between vehicle harness
connector P1 terminal 70 (Ignition Key Switch) Results:
and terminal 65 (-battery).
• YES
Refer to Illustration 117 for the ECM breakout
T-connector. Repair: Refer to the vehicle service manual for
instructions on troubleshooting the vehicle wiring
Expected Result: harness. Troubleshoot the vehicle wiring harness
and repair the vehicle wiring harness, as required.
For 12 Volt Systems, the measured voltage is Verify that the repairs eliminate the problem.
a constant 11.0 to 13.5 VDC with no suspected
intermittent problems at this time. STOP.
For 24 Volt Systems, the measured voltage is • NO

a constant 22.0 to 27.0 VDC with no suspected
intermittent problems at this time. Repair: Recharge or replace the faulty batteries.
Results:
STOP.
• OK – The ECM is receiving the correct voltage.
Test Step 5. Use the Bypass Harness for
Repair: If an intermittent condition is suspected, ET to Bypass the Vehicle Wiring.
- Inspect”.
STOP.
plode.
• Battery Voltage is out of range – Proceed to Test
Step 4.
To avoid injury or death, do not strike a match,
• Intermittent Or No Voltage – Proceed to Test Step
5.
NOTICE
• Key Switch Voltage Out Of Range Do Not connect the bypass harness to the battery un-
til the 20 Amp in-line fuse has been removed from the
Repair: Trace the wiring for the ignition key switch +Battery line. If the fuse is not removed before con-
from the ECM through the key switch circuit to the nection to the battery, a spark may result.
batteries. Find the problem and repair the problem.
Check the circuit protection for the circuit and the
wiring. Refer to the vehicle service manual for
instructions on troubleshooting the circuit for the
ignition key switch.
Verify that the repairs eliminate the problem.
STOP.
272 RENR1367-11
g00741090
Illustration 118
Bypass harness
Note: This bypass harness is only for test E. Connect ET to the data link connector of the
applications. This bypass harness may be left only bypass harness and verify that communication
temporarily on the vehicle. The bypass harness can is established.
be used in order to determine if the cause of the
intermittent problem is interruptions in battery power F. Restore all wiring to the original condition after
to the ECM or the keyswitch circuit. testing.
A. Turn the ignition key switch to the OFF position. Expected Result:
B. Disconnect vehicle harness connector J1/P1 from Installing the bypass eliminates the problem.
the ECM.
Note: The status of the ignition key switch will always
C. Connect a bypass harness to ECM connector J1. indicate “On” while the bypass harness is installed.
D. Remove the 20 Amp in-line fuse from the +Battery Results:

line of the bypass harness and connect the
unswitched +battery and − battery lines directly to • Yes – The symptoms disappear when the bypass
the battery posts. harness is installed. Also, the symptoms return
when the bypass harness is removed. The problem
Note: This bypass directly connects the circuit for the is in the vehicle wiring that supplies power to the
ignition key switch to the ECM. The ECM will remain ECM. Check for aftermarket engine protection
powered until the connection to the unswitched switches that interrupt power. Send the vehicle to
battery line “+” is disconnected. Remove the 20 Amp the OEM dealer to repair. STOP.
fuse from the in-line fuse holder to power down the
ECM. Do Not connect the bypass to the battery posts • No
without first removing the 20 Amp in-line fuse or do
not remove the bypass from the battery posts without Repair: Connect the bypass to another battery and
first removing the 20 Amp in-line fuse. verify if the problem is resolved. If the problem is
resolved, the problem is with the vehicle batteries.
RENR1367-11 273
If the problem still exists, temporarily connect Note: The wiring for your particular application
a test ECM. Remove all jumpers and replace may be slightly different. The circuits for the sensor
all connectors. Recheck the system for active common are used interchangeably by the OEM of
diagnostic codes and repeat the test step. If the the vehicle. The following circuits are common within
problem is resolved with the test ECM, reconnect the ECM:
the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM. • The “Input Sensor Common 1” is terminal 18.
Verify that the repair eliminates the problem. • The “Input Sensor Common 2” is terminal 3.
STOP. • The “AP Sensor/Switch Sensor Common” is
terminal 5.
i01608362

Circuit - Test
SMCS Code: 7332-038-CL

Ignore Brake/Clutch Switch is operating correctly.
Note: This feature is available with MAR98 and

newer software. This feature is also available with
OCT01 and newer software. The parameter “Input
# 5” has been replaced with the parameter “Ignore
Brake/Clutch Switch”. To use this feature, the
“Ignore Brake/Clutch Switch” parameter must be
programmed to “J1/P1:47”.

to this procedure:
The ECM can use various inputs in a number of ways.

The inputs depend on the parameter programming.
Certain features are available on several different
inputs. The configuration for the switch must match
the actual switch installation in order for the switch
to function properly.
The ignore brake/clutch switch is typically used

with a “Cab Switches PTO Configuration” which
requires mobile use of the vehicle during PTO
operation. When the ignore brake/clutch switch is
ON, depressing the brake or the clutch will NOT
disengage PTO operation or a set engine speed. If
the “Input # 5” parameter is programmed to “None”
(default), this feature is not used. If the “Input # 5”
parameter is programmed to “Ignore Brake/Clutch”,
then the feature is available and the switch circuit
should be connected to terminal 47 of the J1/P1 ECM
vehicle harness connector.
274 RENR1367-11
g00682286
Illustration 119
Schematic for ignore brake/clutch switch
g00682292
Illustration 120
Terminal Locations for ECM
Test Step 1. Inspect Electrical Connectors Refer to Illustration 120 for terminal locations for
and Wiring the ECM.
A. Thoroughly inspect the ECM vehicle harness Expected Result:

connector J1/P1, the connectors, and the firewall
bulkhead connectors. Refer to Troubleshooting, All connectors, pins, and sockets are completely
“Electrical Connectors - Inspect” for details. coupled and/or inserted, and the harness and wiring
wires in the ECM connector that are associated Results:
with the circuit for the Ignore Brake/Clutch Switch.
the proper torque of 6.0 N·m (55 lb in). • Not OK – Repair the wiring and connectors or
D. Check the harness and the wiring for abrasion and all of the seals are properly connected. Verify that
pinch points from the ignore brake/clutch switch the repair eliminates the problem. STOP.
to the ECM.
RENR1367-11 275
Test Step 2. Check the Status of the

Ignore Brake/Clutch Switch on ET.
C. Operate the switch in the ON and OFF positions.
D. View the status for parameter “Input # 5” on ET.
Note: For “OCT01” software, view the status for

“Ignore Brake/Clutch Switch”.
E. If the status for parameter “Input # 5” indicates

“None”, then the “Input # 5” parameter has not
been programmed.
Expected Result:
The status screen should indicate “On” if the switch

is turned ON. The status screen should indicate “Off”
if the switch is turned OFF.
Results:
• Yes – The switch is operating normally. Continue

troubleshooting if the original condition is not
resolved. STOP.
• No – The ECM is not reading the change in switch

status. Proceed to Test Step 3.
Test Step 3. Check the Switch Circuit at

the ECM.
g00682301
Illustration 121
Connector for breakout T
A. Turn the ignition key switch to the OFF position. D. Insert the jumper wire into terminal 18 (Input
Sensor Common #1) of the breakout T. Insert
B. Install a breakout T to the ECM vehicle harness the other end of the jumper wire into terminal 47
connector J1/P1. (Ignore Brake/Clutch Switch) of the breakout T.
C. Fabricate a jumper wire 100 mm (4 inch) long. E. Connect ET at the cab data link connector.
276 RENR1367-11
G. Alternately remove the jumper wire and insert the Results:

jumper wire at terminal 18 while you monitor the
status screen on ET. • Yes
Expected Result: Repair: Replace the ignore brake/clutch switch.
The switch status changes from On with the jumper Verify that the repair eliminates the problem.
wire in place to Off when the jumper wire is removed.
STOP.
Results:
• No – There is a problem in the wire harness
• Yes – The ECM is functioning properly at this time. between the Ignore Brake/Clutch Switch and the
Proceed to Test Step 4. ECM. Proceed to Test Step 5.
• No – The ECM is not functioning properly. Test Step 5. Insert a Jumper Wire at the
Bulkhead Connector.
2. Remove all jumpers and replace all connectors. Crimp a Deutsch pin to both ends of the wire.
3. Recheck the system for active diagnostic codes. C. Insert the jumper wire between the two terminals
for the ignore brake/clutch switch on the engine
4. Repeat the test step. side of the ECM bulkhead connector.
5. If the problem is resolved with the test ECM, D. Turn the ignition key switch to the ON position.
E. Alternately connect and then disconnect the
6. If the problem returns with the suspect ECM, jumper wire. At the same time, monitor the status
replace the ECM. screen on ET.
7. Verify that the repair eliminates the problem. Expected Result:
STOP. The switch status changes from On with the jumper

wire in place to “Off” when the jumper wire is
Test Step 4. Insert a Jumper Wire at the removed.
Switch.
Results:
B. Reconnect the ECM vehicle harness connector the bulkhead connector and the switch.
J1/P1.
Repair: Inspect the vehicle wiring and then repair
C. Fabricate a jumper wire 100 mm (4 inch) long. the vehicle wiring. Otherwise, send the vehicle to
Crimp a Deutsch pin to both ends of the wire. the OEM dealer for repair.
D. Insert the jumper wire between the two terminals Verify that the original condition is resolved.
of the ignore brake/clutch switch.
STOP.
• No – The problem is in the vehicle wiring between
F. Alternately remove the jumper wire and then insert the bulkhead connector and the ECM.
the jumper wire at the switch terminals. At the
same time, watch the status screen on ET. Repair: Inspect the vehicle wiring and then repair
the vehicle wiring. Otherwise, send the vehicle to
Expected Result: the OEM dealer for repair.
The switch status changes to On with the jumper wire Verify that the original condition is resolved.
in place to “Off” when the jumper wire is removed.
STOP.
RENR1367-11 277
i01856391 Complete the following test steps. Circle the

appropiate answers in the Results section of each
Injection Actuation Pressure - test step and return with the fuel system component.
Test
A. Connect the electronic service tool to the service
SMCS Code: 1714-038 tool connector.
System Operation Description: B. Turn the ignition keyswitch to the ON position but
do not start the engine.
Use the steps that follow to check the operation of
the HEUI fuel system. Circle the appropriate answer C. Print the “Lifetime Totals” and the “Configuration”
in the Results section of each step. Complete the screen.
pages. Return the pages with any of the requested
parts through the part return system. D. Check for active diagnostic codes.
Expected Result:
There are no active diagnostic codes with the

keyswitch in the ON position and the engine off.
Results:
• OK – There are no active codes. Proceed to Test

Step 2.
• Not OK – Active codes are present with the

keyswitch in the ON position and the engine off.
Repair: Refer to Troubleshooting, “Injection

Actuation Pressure Sensor - Test” if 164-03 or
164-04 is active.
Call technical support if 164-00, 164-02, or 164-11

is active.
STOP.
Test Step 2. Check the Engine Oil Level

A. Check the engine oil level.
B. If the engine oil level is low add oil to the engine.

g00725749
Illustration 122
C. Try to start the engine.
HEUI fuel system components (typical example)
Expected Result:
Test Step 1. Symptoms
The engine starts.
The following symptoms may occur if there is a
problem with the HEUI fuel system:
Results:
• The engine cranks but the engine will not start. • Yes – The engine starts. Proceed to Test Step 9.
• The engine runs rough. • No – The engine does not start. Proceed to Test
Step 3.
• The engine is erratic or unstable at idle or running.
Test Step 3. Engine Cranks but Will not
• Low power Start
• The following fault codes might be currently active Your answers indicated that your engine oil level is
codes or logged event codes: 164-00, 164-02, and
satisfactory. Do not replace the Injection Actuation
164-11.
Pressure Sensor (IAP Sensor) at this time.
278 RENR1367-11
A. Connect the electronic service tool to the engine. Test Step 5. Install a Test Plug and Check
Observe the “Injection Actuation Pressure” and the Oil Pressure
“Engine RPM” when the engine is cranking.
A. Remove the Injection Actuation Pressure Control
________________Record the actual Injection Valve (IAPCV).
Actuation Pressure.
B. Install a 219-2368 Plug and 9X-1484 Seal Kit
________________ Record the observed engine and perform the pressure test.
speed.
________________ Observed pressure reading
Expected Result:
Note: If the 219-2368 Plug is not available, proceed
The injection actuation pressure is above 6 MPa to Test Step 6.
(870 psi).
Expected Result:
Results:
The oil pressure is above 27.5 MPa (4000 psi).
• Yes – The injection actuation pressure is above
6 MPa (870 psi). Results:
Repair: The HEUI system is functioning correctly. • Yes – The oil pressure is above 27.5 MPa
Refer to Troubleshooting , “Engine Cranks but Will (4000 psi). The HEUI pump is OK.
Not Start” which is located in the “Troubleshooting
without a Diagnostic Code” section. Repair: Replace the IAPCV and check the
oil pressure. If the problem continues contact
STOP. technical support.
• No – The injection actuation pressure is below STOP.

6 MPa (870 psi). Proceed to Test Step 4.
• No – The oil pressure is below 27.5 MPa
Test Step 4. Check the Oil Pressure (4000 psi). Proceed to Test Step 7.
Disconnect the high pressure oil line from the cylinder Test Step 6. Install a New IAPCV and
head and install the 8T-0852 Pressure Gauge. Check the Oil Pressure
Crank the engine and record the oil pressure.
Note: Use this Test Step ONLY if the 219-2368 Plug
Note: The pressure readings may vary between is not available.
gauges.
A. Remove the IAPCV.
B. Install a new IAPCV and check the oil pressure.
________________ Observed RPM
________________ Observed “Injection Actuation
Output Percent” Expected Result:
Expected Result: The oil pressure is above 27.5 MPa (4000 psi).
The oil pressure is above 27.5 MPa (4000 psi). Results:
Results: • Yes – The problem has been resolved. STOP.

• Yes – The oil pressure is above 27.5 MPa • No – Remove the new IAPCV and reinstall the
(4000 psi). Proceed to Test Step 8. original IAPCV. Proceed to Test Step 7.
• No – The oil pressure is below 27.5 MPa Test Step 7. Check the Drive Gear
(4000 psi). Proceed to Test Step 5.
A. Remove the high pressure oil pump.
B. Check for any physical damage to the drive gear.

Replace the drive gear, if necessary.
RENR1367-11 279
C. Verify that the drive gear and the retaining bolt Results:
are properly tightened. Also verify that the pump
shaft rotates freely. • OK – Call technical support for assistance. STOP.
Expected Result: • Not OK
The drive gear and the retaining bolt for the high Repair: Replace the O-ring on the injector or
pressure oil pump are tight. The pump shaft rotates replace the damaged injector.
freely.
STOP.
Results:
Test Step 9. Engine Starts
• Yes – The drive gear bolt is properly tightened and
the pump shaft rotates freely. A. Connect the electronic service tool to the engine
and start the engine.
Repair: Replace the high pressure oil pump. If this
does not fix the problem, contact technical support. B. Check for the following codes:
STOP. • 164-00 Injection Actuation Pr Out of Range

• No – The pump shaft does not rotate freely. • 164-02 Injection Actuation Pr Sensor Erratic
Repair: Replace the high pressure oil pump. If this • 164-11 Injection Actuation Pressure System
does not fix the problem, contact technical support.
Expected Result:
STOP.
164-00 or 164-11 is active or logged.
• No – The drive gear bolt is loose. The pump shaft
rotates freely and there is no obvious mechanical Place a check beside the codes that are active or
damage that would indicate a different failure. logged.
Repair: Tighten the drive gear bolt to a torque of • ________________ 164-00

110 ± 14 N·m (80 ± 10 lb ft). Check the pressure
in order to ensure that the problem has been • ________________ 164-02
resolved. If this does not fix the problem, replace
the high pressure oil pump. • ________________ 164-11
STOP. Results:
Test Step 8. Check the High Pressure Oil • Yes – 164-00 or 164-11 is active or logged. 164-02
System for Leaks. may also be active or logged. Proceed to Test Step
10.
• No – 164-02 is active or logged, but 164-00 and

164-11 are not active or logged.
Hot oil and components can cause personal in-
jury. Repair: Refer to Troubleshooting, “Injection
Actuation Pressure Sensor - Test” for information
Do not allow hot oil or components to contact on troubleshooting the active 164-02 code.
skin.
STOP.
A. Remove the valve cover and inspect the high
pressure oil system for oil leaks. Test Step 10. Evaluate the Quality of the
Oil
B. While the engine is being cranked, look around
the injector bores for any signs of oil leakage. Extended oil drain intervals may cause elevated
Inspect the injector spill ports for excessive oil. All levels of soot in the engine oil. The elevated levels
six injectors should spill the same amount of oil. of soot may also deplete the additive package of the
oil. This can affect the operation of the HEUI high
Expected Result: pressure oil system.
No leaks are apparent.

280 RENR1367-11
Use the following formulas to calculate the correct oil • No – Before you proceed, ask the customer
change intervals. Scheduled oil sampling should be to authorize an oil change with a new oil filter.
used to provide the most accurate oil change interval. Oil changes are not covered by the warranty.
After the engine oil and the oil filter have been
The formulas require information to be collected from changed, operate the engine until normal operating
the electronic service tool. Enter the values from the temperature has been reached. Run the engine
electronic service tool for “Total Distance” and “Total up and down through the operating rpm range for
Fuel”. 10 to 15 minutes. This will purge any trapped air
or debris that is in the system. If the problem still
English exists or if the problem reoccurs in a short period
or time, proceed to Test Step 11.
Total Distance ________________ (miles)
/ Total Fuel ________________ (gallons) Test Step 11. Check the System with the
= Overall MPG ________________ “Injection Actuation Pressure Test”
Overall MPG ________________
X 50 A. Install 8T-0852 Pressure Gauge on the high
X Oil Pan Capacity in Quarts ________________ pressure oil rail.
= Recommended Interval ________________
B. Connect the electronic service tool to the service
Metric tool connector.
Total Distance________________ (kilometers) C. Access the “Injection Actuation Pressure Test” in

/ Total Fuel ________________ (liter) the “Diagnostics Menu” of the electronic service
= Overall KPL ________________ tool and begin the test.
Overall KPL ________________
X 200 Note: The “Injection Actuation Pressure Test” can
X Oil Pan Capacity in Liters ________________ increase the injection actuation pressure or the
= Recommended Interval ________________ “Injection Actuation Pressure Test” can decrease the
injection actuation pressure. The test adjusts the oil
Note: The recommended capacities for oil pans that pressure in steps. Depending on the interface which
follow are for truck engines. you are using, you may have either three steps or
four steps.
• The capacity for the shallow oil pan is 21 L (22 qt).
Table 173
• The capacity for the deep oil pan is 28 L (30 qt). Step Manual Pressure Electronic Difference
gauge Service Tool
Record the drain interval that the owner is currently
using. 1
2
________________ Drain interval
3
________________ Miles or Kilometers since the last 4
oil change.
The customer has not exceeded the suggested oil The pressure that is measured with the pressure
change interval and an oil change does not need to gauge for each step and the pressure that is
be performed. displayed on the electronic service tool for each step
are within 1379 kPa (200 psi).
Results:
Results:
• Yes – The injection actuation pressure sensor is
operating properly. Proceed to Test Step 12.
• No – The injection actuation pressure sensor may

be faulty. Replace the sensor and repeat this test
step. If the problem still exists, verify the accuracy
of the pressure gauge. Reinstall the original sensor
and proceed to Test Step 12.
RENR1367-11 281
Test Step 12. Perform the “Injection Table 175

Actuation Pressure Test” at both Low Low Idle
Idle and at High Idle
Step Actual injection “Injection Pressure
Start the engine. Run the “Injection Actuation pressure from the Percentage Output”
Pressure Test” at low idle and at high idle. electronic service from the electronic
tool service tool
Record the data in the following table. 1
Table 174 2
Low Idle 3
Step Actual injection “Injection Pressure 4
pressure from the Percentage Output”
electronic service from the electronic High Idle
tool service tool Step Actual injection “Injection Pressure
1 pressure from the Percentage Output”
electronic service from the electronic
2 tool service tool
3 1
4 2
High Idle 3
Step Actual injection “Injection Pressure 4
pressure from the Percentage Output”
electronic service from the electronic
tool service tool Expected Result:
1 The “Injection Actuation Pressure Output” never

2 exceeds 65% and never falls to 0 %.
3 Results:
4
• Yes – Verify that the problem is solved. STOP.
Expected Result: • No – Reinstall the original IAPCV. Proceed to Test
Step 14.
The “Injection Actuation Pressure Output” never
exceeds 65% and never falls to 0 %. Test Step 14. Check the Oil Pressure
Results: A. Turn the engine off.
• Yes – Call technical support for assistance. STOP. B. Remove the Injection Actuation Pressure Control
Valve (IAPCV).
• No – Proceed to Test Step 13.
C. Install a 219-2368 Plug and 9X-1484 Seal Kit
Test Step 13. Install a New IAPCV and and perform the pressure test.
Repeat the “Injection Actuation Pressure
Test” D. Disconnect the high pressure oil line from the
cylinder head and install the 8T-0852 Pressure
Replace the IAPCV and perform the “Injection Gauge. Crank the engine and record the oil
Actuation Pressure Test”. pressure.
Record the data in the following table. Note: The pressure readings may vary between
gauges.
________________ Observed RPM
Expected Result:
The oil pressure is above 27.5 MPa (4000 psi).

282 RENR1367-11
Results: Test Step 16. Check the High Pressure

Oil System for Leaks
• Yes – The high pressure oil pump is working
• No – The high pressure oil pump may be faulty.

Proceed to Test Step 15. Hot oil and components can cause personal in-
jury.
Test Step 15. Check the Drive Gear
Do not allow hot oil or components to contact
A. Remove the high pressure oil pump. skin.
B. Check for any physical damage to the drive gear. A. Remove the valve cover and inspect the high
Replace the drive gear, if necessary. pressure oil system for oil leaks.
C. Verify that the drive gear and the retaining bolt B. While the engine is being cranked, look around
are properly tightened. Also verify that the pump the injector bores for any signs of oil leakage.
shaft rotates freely. Inspect the injector spill ports for excessive oil. All
six injectors should spill the same amount of oil.
Expected Result:
Expected Result:
The drive gear and the retaining bolt for the high
pressure oil pump are tight. The pump shaft rotates No leaks are apparent.
freely.
Results:
Results:
• OK – Call technical support for assistance. STOP.
• Yes – The drive gear bolt is properly tightened and
the pump shaft rotates freely. • Not OK
Repair: Replace the high pressure oil pump. If this Repair: Replace the O-ring on the injector or
does not fix the problem, contact technical support. replace the damaged injector.
STOP. STOP.
• No – The pump shaft does not rotate freely.

i01856379
Repair: Replace the high pressure oil pump. If this
does not fix the problem, contact technical support. Injection Actuation Pressure
Control Valve Circuit - Test
STOP.
SMCS Code: 1714-038
• No – The drive gear bolt is loose. The pump shaft
rotates freely and there is no obvious mechanical System Operation Description:
damage that would indicate a different failure.
Repair: Tighten the drive gear bolt to a torque of
110 ± 14 N·m (80 ± 10 lb ft). Check the pressure Use the following information in order to troubleshoot
in order to ensure that the problem has been the system when there is an active code:
resolved. If this does not fix the problem, replace
the high pressure oil pump. • 42-11 Injection Actuation Pressure Control Valve
Driver (18)
STOP.
Note: Do not use this procedure for an active
diagnostic code of 164-11 Injection Actuation
Pressure System unless you are directed to this
procedure from the “Injection Actuation Pressure
- Test”. If the diagnostic code of 164-11 Injection
Actuation Pressure System is active, refer to
Troubleshooting, “Injection Actuation Pressure -
Test”.
RENR1367-11 283

to the following procedure:
The injection actuation pressure control valve

regulates the high pressure oil to the injectors
through a high pressure rail. The high pressure oil
manifold is used to actuate the injectors and the
high pressure oil manifold is used to control the fuel
injection pressure. The injection actuation pressure
control valve relieves excess high pressure oil back
to the sump. The ECM controls the operation of
the injection actuation pressure control valve by
monitoring the engine rpm and the injection actuation
pressure sensor.
g00724789
Illustration 123
Location of the injection actuation pressure control valve
g00724834
Illustration 124
Schematic for the injection actuation pressure control valve
284 RENR1367-11
g00724865
Illustration 125
Locations for the ECM terminals
Test Step 1. Use the Electronic service Repair: Refer to Troubleshooting, “Troubleshooting
Tool to Check for Active Diagnostic Without a Diagnostic Code”.
Codes.
STOP.
link connector. Test Step 2. Inspect Electrical Connectors
and Wiring.
B. Start the Engine.
A. Thoroughly inspect the connector J500/P500 for
C. Monitor the “Active Diagnostic Code” screen on the injection actuation pressure control valve and
the electronic service tool. Check and record inspect the ECM engine harness connector J2/P2.
active diagnostic codes. Refer to Troubleshooting, “Electrical Connectors -
Note: Wait at least 15 seconds in order for the
diagnostic codes to become active. B. Perform a 45 N (10 lb) pull test on each of the
Expected Result: with the injection actuation pressure sensor
(terminals 61 and terminal 62).
42-11 Injection Actuation Pressure Valve Driver is
active. C. Check the ECM connector (allen head screw) for
Results:
• Yes – Proceed to Test Step 2. pinch points from the sensors back to the ECM.
• No – Expected Result:

RENR1367-11 285
Results: B. Disconnect the ECM engine harness connector

J2/P2.
C. Check the electrical resistance from the ECM
• Not OK engine harness connector P2 terminal 61 to P2
terminal 62. The resistance should be within 2
Repair: Perform the following repair: ohms of the previous test results.
Repair the connectors or wiring and/or replace D. Check the electrical resistance from the ECM
the connectors or wiring. Ensure that all of the engine harness connector P2 terminal 62 to the
seals are properly in place and ensure that the surrounding terminals for a short circuit:
• Terminal 51
• Terminal 52
STOP.
• Terminal 63
Test Step 3. Measure the Solenoid
Resistance of the Injection Actuation E. Check the resistance from the ECM engine
Pressure Control Valve. harness connector P2 terminal 61 to the
surrounding terminals for a short circuit:
• Terminal 50
B. Disconnect the connector for the injection
actuation pressure control valve J500/P500. • Terminal 51
Note: Ensure that the seal on the connector • Terminal 52
P500 remains on P500 when the connector is
disconnected. • Terminal 60
C. Use a multimeter to measure the resistance Note: The resistance should be greater than 10k
between the two terminals of the section of the ohms.
harness for the injection actuation pressure control
valve. Record the value that was measured. F. Check the resistance from the ECM engine
harness connector P2 terminal 61 to the engine
D. Reverse the leads of the multimeter and measure ground stud and from P2 terminal 62 to the engine
the resistance again. ground stud. The resistance should be greater
than 10k ohms.
Expected Result:
Expected Result:
The solenoid resistance of the injection actuation
pressure control valve should be between 4.0 and The resistance measurements are within the proper
16.0 Ohms. range.
Results: Results:
• Yes – Record the measured resistance. Reconnect • Yes – Proceed to Test Step 5.
the harness connector for the injection actuation
pressure control valve. Proceed to Test Step 4. • No
• No Repair: Replace the harness for the injection
actuation pressure control valve.
Repair: Replace the injection actuation pressure
control valve. Start the engine and verify that the STOP.
fault is no longer active.
Test Step 5. Use the “Injection Actuation
STOP. Pressure Driver Test” on the Electronic
Service Tool to Check the Harness.
Test Step 4. Measure the Solenoid
Resistance through the Engine Harness. A. Connect the electronic service tool to the cab data
link connector.
286 RENR1367-11
C. Access the “Injection Act Press Driver Test”. C. Connect the injection actuation pressure control
valve to the engine harness at connector
D. Disconnect the injection actuation pressure control J500/P500.
valve from the engine harness.
D. Start the engine and run the “Injection Actuation
Note: Do not insert any wire that is larger than 18 Pressure Test”. The “Injection Actuation Pressure
AWG into the harness connector (P500). Do not Test” is located in the “Diagnostics” menu of the
insert the probe for the voltage test lamp into the electronic service tool. Step through all of the
harness connector (P500). These actions will spread pressure ranges.
the sockets of the connector which will damage
the connector. Damaged connectors could cause Note: This is not the “Injection Act Press Driver Test”.
intermittent connections.
E. After performing the “Injection Actuation Pressure
E. Insert a 9X-7200 ECM Pin Terminal into each Test”, check for active diagnostic codes or logged
of the harness connector sockets P500 for the diagnostic codes 42-11.
injection actuation pressure driver.
Expected Result:
F. Connect a voltage test lamp to the ECM pin
terminals that are inserted in the P500 connector The engine should start and the engine should run
and start the “Injection Act Press Driver Test” with without triggering any diagnostic codes.
the electronic service tool. Then stop the “Injection
Act Press Driver Test” with the electronic service Results:
tool.
• Yes – The problem has been corrected. STOP.
Note: This test procedure may cause a 42-11
Injection Actuation Pressure Control Valve Driver • No
(18). This is normal.
Repair: Replace the injection actuation pressure
Expected Result: control valve. Verify that the problem is resolved.
The voltage test lamp should come on when the test STOP.
is active.
Test Step 7. Use the “Injection Act Press
Note: Personality Modules with a manufactured Driver Test” on the Electronic Service
date before JUNE 99 require an electrical connector Tool to Check the ECM.
for the injection actuation pressure sensor to be
disconnected in order for the “Injection Actuation A. Disconnect the ECM engine harness connector
Pressure Control Valve Driver Special Test” to turn off J2/P2.
the driver for the injection actuation pressure control
valve. If the connector J204/P204 for the injection B. Turn the ignition key switch to the ON position.
actuation pressure sensor is not disconnected, the
voltage test lamp will remain on when the special test C. Access the “Injection Act Press Driver Test” in the
is not active. “Diagnostics” menu of the electronic service tool.
Results: D. Connect a breakout T to the ECM engine harness

connector J2.
E. Connect a voltage test lamp to the engine harness
• No – Proceed to Test Step 7. connector for the injection actuation pressure
control valve, terminal 61 and terminal 62 of the
Test Step 6. Perform “Injection Actuation breakout T.
Pressure Test”.
F. Start and stop the “Injection Act Press Driver Test”.
A. Disconnect the injection actuation pressure control
valve from the engine harness at connector Note: This test procedure may cause a 42-11
J500/P500. Injection Actuation Pressure Control Valve Driver
(18). This is normal.
B. Crank the engine for 30 seconds. Crank the
engine three times. This will purge the air from
the system.
RENR1367-11 287
Expected Result: The injection actuation pressure sensor measures the

pressure of the oil in the high pressure oil manifold.
The voltage test lamp should come on when the test The high pressure oil in the manifold is used to
is active. actuate the injectors and the high pressure oil is used
to control the fuel injection pressure. Fuel injection
Note: Personality Modules with a manufactured pressure is based on inputs from the sensors. The
date before JUNE 99 require an electrical connector inputs are used by the ECM for calculating the fuel
for the injection actuation pressure sensor to be injection pressure. The ECM uses the reading from
disconnected in order for the “Injection Actuation the injection actuation pressure sensor in order
Pressure Control Valve Driver Special Test” to turn off to control the operation of the injection actuation
the driver for the injection actuation pressure control pressure control valve.
valve. If the connector J204/P204 for the injection
actuation pressure sensor is not disconnected, the
voltage test lamp will remain on when the special test
is not active.
Results:
• Yes
Repair: Replace the harness for the injection
actuation pressure control valve.
STOP.
• No
Repair: Temporarily install a test ECM. Repeat the
test step. If this corrects the problem, then reinstall
the old ECM and verify that the problem reoccurs.
Replace the ECM if the problem reoccurs with the
old ECM.
g00725343
Illustration 126
STOP.
location of the injection actuation pressure control valve
i01857920
Injection Actuation Pressure

Sensor - Test
SMCS Code: 1925-038
Use the following information in order to troubleshoot

the system when there is an active code:
• 164-02 Injection Actuation Pr Sensor Erratic (15)

Note: This procedure can check the accuracy of
the injection actuation pressure sensor against a
pressure gauge.

to the following procedure:
288 RENR1367-11
g00725355
Illustration 127
Schematic for the injection actuation pressure sensor
g00725426
Illustration 128
Locations for the ECM terminals
Test Step 1. Use an Electronic Service Expected Result:

Tool to Check for Active Diagnostic
Codes. 164-02 Injection Actuation Pressure Erratic is active.
A. Connect the electronic service tool to the cab data Results:

link connector.
• Yes – The engine will not start. Proceed to Test
B. Turn the ignition key switch to the ON position. Step 2.
Note: If the 164-02 Injection Actuation Pr Sensor • No – The engine will not start. Proceed to Test
Erratic (15) is not active or logged, try to start the Step 2.
engine.
Test Step 2. Disconnect the Injection
Note: If 164-03 Injection Actuation Pr Sensor Open Actuation Pressure Sensor and Start the
Circuit (15) or 164-04 Injection Actuation Pr Sensor Engine.
Short Circuit (15) is active, refer to Troubleshooting,
“Engine Pressure Sensor Open or Short Circuit-Test”. A. Turn the ignition key switch to the OFF position.
RENR1367-11 289
B. Disconnect the electrical connector J204/P204 for Verify that the repair eliminates the problem.
the injection actuation pressure sensor from the
engine harness. STOP.
C. Try to start the engine. Test Step 4. Check the Sensor Status
with the Engine Off.
Expected Result:
The engine starts. link connector.
Results: B. Turn the ignition key switch to the ON position.
• Yes – Proceed to Test Step 3. C. Check the injection actuation pressure on the
electronic service tool status screen.
• No
Note: The following codes will cause the injection
Repair: Reconnect the electrical connector actuation pressure sensor to default to 17500 kPa
J204/P204 for the injection actuation pressure (2538 psi).
sensor to the engine harness. Refer to
Troubleshooting, “Engine Cranks but Will Not • 164-03 Injection Actuation Pr Open Circuit (15)
Start”.
• 164-04 Injection Actuation Pr Sensor Short
STOP. Circuit (15)
Test Step 3. Inspect Electrical Connectors • 232-03 5 Volt Supply Above Normal (21)
and Wiring.
• 232-04 5 Volt Supply Below Normal (21)
A. Thoroughly inspect the connector J204/P204
for the injection actuation pressure sensor and Expected Result:
inspect the ECM engine harness connector
J2/P2. Refer to Troubleshooting, “Electrical The injection actuation pressure sensor indicates
Connectors-Inspect” for details. 0 kPa (0 psi).
B. Perform a 45 N (10 lb) pull test on each of the Results:

with the injection actuation pressure sensor • Yes – Proceed to Test Step 6.
(terminals 61 and terminal 62).
the proper torque of 6.0 N·m (55 lb in). Test Step 5. Check the Voltage Supply of
the Injection Actuation Pressure Sensor.
pinch points from the sensors back to the ECM. A. Turn the ignition key switch to the OFF position.
Expected Result: B. Disconnect the electrical connector J204/P204 for

the injection actuation pressure sensor from the
All connectors, pins and sockets should be completely engine harness.
should be free of corrosion, abrasion or pinch points. C. Connect a 3-Terminal breakout T to the electrical
connector J204 only.
Results:
E. Use a digital multimeter that is set on DC voltage.
• Not OK Measure the voltage supply from terminal A to
Terminal B at the breakout T.
Expected Result:
the connectors or wiring. Ensure that all of the The voltage reading should be between 4.5 to 5.5
seals are properly in place and ensure that the VDC.
290 RENR1367-11
Results: Table 176

Service Tool Pressure Pressure Gauge Reading
• Yes – Proceed to Test Step 6. Reading Range
• No 6000 kPa 4000-7800 kPa (580-1130

psi)
Repair: The voltage supply for the injection 10000 kPa 8000-11800 kPa
actuation pressure sensor is not correct. Refer to (1160-1710 psi)
Troubleshooting, “5 Volt Engine Pressure Sensor
Supply Circuit - Test”. 15000 kPa 13000-16800 kPa
(1885-2435 psi)
STOP. 23000 kPa 21000-24800 kPa
(3045-3595 psi)
Test Step 6. Compare the Injection
Actuation Pressure Sensor Reading to a Expected Result:
Pressure Gauge Reading.
The reading that is displayed on the electronic
service tool and the reading on the pressure gauge
readings agree.
Escaping fluid under pressure, even a pinhole size
leak, can penetrate body tissue, causing serious Results:
injury, and possible death. If fluid is injected into
your skin, it must be treated immediately by a doc- • Yes
tor familiar with this type of injury.
Repair: The injection actuation pressure sensor
Always use a board or cardboard when checking and the ECM are working properly. Refer to
for a leak. Troubleshooting, “Troubleshooting without a
Diagnostic Code”.
A. Turn the ignition key switch to the OFF position. STOP.
B. Install a 8T-0852 Pressure Gauge to an oil supply • No
port on the high pressure oil rail that is located on
the cylinder head. Repair: Temporarily replace the injection actuation
pressure sensor and repeat the test. Replace the
C. Connect the electronic service tool to the cab data injection actuation pressure sensor if this corrects
link connector. the problem. If the new sensor is out of the range,
then the pressure gauge is faulty.
D. Start the engine.
STOP.
E. Go to the “Injection Actuation Pressure Test” on
the Diagnostic Menu of the electronic service tool.
i01632162
F. Start the test and monitor the Injection Actuation
Pressure Sensor reading from the electronic Injector Solenoid Circuit - Test
service tool. Compare the pressure reading from
the electronic service tool to the pressure reading SMCS Code: 1290-038
on the 8T-0852 Pressure Gauge. Perform a
comparison of the two different pressure indicators System Operation Description:
at varying engine rpm.
Note: Use Table 176 for the approximate range for
the injection actuation pressure sensor. Compare the Use this procedure if any of the following diagnostic
8T-0852 Pressure Gauge pressure reading to the codes are present:
pressure reading from the table.
• 1-11 Cylinder 1 Fault (72)
RENR1367-11 291

Also use this procedure if you have been referred
to this test from Troubleshooting, “Engine Misfires,
Runs Rough or Is Unstable ” or Troubleshooting,
“Low Power/Poor or No Response to Throttle”.
Perform this procedure under conditions that are

identical to the conditions that exist when the problem
occurs. Typically, problems with the injector solenoid
occur when the engine is warmed up and/or when
the engine is under vibration (heavy loads).

to this procedure:
The engines use Hydraulic Electronic Unit Injectors

that are hydraulically actuated and electronically
energized. The solenoid is mounted on top of the fuel
injector body.
The injectors can be individually cut out to aid in

troubleshooting misfire problems. Use the Cylinder
Cutout Test to disable individual injectors.
The injector solenoids can also be actuated without

running the engine in order to check the operation
of the solenoids. Use the Injector Solenoid Test to
perform this function.
Note: The Injector Solenoid Test will not help find

leaks in the high pressure oil system.
g00723522
Illustration 129
292 RENR1367-11
g00782844
Illustration 130
Circuit schematic for the injectors
RENR1367-11 293

and Wiring.
g00723444
Illustration 131
Pin locations for ECM
F. Check the harness and wiring for abrasion and

pinch points from the injectors to the ECM.
Electrical shock hazard. The electronic unit injec-
Expected Result:
tor system uses 90-120 volts.
A. Turn the ignition key switch to the OFF position. coupled and/or inserted and the harness and wiring
A strong electrical shock hazard is present if the should be free of corrosion, abrasion or pinch points.
ignition key is not turned OFF.
Results:
B. Thoroughly inspect the ECM engine harness
connector J2/P2 and the solenoid connector for • OK – Proceed to Test Step 2.
the injector J300/P300. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details. • Not OK
C. Perform a 45 N (10 lb) pull test on each of the Repair: Perform the following repair:
wires in the ECM connector and the solenoid
connector for the injector J300/P300 that are Repair the connectors or wiring and/or replace
associated with injector solenoids. the connectors or wiring. Ensure that all of the
Refer to Illustration 131. connectors are completely coupled.
D. Check the ECM connector (allen head screw) for Verify that the repair eliminates the problem.
STOP.
E. Check the solenoid connector for the injector
J300/P300 in order to ensure the proper mating Test Step 2. Use ET to Check for Logged
of the connector. Diagnostic Codes.
294 RENR1367-11
B. Turn the ignition key switch to the ON position. I. Verify that cutting out a specific cylinder causes
only a slight change to the Fuel Position of the
C. Monitor the “Logged Diagnostic Code” screen of other cylinders in comparison to the change to the
ET. Fuel Position that occurs when other cylinders are
cut out. If a cylinder is cut out and only a slight
Expected Result: change occurs to the Fuel Position of the other
cylinders, a mechanical problem with the injector
One or more of the listed codes have been logged: or a mechanical problem with the cylinder may
exist.
J. After the test is finished, use ET to check for active
• 2-11 Cylinder 2 Fault (72) diagnostic codes or for logged diagnostic codes
that are new.
Expected Result:
An active diagnostic code for a cylinder fault results
• 5-11 Cylinder 5 Fault (74) from running the Cylinder Cutout Test.
• 6-11 Cylinder 6 Fault (74) Results:
Results: • Yes – Proceed to Test Step 4.

• Yes – Proceed to Test Step 4. • No – Perform the following repair:
• No – Proceed to Test Step 3. Repair: If a cylinder is cut out and only a slight
change occurs to the Fuel Position of the other
Test Step 3. Check the Variation of the cylinders, a mechanical problem with the injector or
Injectors From Cylinder to Cylinder. a mechanical problem with the cylinder may exist.
If the engine is misfiring or if the engine has low
A. Connect ET to the cab data link connector. power, refer to Troubleshooting, “Engine Misfires,
Runs Rough or Is Unstable” and Troubleshooting,
B. When possible, put the truck on a dynamometer. “Low Power/Poor or No Response to Throttle”.
C. Start the engine. If a diagnostic code for a cylinder fault results from
running the Cylinder Cutout test, proceed to Test
D. Allow the engine to warm up to normal operating Step 4.
temperature 77 °C (171 °F).
Test Step 4. Use the Injector Solenoid
E. After the engine is warmed to operating Test to Test the Injector Solenoids.
temperature, access the “Cylinder Cutout Test” by
accessing the following display screens in order: A. Start the engine.
• “Diagnostics” B. Allow the engine to warm up to 77 °C (171 °F)

which is the normal operating temperature.
• “Diagnostic Tests”
C. Turn the ignition key switch to the OFF position.
• “Cylinder Cutout Test”
D. Connect ET at the cab data link connector.
F. Enable the cooling fan, if the fan is not controlled
by the ECM. If the ECM controls the cooling fan, E. Turn the ignition key switch to the ON position.
the cooling fan will start automatically when the
test begins. F. After the engine is warmed to operating
temperature, access the “Injector Solenoid Test”
G. Shut off all parasitic loads such as the air by accessing the following display screens in
conditioning and the air compressors which could order:
affect the results of the test.
• “Diagnostics”
H. Cut out each cylinder and watch the “Fuel
Position” of all of the other cylinders. • “Diagnostic Tests”
RENR1367-11 295
• “Injector Solenoid Test” Expected Result:
G. Activate the test. The status of the circuit for the suspect injector
displays “SHORT” before J300/P300 is disconnected.
Note: Do not confuse the Injector Solenoid Test with The status of the circuit for the suspect injector
the Cylinder Cutout Test. The Cylinder Cutout Test is changes to “OPEN” after J300/P300 is disconnected.
used to shut off fuel to a specific cylinder while the
engine is running. The Injector Solenoid Test is used Results:
in order to actuate the injector solenoids. This allows
the click of the injector solenoids to be heard when • Yes – Reconnect J300/P300. Proceed to Test
the engine is not running in order to determine that Step 7.
the circuit is functioning properly.
H. As each solenoid is energized by the ECM an
audible click can be heard at the valve cover. A Test Step 6. Check the Injector Harness
black square will appear over the cylinder number from P2 to J300 for an Open Circuit.
when the cylinder is being fired.
I. Perform the Injector Solenoid Test at least two

times.
Expected Result: tor system uses 90-120 volts.
All cylinders indicate “OK”. A. Turn the ignition key switch to the OFF position.
A strong electrical shock hazard is present if the
Results: ignition key switch is not turned off.
• Yes – There is not an electronic problem with the B. Disconnect the 12-pin connector (J300/P300).
injectors at this time. STOP.
C. Insert one end of a jumper wire into the socket of
• No – ET displays “SHORT” for any cylinder. the suspect injector. Insert the other end of the
Proceed to Test Step 5. jumper wire into the socket of the injector common
line for the connector (J300/P300).
• No – ET displays “OPEN” for any cylinder.
Proceed to Test Step 6. D. Turn the ignition key switch to the ON position.
Test Step 5. Check the Injector Harness E. Access the “Injector Solenoid Test” on ET and
from P2 to J300 for Short Circuits. begin the test.
Expected Result:
Electrical shock hazard. The electronic unit injec- The status of the circuit for the suspect injector
tor system uses 90-120 volts. displays “OPEN” before J300/P300 is disconnected.
The status of the circuit for the suspect injector
changes to “SHORT” after J300/P300 is
A. Turn the ignition key switch to the OFF position. disconnected.
ignition key switch is not turned off. Results:
B. Disconnect the 12-pin connector (J300/P300). • Yes – Proceed to Test Step 9.
Check for evidence of moisture entry. Refer to
Troubleshooting, “Electrical Connectors - Inspect” • No – Proceed to Test Step 10.
for details.
Test Step 7. Check the Injector Harness
C. Turn the ignition key switch to the ON position. for a Short Circuit Between Connector
P300 and the Injector.
D. Access the “Injector Solenoid Test” on ET and
begin the test.

296 RENR1367-11
A. Turn the ignition key switch to the OFF position. Test Step 8. Use the “Injector Solenoid
A strong electrical shock hazard is present if the Test” to Check for Short Circuits in the
ignition key is not turned OFF. ECM and in the Harness.
B. Remove the valve cover.
C. Disconnect the harness from the problem injector Electrical shock hazard. The electronic unit injec-
at the connector that is attached to the injector tor system uses 90-120 volts.
solenoid. For example, if the number one injector
is the suspect injector, disconnect P301 from
J301. A. Turn the ignition key switch to the OFF position.
D. Turn the ignition key switch to the ON position. ignition key is not turned OFF.
E. Access the “Injector Solenoid Test” on ET and B. Disconnect ECM engine harness connector
perform the test three times. “J2/P2” from the ECM and check for evidence
of moisture entry. Refer to Troubleshooting,
Note: Ensure that the seal is installed in the harness “Electrical Connectors - Inspect” for details.
connector before connecting the harness to the
connector. If the seal is missing, use a replacement C. Turn the ignition key switch to the ON position.
seal. Ensure that the seal is not stuck in the injector
connector. D. Access the “Injector Solenoid Test” on ET and
begin the test.
Expected Result:
Note: When ECM Connector J2/P2 is disconnected,
The status for the injector that is disconnected all of the open circuit diagnostic codes for the sensors
changes to “OPEN” when the harness is and the open circuit diagnostic code for the Air
disconnected. Inlet Heater will be active. This is normal. Clear all
diagnostic codes after completing this test step.
Results:
Expected Result:
• Yes – Perform the following repair:
All cylinders indicate “OPEN” when the engine
Repair: Temporarily connect a new injector to harness connector P2 is disconnected from the ECM.
the harness. Run the “Injector Solenoid Test”. If
all cylinders indicate “OK”, turn the keyswitch to Results:
OFF and reconnect the old injector. If the original
injector again reads “OPEN”, replace the injector. • Yes – Repair the harness between the ECM
Restore the wiring to the proper injectors. Use the Connector P2 and the 12-pin connector (J300).
“Injector Solenoid Test” to verify that the repair If the harness cannot be repaired, replace the
eliminates the problem. harness. STOP.
Do not install the valve cover until the problem is • No – Temporarily connect a test ECM. Repeat this
resolved. Clear all diagnostic codes. test step. If the problem is resolved with the test
ECM, install the old ECM in order to verify that the
STOP. problem returns. If the test ECM works and the old
ECM does not work, replace the ECM. STOP.
• No – Perform the following repair:
Test Step 9. Check the Injector Harness
Repair: There is a short in the wiring harness. for an Open Circuit Between Connector
Replace the wiring harness between the 12-pin P300 and the Injector.
connector (P300) and the injector.
STOP. Electrical shock hazard. The electronic unit injec-


RENR1367-11 297
B. Remove the valve cover. Repair: Temporarily connect a new injector to

the harness. Run the “Injector Solenoid Test”. If
C. Disconnect the harness from the problem injector all cylinders indicate “OK”, turn the keyswitch to
at the connector that is attached to the injector OFF and reconnect the old injector. If the original
solenoid. For example, if the number one injector injector again reads “OPEN”, replace the injector.
is the suspect injector, disconnect P301 from Restore the wiring to the proper injectors. Use the
J301. “Injector Solenoid Test” to verify that the repair
Do not install the valve cover until the problem is

resolved. Clear all diagnostic codes.
STOP.
Test Step 10. Use the “Injector Solenoid

Test” to Check for Open Circuits in the
ECM and in the Harness.


Illustration 132
g00723455 B. Disconnect ECM engine harness connector
“J2/P2” from the ECM and check for evidence
Connector for injector solenoids
of moisture entry. Refer to Troubleshooting,
D. Insert a jumper wire across the terminals of the
harness connector that was removed from the
C. Connect a 70-Terminal breakout T into the ECM.
injector. For example, if the number one injector is
Do not connect the engine harness connector P2
the suspect injector, place the jumper wire across
into the breakout T.
the terminals of “P301”.
D. Use a jumper wire to short between the socket
of the suspect injector and the common socket
of the suspect injector.
F. Access the “Injector Solenoid Test” on ET and
monitor the cylinder.
Expected Result:
F. Access the “Injector Solenoid Test” on ET and
begin the test.
The status of the injector with the short in place
indicates an “OPEN”.
Note: When ECM connector J2/P2 is disconnected,
all of the open circuit diagnostic codes for the sensors
Results:
and the open circuit diagnostic code for the air inlet
heater will be active. All of the injectors that are not
• Yes – There is an open circuit in the harness. jumpered will indicate an OPEN circuit during the
Repair the harness between the 12-pin connector
“Injector Solenoid Test”. This is normal. Clear all
(J300) and the injector. Replace the harness if the
diagnostic codes after completing this test step.
harness cannot be repaired. Verify that the repair
eliminates the problem. STOP.
Expected Result:
• No ET displays “SHORT” for the cylinder with the jumper
wire.
298 RENR1367-11
Results: In order to use torque limiting, the parameter

“Torque Limit” must be programmed. The “Torque
• Yes – Repair the harness between the 12-pin Limit” parameter is located under the “Dedicated
connector (J300) and the ECM connector P2. PTO Parameters”. The default setting is 2712 N·m
Replace the harness if the harness cannot be (2000 lb ft). The “Input # 4” parameter must be
repaired. STOP. programmed to “Torque Limit Switch”. If the “Input #
4” parameter is programmed to “None” (default), this
• No – Temporarily connect a test ECM. Repeat this feature is not used.
test step. If the problem is resolved with the test
ECM, install the old ECM in order to verify that the OCT01 Software
problem returns. If the test ECM works and the old
ECM does not work, replace the ECM. STOP. The parameter “Input # 4” has been replaced by the
parameter “Torque Limit Switch”. This parameter can
be programmed to “J1/P1:7”, “J1/P1:23”, or “None”.
i01858012
Input Selection Switch Circuit Input 5 (Ignore Brake/Clutch Switch)
- Test MAR98 and Newer Software
SMCS Code: 7332-038 The ignore brake/clutch switch is typically used when
the parameter “PTO Configuration” is programmed
System Operation Description: to “Cab Switches”. This configuration requires mobile
use of the vehicle during PTO operation. When the
Use this procedure under the following situation: ignore brake/clutch switch is on, depressing the
brake or the clutch will not disengage PTO operation
Use this procedure to determine if the following or a set engine speed. If the “Input # 5” parameter is
circuits are operating correctly: programmed to “None” (default), this feature is not
used. For information on troubleshooting this switch,
• Torque limit switch refer to Troubleshooting, “Ignore Brake/Clutch Switch
Circuit - Test”.
• Ignore brake/clutch switch
OCT01 Software
• Two-speed axle switch
The parameter “Input # 5” has been replaced by
• Diagnostic enable switch the parameter “Ignore Brake/Clutch Switch”. This
parameter can be programmed to “J1/P1:47” or
• PTO Engine RPM Set Speed Input A Switch “None”.
• PTO Engine RPM Set Speed Input B Switch Input 6 (Two-Speed Axle Switch)
The following background information is related MAR98 and Newer Software

to this procedure:
When a two-speed axle is used, the change in gear
The ECM can use various inputs in a number of ways. ratios from the main drive axle ratio will alter the
The inputs depend on the parameter programming. calibration of the vehicle speed signal. When the
Certain features are available on several different two-speed axle switch is in the ON position, the ECM
inputs. The configuration for the switch must match will automatically adjust the vehicle speed calibration.
the actual switch installation in order for the switch This will ensure that the ECM driven speedometer
to function properly. and the stored information in the ECM correctly
reflect the actual vehicle speed. In order for this
Input 4 (Torque Limit Switch) feature to function properly, the “Low Speed Range
Axle Ratio” and “High Speed Range Axle Ratio”
MAR98 and Newer Software parameters must be programmed. If the “Input # 6”
parameter is programmed to “None” (default), this
The torque limit switch provides a way to temporarily feature is not used.
protect equipment from damage that is caused by
applying too much torque. Torque limiting is typically OCT01 Software
used during PTO operation. Torque limiting can also
be used when the PTO on/off switch is in the OFF The parameter “Input # 6” has been replaced by the
position. parameter “Two-Speed Axle Switch”. This parameter
can be programmed to “J1/P1:6” or “None”.
RENR1367-11 299
Input 7 (Diagnostic Enable Switch) OCT01 Software
JUL99 and Newer Software The parameter “Input # 7” is no longer used. “PTO
Engine RPM Set Speed Input A” is the parameter that
The diagnostic enable switch is used to prompt is used to configure a PTO Engine RPM Set Speed
diagnostic flash codes on the check engine lamp. Input A switch. This parameter can be programmed
For more information, refer toTroubleshooting, “Flash to “J1/P1:46”, or “None”. The “PTO Configuration”
Programming” and Troubleshooting, “Check Engine parameter must be programmed to “Cab Switches”,
Lamp or Warning Lamp is Malfunctioning”. If the “Remote Switches” or “Remote Throttle” and the
“Input # 7” parameter is programmed to “None” “PTO Engine RPM Speed A” parameter must be
(default), then the feature is not used. If the “Input # programmed to a valid speed.
7” parameter is programmed to “Diagnostic Enable
Switch”, then the feature is available and the switch Input 19 (PTO Engine RPM Set Speed Input B
circuit should be connected to terminal 46 of the Switch)
J1/P1 ECM vehicle harness connector.
JUL99 and Newer Personality Modules.
OCT01 Software
“Input # 19” can be programmed to “PTO Engine
The parameter “Input # 7” is no longer used. RPM Set Speed Input B” or to “None”. If the “Input
“Diagnostic Enable” is the parameter that is used # 19” parameter is programmed to “PTO Engine
to configure a diagnostic enable switch. This RPM Set Speed Input B”, the switch is used to
parameter can be programmed to “J1/P1:46”, “J1939 control engine speed during PTO operation. The
Cab Controller”, “J1939 Body Controller”, “J1939 “PTO Configuration” parameter must be programmed
Instrument Cluster”, or “None”. For troubleshooting to “Cab Switches”, “Remote Switches” or “Remote
the J1939 options, refer to Troubleshooting, Throttle” and the “PTO Engine RPM Speed B”
“Powertrain Data Link Circuit - Test”. parameter must be programmed to a valid speed.
JUL99 and Newer Software The “PTO Engine RPM Set Speed B” parameter
requires an engine rpm to be programmed. The “PTO
“Input # 7” can be programmed to “Diagnostic Enable Engine RPM Set Speed B” parameter is located in
Switch” or to “PTO Engine RPM Set Speed Input A”. the “Dedicated PTO Parameter Group”. The “PTO
If the “Input # 7” parameter is programmed to “PTO Engine RPM Set Speed Input B” parameter is located
Engine RPM Set Speed Input A” the switch is used in the “Input Selections Parameter Group”. The
to control engine speed during PTO operation. The function of the switch for the “PTO Engine RPM Set
switch circuit should be connected to terminal 46 Speed Input B” is similar to the function of the switch
of the J1/P1 ECM vehicle harness connector. The for the “PTO Engine RPM Set Speed Input A”. The
“PTO Configuration” parameter must be programmed engine will operate at Set Speed “A” when both of
to “Cab Switches”, “Remote Switches” or “Remote the switches are on. If the “PTO Engine RPM Set
Throttle” and the “PTO Engine RPM Speed Input A” Speed Input B” parameter is programmed to “None”
parameter must be programmed to a valid speed. (default), this feature is not used.
The “PTO Engine RPM Set Speed A” parameter OCT01 Software

requires an engine rpm to be programmed. The “PTO
Engine RPM Set Speed A” parameter is located in The parameter “Input # 19” is no longer used. “PTO
the “Dedicated PTO Parameter Group”. The “Input Engine RPM Set Speed Input B” is the parameter
# 7” parameter is located in the “Input Selections that is used to configure a PTO Engine RPM Set
Parameter Group”. The engine will ramp up to the Speed Input B switch. This parameter can be
engine rpm that is programmed under the following programmed to “J1/P1:7”, “J1/P1:23”, or “None”. The
conditions: “PTO Configuration” parameter must be programmed
to “Cab Switches”, “Remote Switches” or “Remote
• The switch for the PTO Engine RPM Set Speed Throttle” and the “PTO Engine RPM Speed B”
Input A Switch is in the ON position and the PTO parameter must be programmed to a valid speed.
on/off switch is then turned on.
Note: The wiring for your particular application
• The switch for the PTO Engine RPM Set Speed may be slightly different. The circuits for the sensor
Input A Switch is turned to the ON position when common are used interchangeably by the OEM of
the PTO on/off switch is on. the vehicle. The following circuits are common within
the ECM:
The PTO on/off switch or the switch for the PTO
Engine RPM Set Speed Input A must be cycled from • The “Input Sensor Common 1” is terminal 18.
the OFF position to the ON position in order to return
to the programmed engine rpm if the PTO operation • The “Input Sensor Common 2” is terminal 3.
is disabled.
300 RENR1367-11
• The “AP Sensor/Switch Sensor Common” is

terminal 5.
g00728802
Illustration 133
Schematic for Torque Limit Switch
OCT01 Software may also be configured to use J1/P1:23 for the Torque Limit Switch.
g00682286
Illustration 134
Schematic for ignore brake/clutch switch
g00682705
Illustration 135
Schematic for Two Speed Axle Switch Circuit
g00728804
Illustration 136
Schematic for Diagnostic Enable Switch or the PTO Engine RPM Set Speed Input A Switch
RENR1367-11 301
g00728803
Illustration 137
Schematic for the PTO Engine RPM Set Speed Input B Switch
OCT01 Software may also be configured to use J1/P1:7 for the PTO Engine RPM Set Speed Input B Switch.
g00728814
Illustration 138
Terminal Locations for ECM
Test Step 1. Inspect Electrical Connectors B. Perform a 45 N (10 lb) pull test on each of the
and Wiring wires in the ECM connector that are associated
with the suspect switch circuit.
connector J1/P1, the connectors, and the firewall C. Check the ECM connector (allen head screw) for
bulkhead connectors. Refer to Troubleshooting, the proper torque of 6.0 N·m (55 lb in).
302 RENR1367-11

for pinch points from the battery to the ECM. Then,

the ECM.
Expected Result:

Results:

• Not OK – Repair the wiring and connectors or
Test Step 2. Check the Switch Status on

an Electronic Service Tool
link connector.

OFF position.
D. View the switch status on the electronic service

tool.
E. If the switch status indicates “Not Installed”, then

the switch parameter has not been programmed.
Expected Result:
The status screen should indicate “ON” if the switch

is turned ON. The status screen should indicate
“OFF” if the switch is OFF.
Results:
• Yes – The switch is operating normally. Continue

troubleshooting if the original condition is not
resolved. STOP.

RENR1367-11 303
Test Step 3. Check the Switch Circuit for

the ECM.
g00682375
Illustration 139
Connector for Breakout T
A. Turn the ignition key switch to the OFF position. 4. Repeat the test step.
B. Install a breakout T to the ECM vehicle harness 5. If the problem is resolved with the test ECM,
connector J1/P1. reconnect the suspect ECM.
C. Fabricate a jumper wire 100 mm (4 inch) long. 6. If the problem returns with the suspect ECM,
Crimp a Deutsch pin to both ends of the wire. replace the ECM.
D. Insert the jumper wire into the suspected terminal 7. Verify that the repair eliminates the problem.
of the breakout T. Connect the other end of
the jumper wire to terminal 5 in the breakout T. STOP.
Terminal 5 is AP sensor/switch common.
Test Step 4. Insert a Jumper Wire at the
E. Connect the electronic service tool to the cab data Switch.
link connector.
G. Alternately remove the jumper wire and then insert J1/P1.
the jumper wire from terminal 5. At the same time,
monitor the status screen on the electronic service C. Fabricate a jumper wire 100 mm (4 inch) long.
tool. Crimp a Deutsch pin to each end of the wire.
Expected Result: D. Insert the jumper wire between the two switch
terminals.
The switch status changes to “ON” with the jumper
wire in place. The switch status changes to “OFF” E. Turn the ignition key switch to the ON position.
F. Alternately remove the jumper wire and then
Results: insert the jumper wire at the switch terminals. At
the same time, watch the status screen on the
• Yes – The ECM is functioning properly at this time. electronic service tool.
Expected Result:
The switch status changes to “ON” with the jumper
Repair: Perform the following repair: wire in place. The switch status changes to “OFF”
Results:
• Yes
304 RENR1367-11
Repair: Replace the switch. i01604768
Verify that the repair eliminates the problem. Neutral Switch Circuit - Test
STOP. SMCS Code: 1435-038
• No – There is a problem in the wire harness System Operation Description:

between the switch and the ECM. Proceed to Test
Step 5. Use this procedure under the following situation:
Test Step 5. Insert a Jumper Wire at the Use this procedure to determine if the neutral switch
Bulkhead Connector. is preventing normal operation of cruise control, fast
idle, idle set speed, or PTO operation:
B. Fabricate a jumper wire 100 mm (4 inch) long. correct operation of the cruise control, fast idle, idle
Crimp a Deutsch pin to each end of the wire. set speed or PTO operation:
C. Locate the suspect switch socket in the engine • Service brake pedal position (switch 1)
side of the ECM bulkhead connector.
D. Insert the wire jumper pin between the switch
socket and the sensor common connection. Install • Neutral switch
the jumper wire on the engine side of the ECM
bulkhead connector. • Cruise control set/resume switch
E. Turn the ignition key switch to the ON position. • Cruise control on/off switch
F. Alternately connect and then disconnect the • PTO on/off switch

jumper wire. At the same time, monitor the status
screen on the electronic service tool. • cruise control pause switch
Expected Result: The switches are described in the respective circuit

tests in Troubleshooting.
The switch status changes from “ON” with the jumper
wire in place. The switch status changes to “OFF” All of the following Customer Programmable
when the jumper wire is removed. Parameters can affect cruise control, fast idle, idle
set speed, and PTO operation:
Results:
the bulkhead connector and the switch. Inspect the • “High Cruise Control Speed Set Limit”
vehicle wiring and then repair the vehicle wiring.
Otherwise, send the vehicle to the OEM dealer for • “Idle Vehicle Speed Limit”
repair. Verify that the original condition is resolved.
STOP. • “Fast Idle RPM #1”
• No – The problem is in the vehicle wiring between • “Fast Idle RPM #2”
the bulkhead connector and the ECM. Inspect the
vehicle wiring and then repair the vehicle wiring. • “Cruise/Idle/PTO Switch Configuration”
Otherwise, send the vehicle to the OEM dealer for
repair. Verify that the original condition is resolved. • “Idle/PTO Bump rpm”
STOP.
• “Idle/PTO rpm Ramp Rate”
• “Cruise Pause Switch”
RENR1367-11 305
The vehicle speed calibration can also affect the This switch must be ON before cruise control or
Cruise Control, the Idle Set Speed, and the PTO if the controlled idle can be activated. This switch is ON
vehicle speed calibration is incorrectly programmed. when the switch is closed. When the switch is closed
Refer to Troubleshooting, “Customer Specified the following terminals are connected:
Parameters”.
Automatic Transmission Neutral Switch on/off switch)
The automatic transmission neutral switch is • Terminal 5 (AP sensor/switch sensor common)
required when the “Transmission Style” parameter
is programmed to “Automatic Option 3”, “Automatic Note: If the vehicle is programmed to use the
Option 4”, “AT/MT/HT Option 3”, or “AT/MT/HT Option “Dedicated PTO”, the PTO on/off switch overrides the
4”. This switch is used to indicate when the automatic cruise control on/off switch. The PTO on/off switch
transmission is in neutral. overrides the cruise control on/off switch when the
The automatic transmission neutral switch is an open Speed Limit” that is programmed.
circuit when the transmission is in gear. Shifting the
transmission to the neutral position should close Set/Resume Switch
the circuit, which connects the input to the battery
voltage. Many other switches in the system connect With the cruise control on/off switch in the ON
the input to ground when the circuit is closed. position and the vehicle speed within the range of
the programmed “Low Cruise Control Speed Set
This switch may not be connected to an input on the Limit” and the “High Cruise Control Speed Set Limit”,
ECM. The parameter “Transmission Neutral Switch” momentarily pressing the set switch will activate
determines the input to the ECM. If the parameter is cruise control, and the ECM will maintain the current
programmed to J1/P1:62 a switch must be connected speed.
to terminal 62. If the parameter is programmed to
“J1939”, the switch position will be transmitted to After a speed has been set and the speed is then
the ECM over the J1939 data link. If a problem disengaged by using the brake, the clutch, the cruise
is suspected with the J1939 data link, refer to control pause switch, or the on/off switch, the ECM
Troubleshooting, “Powertrain Data Link Circuit - Test”. will seek the previous set speed when the resume
switch is toggled. This assumes that the vehicle
The following background information is related speed is above the “Low Cruise Control Speed Set
to this procedure: Limit” for cruise control or the vehicle speed is below
the “Idle/PTO Vehicle Speed Limit” for the idle and
The kickout switch refers to the switch that is used to the PTO.
exit the cruise control, the fast idle, the PTO, or the
idle set speed. After a speed has been set, pressing and holding the
set/resume switch in position will cause the engine
The operation of the Caterpillar electronic engine to establish a new set speed. The system’s reaction
cruise control is similar to the operation of the depends on the programming of the “Cruise/Idle/PTO
cruise controls that are installed in automobiles. The Switch Configuration”.
operation of fast idle, idle, and PTO are similar to the
operation of cruise except that the idle and the PTO When the set/resume switch is momentarily pressed,
govern engine rpm instead of vehicle speed. the cruise set point will change one mph. The rate of
change is dependent on the programmed “Idle/PTO
Note: Idle in this procedure is an engine idle rpm Bump rpm” when the engine is setting on idle speed.
by using the cruise control on/off switch and the Cruise Control Pause Switch
Switch Circuit - Test” for additional information The cruise control pause switch is not a switch that
regarding the programmable options for the is wired to an input. The switch position is broadcast
Dedicated PTO. over a J1939 data link. The parameter “Cruise Pause
Switch” must be programmed to use a cruise control
Note: Fast idle in this procedure is an engine idle pause switch. After a speed has been set and the
rpm above the programmed low idle rpm. Fast idle is speed is then disengaged by using the cruise control
set by using a dedicated fast idle switch. pause switch, the ECM will seek the previous set
speed when the resume switch is toggled. This
Cruise Control On/Off Switch assumes that the vehicle speed is above the “Low
Cruise Control Speed Set Limit” for cruise control
Speed Limit” for the idle and the PTO.
306 RENR1367-11
Kickout Switches Table 177

Switch Usage.
The brake pedal position switches, the neutral switch, Setting For
the cruise control pause switch, and the clutch pedal Transmission Service Service
position switch are used in the cruise control mode, Style Brake Brake
Clutch Neutral
the PTO mode, the fast idle mode, and the idle mode Parameter Switch Switch
to discontinue cruise operation, PTO operation, fast 1 2
idle operation, or idle operation. The capability to “Manual
override the idle shutdown timer is determined by the X X
Option 1”
“Allow Idle Shutdown Override” parameter setting.
“Manual
The “Allow Idle Shutdown Override” is a Customer X X X
Option 2”
Parameter.
“Automatic
X
Usage of Transmission Style Switches Option 1”
“Automatic
The “Transmission Style” parameter determines the X X
Option 2”
can be used with being dependent on the parameter “Automatic
X X X
setting: Option 3”
“Automatic
• clutch pedal position X X
Option 4”
“AT/MT/HT
• neutral Option 1”
X
• service brake pedal position (switch 1) “AT/MT/HT

X X
Option 2”
• service brake pedal position (switch 2) “AT/MT/HT
X X X
Option 3”
Refer to Table 177 for additional information.
“AT/MT/HT
X X
Option 4”
“Universal
X X X
Option”
If the “Transmission Style” parameter is programmed

to one of the following options, the input for the clutch
pedal position switch is not used:
• “Automatic Options 1”
RENR1367-11 307
A Service Brake Pedal Position (Switch 1) is required • “Idle Kickout”

for all configurations. The Service Brake Pedal
Position (Switch 1) connects to the ECM through • “PTO Kickout”
connector P1 terminal 45. The Service Brake Pedal
Position (Switch 2) connects to the ECM through • “Fast Idle Kickout”
connector P1 terminal 64. The Clutch Pedal Position
Switch connects to the ECM through connector P1 This parameter is blank when the ECM is first
terminal 22. The neutral switch connects to the ECM powered up. If this parameter is blank, “No
through connector P1 terminal 62. Occurrence” is indicated. This parameter remains
Some engines that were built before JULY 1999 Cruise/Idle/PTO Mode. Also, this parameter remains
may have a Basic ECM. The Basic ECM was used blank until the ECM detects the disengagement of
only on General Motors chassis. Other chassis used the Cruise/Idle/PTO Mode. Refer to Tables 178, 179
engines that were built with a Full Feature ECM. and 180 in order to interpret the status screen kickout
Basic ECM software does not have the parameter status parameter.
for “Transmission Style”. For these systems, a
jumper wire must be installed between the clutch
of the vehicle.

procedure:
After the kickout, review the “ET Status” parameter.

The “ET Kickout Status” parameter indicates the
cause. This must be performed before the ignition
key switch is turned OFF. It is important to remember
that the parameter will only indicate the last kickout
since the ECM has been powered by the ignition
key switch.
The following Kickout Status parameters are

available:
308 RENR1367-11
Table 178
condition.
Switch”
circuit condition.
The clutch pedal is depressed or the Refer to Troubleshooting, “Clutch Pedal
clutch pedal switch circuit has an open Position Circuit - Test”.
The transmission is not in gear or the Proceed with the test procedure.
“Neutral” transmission switch circuit has a short
circuit condition.
exists.
circuit condition.
RENR1367-11 309
Table 179
The Cruise/Idle On/Off switch is turned OFF Refer to Troubleshooting, “Cruise Control
condition.
Switch”
circuit condition.
The transmission is not in neutral or the Proceed with the test procedure.
“Neutral” transmission neutral switch circuit has an
The PTO On/Off switch is turned ON or the Refer to Troubleshooting, “PTO Switch
“PTO Switch On” PTO On/Off switch circuit has a short circuit Circuit - Test”.
condition.
Idle set speed has not been enabled since Operate the vehicle in the Idle mode in order
“No Occurrence”
the ECM has been powered up. to create the problem again.
310 RENR1367-11
Table 180
The Fast Idle On/Off switch is turned OFF Refer to Troubleshooting, “Cruise Control
condition.
Switch”
circuit condition.
“Neutral” transmission neutral switch circuit has an
Fast Idle set speed has not been exited Operate the vehicle in the Idle mode in order
“No Occurrence”
since the ECM has been powered up. to create the problem again.
RENR1367-11 311
Table 181
No Engine Speed
The PTO On/Off switch is turned OFF or the Refer to Troubleshooting, “Cruise Control
Switch Turned Off
Switch”
circuit condition.
Neutral transmission neutral switch circuit has an
g00646460
Illustration 140
Schematic for transmission neutral switch
Test Step 1. Determine the Type of • “Idle Vehicle Speed Limit”

Problem.
PTO Parameters
C. If the vehicle will not allow setting a Cruise speed,
an Idle speed or a PTO speed, check the following • “PTO Configuration”
• “Low Cruise Control Speed Set Limit” a problem due to one of these parameters.
• “High Cruise Control Speed Set Limit” Parameters” for a description of the parameters, if
necessary.
Idle Parameters
• “Fast Idle RPM #1” cause of a kickout for one of the following modes:
• “Fast Idle RPM #2” • Cruise Kickout

312 RENR1367-11
• Idle Kickout
• PTO Kickout
meaning of the ET status screen parameter.
Expected Result:

Results:

the driver. STOP.
• No
If a problem is still suspected with the neutral

switch circuit perform the following procedure:

and Wiring.
g00705233
Illustration 141
RENR1367-11 313
A. Thoroughly inspect ECM vehicle harness C. Shift the transmission into the Neutral position
connector J1/P1, the firewall bulkhead connector while the status of the neutral switch is being
and the terminals for the following switches in the observed. Also, shift out of Neutral while the status
connectors: of the neutral switch is being observed.
• neutral switch (terminal 62) Note: If the status indicates “Not Installed”, check the
programming of the “Transmission Style” Parameter.
Refer to Troubleshooting, “Electrical Connectors - The “Transmission Style” must be programmed to
Inspect” for details. “Automatic Option 3” or “Automatic Option 4”.
B. Perform a 45 N (10 lb) pull test on each of the Expected Result:

with the switches. The switch status changes per the information in
Table 182.
Results:
the proper torque of 6.0 N·m (55 lb in). • Yes – The switch is operating normally. STOP.
D. Check the harness and wiring for abrasion and • Intermittent Problem Suspected – Proceed to Test
pinch points from the sensor to the ECM. Step 4.
Expected Result: • No – The ECM is not reading the switch status

coupled and/or inserted and the harness and wiring Test Step 4. Operate the Vehicle and
should be free of corrosion, abrasion or pinch points. Check the Kickout Status Parameter.
Results: A. For an intermittent Cruise Control Kickout, talk
to the driver in order to determine the conditions
• OK – Proceed to Test Step 3. when the kickout occurs. Topics of examination
could be the following examples:
• Not OK
• specific speed
replace the connectors or wiring. Ensure that all of • road conditions
connectors are completely coupled. • weather conditions
Verify that the repair eliminates the problem. Take the vehicle for a road test in order to
duplicate these conditions and set the cruise
STOP. control. Operate the vehicle in cruise control until
Test Step 3. Check Neutral Switch Status
on ET. B. For an intermittent Idle Kickout, talk to the driver
Table 182 kickout occurs. A topic of examination could be
Neutral Switch Status Table the following example:
Switch Position Switch Status Circuit • Specific engine rpm
The transmission is in
ON Closed Start the engine. Duplicate these conditions and
Neutral.
set the idle rpm. Operate the vehicle in idle until
The transmission is in the problem reoccurs.
OFF Open
Gear.
Note: The status screen will only indicate the last
A. Access the ET status screen. kickout. The status screen will lose this information if
the ignition key switch is turned OFF.
C. Connect ET and check the status screen for the
last cause of the kickout. Refer to Tables 178,
179, 180, and 181 for an explanation of the status
parameter.
314 RENR1367-11
D. If the status screen is blank, then either there was Results:

no kickout of the cruise control, or the power to
the ECM was turned OFF before the information • Result 1 – Proceed to Test Step 5.
• Result 2
Note: A status screen that is blank indicates “No
Occurrence”. Repair: Perform the following diagnostic
procedure:
Expected Result:
RESULT 1 The ET Kickout Status displays the Test”
following result:
STOP.
• “Neutral”
• Result 3
RESULT 2 The ET Kickout Status displays the
following result: Repair: Perform the following diagnostic
procedure:
• “Switch Turned Off”
RESULT 3 The ET Kickout Status displays the Test”
following result:
STOP.
• “Cruise Control PAUSE Switch”
• Result 4
procedure:
• “Brake”
Troubleshooting, “Service Brake Pedal Position
RESULT 5 The ET Kickout Status displays the (Switch 1) Circuit - Test”
following result:
STOP.
• “Vehicle Speed < Limit”
• Result 5
• “Vehicle Speed ≥ Limit” procedure:
RESULT 6 The ET Kickout Status displays the Troubleshooting, “Vehicle Speed Circuit - Test”
following result:
STOP.
• Result 6
procedure:
• “Clutch”
following result: STOP.
• “No Engine Speed” • Result 7

RESULT 9 The ET Kickout Status displays the Repair: Perform the following diagnostic
following result: procedure:
• “Ser Switch Timeout” Troubleshooting, “Clutch Pedal Position Switch

Circuit - Test”
• “Resume Switch Timeout”
STOP.
RENR1367-11 315
• Result 8 Expected Result:
Repair: Perform the following diagnostic The switch status changes per the information in
procedure: Table 183.
Troubleshooting, “Engine Speed/Timing Circuit - Results:

Test”
STOP. to test step 6.
• Result 9 • No – The ECM is not functioning properly.

Repair: Perform the following diagnostic Repair: Perform the following repair:
procedure:
Test”. 2. Remove all jumpers and replace all connectors.
STOP. 3. Recheck the system for Active diagnostic codes.
Test Step 5. Check the Switch Circuit for 4. Repeat the test step.
the ECM.
Table 183 reconnect the suspect ECM.
Neutral Switch Input Status Table
Condition of Switch replace the ECM.
Circuit
Terminal 62 is open. OFF Open 7. Verify that the repair eliminates the problem.
Terminal 62 connected STOP.
ON Closed
to +battery.
Test Step 6. Insert a Jumper at the Neutral
A. Turn the ignition key switch to the OFF position. Switch.
B. Fabricate a jumper wire 100 mm (4 inch) long. Table 184
Crimp a Deutsch pin to both ends of the wires. Neutral Switch Input Status Table
C. Disconnect vehicle harness connector P1 from Condition of Switch

the ECM. Circuit
Neutral switch wires are
OFF in gear Open
D. Connect a breakout T to ECM connector J1 and disconnected.
connect P1 to the breakout T.
Neutral switch wires are
ON in neutral Shorted
connected.
E. Install the jumper into terminal 62 (neutral switch)
of the breakout T. Connect the other end of the
jumper to terminal 52 unswitched +battery of the A. Turn the ignition key switch to the OFF position.
breakout T.
F. Turn the ignition key switch to the ON position. is connected.
G. Connect ET to the cab data link connector. C. Find the neutral switch in the vehicle.
H. Access the status screen. D. Disconnect the wires from the neutral switch
terminals.
I. While the neutral switch status is being monitored
on the status screen slowly remove the jumper E. Turn the ignition key switch to the ON position.
from terminal 52 unswitched +battery. Now, slowly
insert the jumper into terminal 52 unswitched F. Connect ET to the cab data link connector.
+battery.
Refer to Table 183.
316 RENR1367-11
H. While the switch status is being monitored on the H. While the switch status is being monitored on the
status screen slowly connect the switch wires and status screen alternately remove the jumper wire
slowly disconnect the switch wires. between the two terminals, and alternately insert
the jumper wire between the two terminals.
Refer to Table 184.
Refer to Table 185.
Expected Result:
Expected Result:
Table 184. The switch status changes per the information in
Table 185.
Results:
Results:
• Yes – The switch is not functioning properly.
Repair: Perform the following repair: the bulkhead connector and the switch.
Replace the faulty switch. Repair: Perform the following repair:
Verify that the repair eliminates the problem. Inspect the vehicle wiring and repair the vehicle
STOP. the wiring, send the vehicle to the OEM dealer.
• No – There is a problem in the harness between STOP.

the switch and the ECM. Proceed to Test Step 7.
Test Step 7. Insert a Jumper at the the bulkhead connector and the ECM.
Bulkhead Connector.
Table 185
Neutral Switch Input Status Table Inspect the vehicle wiring and repair the vehicle
Condition of Switch the wiring, send the vehicle to the OEM dealer.
Circuit
Bulkhead wires are STOP.
OFF in gear Open
disconnected.
Bulkhead wires are i01858020
ON in neutral Shorted
connected.
Powertrain Data Link Circuit -
A. Turn the ignition key switch to the OFF position. Test
B. Fabricate a jumper wire 100 mm (4 inch) long. SMCS Code: 1901-038
C. Find the neutral switch terminal and the +battery
connection in the engine side of the bulkhead Use this procedure under the following situation:
connector for the vehicle harness.
Use this procedure if one of the following diagnostic
D. Insert the jumper wire between the two terminals codes are active:
• 231-02 J1939 Required Data Not Received (58)
• 231-11 J1939 Data Link Fault (58)
F. Connect ET to the cab data link connector.
• 231-12 J1939 Device Not Responding (58)
Also, use this procedure when ET indicates that the
sensor and the ECM are functioning but the engine
is not responding to the accelerator pedal position
sensor.
RENR1367-11 317
The following background information is related The J1939 refers to the standard for data link
to this procedure: communications of the Society of Automotive
Engineers Inc.. The ECM has a customer
Power train Data Link programmable parameter that is called “Powertrain
Data Link” which can be programmed to either of the
The power train data link is designed to offer following options:
electronically controlled Anti-Lock Brakes (ABS),
traction control systems, and/or transmission • J1939
controls. This is accomplished by a momentary
reduction of engine rpm and/or engine torque, that • NONE
is triggered by a signal from an off-engine control
module for the ABS, the traction control, or the Anti-Lock Brake Systems (ABS)
transmission. An off-engine control module is a
control module that is not part of the Caterpillar The J1939 data link may be used by an anti-lock
engine control system. brake system (ABS) in order to disable the exhaust
brake when the anti-lock brake control determines
With OCT01 and newer Personality Modules, that the exhaust brake should be disabled. This is
information from switches may also be transmitted usually achieved when the ABS system is active.
over the J1939 data link. The following parameters
can be programmed to send switch information over Traction Control Systems
the J1939 data link:
Loss of traction is determined by sensors on the
• “Cruise Control On/Off Switch” vehicle that are mounted near the wheels. These
sensors are also used by the ABS system. Typically, a
• “Cruise Control Set/Resume Switch” system with traction control includes anti-lock brakes.
• “Cruise Pause Switch” Transmission Control
• “Service Brake Pedal Position Switch #1” The following characteristics are determined by a
vehicle speed sensor in the transmission:
• “Clutch Pedal Position Switch”
• transmission shift points
• “Fan Override Switch”
• engine rpm
• “Exhaust Brake Switch”
• load
• “Diagnostic Enable Switch”
The sensors for power train control provide signals
• “A/C High Pressure Switch” to the vehicle control module of the “Powertrain Data
Link”. The vehicle control module of the “Powertrain
• “A/C Fan Request Switch” Data Link” then communicates with the engine
ECM. The engine ECM receives a request from the
Any combination of the following systems may be “Powertrain Data Link”. The engine ECM responds
installed together on a vehicle: by momentarily limiting the following characteristics:
• Traction Control • engine rpm

• Transmission Control • torque
• ABS • both engine rpm and torque
• Switch Information The presence of an active J1939 data link circuit can
be determined by observing the “Powertrain Status”
The required components are installed at the OEM parameter on ET. The ET status screen will display
when the vehicle is built. “INSTALLED” if the proper Personality Module is
installed on the ECM, and there is no action that is
Powertrain data link sensors, off-engine control being requested at that time by any of the control
modules, and wiring are installed by the vehicle OEM. modules on the data link.
Questions that relate to the hardware configuration,
software, and installation should be referred to the
vehicle OEM.
318 RENR1367-11
If an action is being requested by one of the vehicle

control modules, the display will indicate the control
that is making the request (traction control or
transmission control) or a combination of the two
(traction control and transmission control). Power
train control is also displayed in the upper right hand
corner of the display status screen.
J1939 Data Link
SAE J1939 is standard on the Full Feature ECM.

The SAE J1939 is not available on the Basic ECM.
All 3126B truck engines ((S/N: 8YL)) have the SAE
J1939 Data Link.
If the “Truck Manufacturer” parameter is programmed

to “GM”, then the “Powertrain Data Link” parameter
defaults to “J1939”. If the truck manufacturer is
programmed to “OTHER”, then the default is “NONE”.
If the data link is required, then the “Powertrain Data
Link” parameter must be programmed to “J1939”.
If the “Truck Manufacturer” parameter is programmed

to “GM” then the “J1939” Data Link is self-adjusting.
Note: The “Service Engine Soon lamp” will not be

illuminated if a message is not broadcast over the
data link for a period of 5 hours.
Note: The wiring for the J1939 data link is a shielded

twisted pair cable and the wiring is not serviceable.
The wiring must be replaced when the wiring is
damaged.
g00830986
Illustration 142
Schematic for Power train data link
RENR1367-11 319
g00768550
Illustration 143
ECM pin locations
320 RENR1367-11
g00721539
Illustration 144
Test Step 1. Inspect Electrical Connectors Results:

and Wiring.
A. Thoroughly inspect ECM vehicle harness
connector J1/P1, the firewall bulkhead connector, • Not OK
the connectors for the power train control module,
and the connector terminals for the SAE J1939 Repair: Perform the following repair:
data link. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details. Repair the connectors or wiring and/or replace
B. Perform a 45 N (10 lb) pull test on each of the seals are properly in place and ensure that the
wires in the ECM connector that are associated connectors are completely coupled.
with the SAE J1939 Data Link.
STOP.
the proper torque of 6.0 N·m (55 lb in). Test Step 2. Connect an Electronic
Service Tool and Check for Active
D. Check the harness and wiring for abrasion and Diagnostic Codes.
pinch points from the data link connectors back
to the ECM. A. Connect the electronic service tool to the cab data
link connector.
Expected Result:
coupled and/or inserted and the harness and wiring C. Monitor the active diagnostic code screen of the
should be free of corrosion, abrasion or pinch points. electronic service tool. Check and record active
diagnostic codes.
RENR1367-11 321
One of the following diagnostic codes is active: The electronic service tool displays the devices that
are used on the vehicle and the ECM is receiving
• 231-11 J1939 Data Link Fault (58) messages from the devices.
Note: The “Powertrain Data Link” parameter is a Results:

customer parameter that must not be programmed
to “J1939”, unless the J1939 Data Link is being • Yes – The ECM is receiving messages from the
used. If J1939 is not connected and the parameter is devices that are installed on the vehicle. STOP.
programmed for J1939 the following active diagnostic
code will occur: • No – The ECM is not receiving messages from the
devices that are installed on the vehicle.
• 231-11 J1939 Data Link Fault (58)
Repair: The devices that can be programmed to
Results: use the J1939 data link can be circuits with two
wires or circuits with three wires. Bad connections
• Yes 231-11 Active – Proceed to Test Step 3. are the most frequent problem. Repair the
connectors or wiring and/or replace the connectors
• No – Proceed to Test Step 4. or wiring. Ensure that the connectors are free of
corrosion.
Test Step 3. Use the Special Test on an
Electronic Service Tool to Check the STOP.
Devices on the J1939 Data Link.
link connector.
B. Access the special test “J1939 Receive

Communication Status”. The special tests are
located under the Diagnostic menu.
C. The electronic service tool will display the J1939

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

Cluster”
• Switches that are programmed to “Body

Controller”
• Switches that are programmed to “Cab

Controller”
D. The electronic service tool will display the J1939

source in the “Description” column. The “Status”
column displays the status of the device.
E. If a message is not received from a device, the

electronic service tool will display “Not Receiving”.
F. The status screen on the electronic service tool

can be set to display the status of a device that is
not working. The status screen will display “No
Comm” if a message is not received from the
device.
322 RENR1367-11
Test Step 4. Check the Power Train Status

Screen on an Electronic Service Tool.
g00721856
Illustration 145
Display screen for the electronic service tool
Table 186
Powertrain Status Parameter Group Definition Table
Heading On Status Screen Displayed Message Definition of Message
Engine Speed Actual engine rpm of the engine

Percent Torque Current engine torque during operation
that is expressed as a percent of peak
torque
Powertrain Status “Not Installed”, “ABS Control”, “Traction Communication of the power train
Control”, “Traction and ABS Control”, control module
“Trans Control”, “Trans and ABS
Control”, “Trans and Traction Control”,
“Trans and Traction and ABS”
(continued)
RENR1367-11 323
(Table 186, contd)
TC Status or Transmission Status “No Communication” Communication from the vehicle control
is not being received by the ECM. One
of the following conditions exists: The
vehicle does not support this feature.
The vehicle control is not currently
powered, or the wiring is damaged or
disconnected.
“Not Active” No requests from the Vehicle Power
Train ECU (Electronic Control Unit)
“Speed Command” Engine rpm is being controlled by a
Vehicle ECU.
“Torque Command” Engine torque is being controlled by a
Vehicle ECU.
“Speed and Torque Limit” Engine rpm and torque is being
determined by a Vehicle ECU.
“Torque Limit” The Torque limit is being determined by
a Vehicle ECU.
“Speed Limit” The rpm limit is being determined by a
Vehicle ECU.
TC Speed The TC Speed is the desired engine
rpm setpoint or the engine rpm limit
that is being requested by the vehicle’s
Traction Control ECU.
TC Torque The TC Torque is the desired percent of
torque or the desired percent of torque
limit that is being requested by the
Vehicle’s Traction Control ECU.
Transmission Output Speed The Transmission Output Speed is
the desired engine rpm setpoint or the
engine rpm limit that is being requested
by the Vehicle’s Traction Control ECU.
Transmission Torque The Transmission Torque is the desired
percent of torque or the percent of
torque limit that is being requested by
the Vehicle’s Traction Control ECU.
(continued)
324 RENR1367-11
(Table 186, contd)
ABS Status “No Communication” The ECM is not receiving

communication from the vehicle’s
ABS/Traction Control System. One of
the following conditions exists: The
vehicle does not support this feature.
The vehicle’s ABS/Traction Control
System is not currently powered. The
wiring is damaged or disconnected.
“Not Active” There are no requests from the ABS
Control .
“Disable Retarder” The control for the ABS system
requests the operation of the engine
retarder to stop.
A. Connect the electronic service tool to the cab data Note: Some power train control modules have test
link connector. modes that are available by activating diagnostic
switches. Ensure that the Caterpillar ECM is not
B. While the vehicle is being driven by someone reacting to a test by the power train control module if
else, monitor the electronic service tool. Use the the problem is related to power train control operation
following procedure: and you believe that the system should not be active.
a. Access the status screen. Select the Results:

“Powertrain Status” screen. The “Powertrain
Status” screen relates to the J1939 data link. • Yes – If the response is abnormal, send the vehicle
to the OEM dealer for repairs. STOP.
b. While the vehicle is being operated, monitor
the “Powertrain Status” Screen. • No
Refer to Table 186 for an explanation of Repair: Perform the following diagnostic
the parameters that are displayed in the procedure:
“Powertrain Status” screen of the electronic
service tool. Troubleshooting, “Troubleshooting without a
Diagnostic Code”
Note: Transmission shifts and/or a momentary loss
of traction should trigger the electronic service tool STOP.
display and the appropriate action by the ECM when
the correct sensors, controls and wiring are installed
i02375748
on the vehicle.
Expected Result:
PTO Engine Shutdown Switch
Circuit - Test
The electronic service tool status screen indicates
that the ECM is responding to a power train control. SMCS Code: 7332-038

PTO engine shutdown switch is operating correctly.
RENR1367-11 325
Background Information
An input is available to the Engine Control Module

(ECM) for connecting a switch to shut down the
engine while the engine is operating in PTO mode. To
use this feature, the “PTO Configuration” parameter
must be programmed to “Cab Switches”, to “Remote
Switches”, or to “Remote Throttle”. The following
conditions must also be met in order to use this
feature:
• “PTO Engine Shutdown Switch” must be

programmed to “P1/J1:7” or to “P1/J1J1:23”.
• The PTO On/Off Switch is in the ON position and

the PTO is active.
• The PTO Engine Shutdown Switch is in the ON

position.
• 186-04 is not active.

• The vehicle speed is equal to zero.
• No vehicle speed faults are active.
If the vehicle speed is not equal to zero, or if there are
active vehicle speed faults, the engine will go to low
idle. The engine will not shut down when the vehicle
speed falls to zero. When the PTO engine shutdown
switch is pressed, a 186-14 will become active. The
code will stay active until the engine shuts down.
When the engine shuts down, the code will be logged.
g01152403
Illustration 146
Typical circuit schematic for the PTO engine shutdown switch
Note: The PTO engine shutdown switch may also be

connected to P1/J1-7 Input 4. The parameter “PTO
Engine Shutdown Switch” must be programmed to
“P1/J1:7”.
326 RENR1367-11
Test Step 1. Inspect Electrical Connectors Expected Result:

and Wiring
Results:

• Not OK – Repair the wiring and connectors or
Test Step 2. Check the Switch Status on

Caterpillar Electronic Technician (ET)

OFF position.
D. View the switch status on Cat ET.
E. If the switch status indicates “Not Installed”, the

parameter “PTO Engine Shutdown Switch” has
not been programmed.
Expected Result:
The status screen indicates “ON” when the switch is

Illustration 147
g01152420 turned ON. The status screen indicates “OFF” when
Pin locations on ECM connector the switch is OFF.
(P1-3) Sensor common 2
(P1-7) PTO engine shutdown (switch can be connected to pin 7 or Results:
to pin 23
(P1-23) PTO engine shutdown (switch can be connected to pin • Yes – The switch is operating normally. Continue
7 or to pin 23 troubleshooting if the original condition is not
resolved. STOP.
connector J1/P1, the connectors, and the firewall • No – The ECM is not reading the change in the
bulkhead connectors. Refer to Troubleshooting, status of the switch. Proceed to Test Step 3.

with the suspect switch circuit.


for pinch points from the battery to the ECM. Then,

the ECM.
RENR1367-11 327
Test Step 3. Check the Switch Circuit for 1. Temporarily connect a test ECM.
the ECM.


replace the ECM.
STOP.
g01152428
Illustration 148 Test Step 4. Insert a Jumper Wire at the
Breakout T Switch.
(3) Sensor common 2
(7) PTO engine shutdown (switch can be connected to pin 7 or A. Turn the ignition key switch to the OFF/RESET
to pin 23 position.
(23) PTO engine shutdown (switch can be connected to pin 7 or
to pin 23
A. Turn the ignition key switch to the OFF/RESET J1/P1.
position.
C. Fabricate a jumper wire 100 mm (4 inch) long.
B. Install a breakout T to the ECM connector J1/P1. Install a Deutsch pin to both ends of the wire.
C. Fabricate a jumper wire 100 mm (4 inch) long. D. Insert the jumper wire between the two switch
Crimp a Deutsch pin to both ends of the wire. terminals.
D. Insert the jumper wire into terminal 7 or terminal E. Turn the ignition key switch to the ON position.
23 of the breakout T. Connect the other end of
the jumper wire to terminal 3 in the breakout T. F. Alternately remove the jumper wire and then insert
Terminal 3 is sensor common. the jumper wire at the switch terminals. At the
same time, watch the status screen on Cat ET.
E. Verify that Cat ET is connected to the data link
connector. Expected Result:
F. Turn the ignition key switch to the ON position. The status of the switch changes to “ON” with
the jumper wire in place. The status of the switch
G. Alternately remove the jumper wire and then insert changes to “OFF” when the jumper wire is removed.
the jumper wire from terminal 5. At the same time,
monitor the status screen on the electronic service Results:
tool.
• Yes – The status is correct.
Expected Result:
Repair: Replace the switch.
The status of the switch changes to “ON” with
the jumper wire in place. The status of the switch Verify that the repair eliminates the problem.
changes to “OFF” when the jumper wire is removed.
STOP.
Results:
• No – There is a problem in the wire harness
• Yes – The ECM is functioning properly at this time. between the switch and the ECM. Proceed to Test
Proceed to Test Step 4. Step 5.

328 RENR1367-11
Test Step 5. Insert a Jumper Wire at the PTO Shutdown Timer

Bulkhead Connector.
A programmable parameter for the PTO Shutdown
A. Turn the ignition key switch to the OFF/RESET Timer is provided. This timer will shut down the
position. engine when all of the following conditions are met:
B. Fabricate a jumper wire 100 mm (4 inch) long. • The PTO shutdown time that is programmed has
Crimp a Deutsch pin to both ends of the wire. expired.
C. Locate the suspect terminal on the engine side of • The ECM is programmed to use “Dedicated PTO”
the bulkhead connector. parameters.
D. Insert the wire jumper pin between the switch • The PTO on/off switch is ON and the ECM is in
socket and the sensor common connection. Install the dedicated PTO mode.
the jumper wire on the engine side of the bulkhead
connector. • The engine is not in the Cold Mode.
E. Turn the ignition key switch to the ON position. During the last 90 seconds of the PTO Shutdown
Timer, the check engine lamp will begin flashing. If
F. Alternately connect and then disconnect the the vehicle is equipped with a PTO switch on lamp,
jumper wire. At the same time, monitor the status the PTO switch on lamp will begin flashing during
screen on the electronic service tool. the last 90 seconds.
Expected Result: If the PTO shutdown timer is activated and the timer
stops the engine, the following event code will be
The status of the switch changes from “ON” with generated.
the jumper wire in place. The status of the switch
changes to “OFF” when the jumper wire is removed. • 71-14 PTO Shutdown (47)
Results: Note: Fuel rates are not monitored while the PTO
shutdown timer is active. Shutdown will occur
• Yes – The problem is in the vehicle wiring between regardless of load. Unlike the idle shutdown timer,
the bulkhead connector and the switch. Inspect the the PTO shutdown timer cannot be overridden by
vehicle wiring and then repair the vehicle wiring. using the clutch pedal or the brake pedal.
Otherwise, send the vehicle to the OEM dealer for
repair. Verify that the original condition is resolved. Test Step 1. Verify Activation of the PTO
STOP. Shutdown Timer
• No – The problem is in the vehicle wiring between A. Connect the electronic service tool to the data link
the bulkhead connector and the ECM. Inspect the connector.
vehicle wiring and then repair the vehicle wiring.
Otherwise, send the vehicle to the OEM dealer for B. Access the Customer Parameters on the
repair. Verify that the original condition is resolved. electronic service tool. Access the following
STOP. display screens in order:
i01903372
• “Service”
PTO Shutdown Timer - Test • “Configuration”
SMCS Code: 1901-038 a. Record the programmed PTO shutdown time.

The PTO shutdown Time must be between 3
System Operation Description: and 1440 minutes. If the PTO shutdown time is
programmed to 0, the timer is disabled.
C. Start the engine. Allow the engine to warm up until
Use this procedure to determine if the PTO Shutdown the coolant temperature is 38 °C (100 °F). Allow
is operating correctly. the engine to operate at the programmed low idle
and turn off any unnecessary accessory devices.
to this procedure: D. Ensure that all unnecessary loads are turned off.
RENR1367-11 329
E. Use the following procedure in order to check the • PTO switch on lamp
operation of the PTO shutdown:
During the 90 second period before the scheduled
a. Park the vehicle. shutdown, the status should change from
“COUNTING” to “DRIVER ALERT”. The check
b. Ensure that the PTO configuration is engine lamp and the PTO switch on lamp should
programmed to “Cab Switches”, “Remote flash rapidly.
Switches” or “Remote Throttle”.
Note: A PTO switch on lamp is an optional feature
c. Ensure that the status of the PTO on/off switch and the PTO switch on lamp may not be installed.
is on.
D. Reprogram the PTO shutdown timer to the value
d. Observe the status of the “PTO Shutdown”. that was recorded earlier for this test.
Result 1 The status of the parameter for “PTO Result 1 The driver alert function of the PTO
Shutdown” indicates “COUNTING”. shutdown operates in the manner that is described
above.
Result 2 The ECM is not reading the proper
conditions for activation of the timer. Result 2 The PTO switch on lamp did not flash.
Results: Result 3 The check engine lamp did not flash.
• Result 1 – The ECM is reading the proper Results:

conditions for the activation of the PTO shutdown
timer. Proceed to Test Step 2. • Result 1 – The PTO shutdown timer is operating
properly. Clear all diagnostic codes. STOP.
• Result 2 – The PTO switch on lamp did not flash
Test Step 2. Use the Electronic Service during the driver alert.
Tool to Verify the Driver Alert Function of
the PTO Shutdown Repair: Perform the following diagnostic
procedure: Troubleshooting, “PTO Switch ON
A. Connect the electronic service tool to the data link Lamp Circuit - Test”
connector.
STOP.
B. Use the following procedure in order to activate
the PTO shutdown timer: • Result 3 – The check engine lamp did not flash
during the driver alert.
a. Access the “Customer Parameters” on the
electronic service tool. Access the following Repair: Perform the following diagnostic
display screens in order: procedure:
• “Service” Troubleshooting, “Check Engine Lamp Circuit -

Test”
STOP.
b. Record the programmed PTO shutdown time.
The PTO shutdown time must be between 3 Test Step 3. Check the State of the
and 1440 minutes. If the PTO shutdown time is Related Conditions when the Vehicle is
programmed to 0, the timer is disabled. Parked
c. Reprogram the PTO shutdown time to 3 A. Check the state of the following related conditions
minutes for this test. when the vehicle is parked:
C. Observe the following items during the 90 second a. Ensure that the vehicle speed is 0 km/h
period before the programmed shutdown time: (0 mph) on the electronic service tool or the
dash display.
• Check engine lamp
b. Ensure that the engine is not in cold mode.
• Status of the PTO shutdown timer
330 RENR1367-11
Note: The electronic service tool status screen will P1-56 Input 1 is used for the circuit for the PTO on/off
indicate if the cold mode is active. switch when the PTO configuration is programmed to
“Cab Switches”, to “Remote Switches”, or to “Remote
c. Ensure that the PTO on/off switch is on. Throttle”.
Expected Result: When the PTO on/off switch is on, the ECM will be
in dedicated PTO mode.
Result 1 Vehicle speed is not indicated as 0 km/h
(0 mph). When the ECM is in the dedicated PTO mode the
PTO Top Engine Limit (TEL) is activated. The engine
Result 2 The electronic service tool status screen may proceed directly to the PTO engine rpm set
indicates that the engine is in the cold mode. speed if the parameter is programmed. If a PTO
switch on lamp is connected to the P1-30 output 1,
Result 3 The PTO on/off switch is not on. the PTO switch on lamp will turn on whenever the
PTO on/off circuit is on.
Results:
If the problem is with undetermined PTO kickouts,
• Result 1 – Continue by testing the vehicle speed use the following procedure:
circuit.
Operate the vehicle in PTO mode.
procedure: Troubleshooting, “Vehicle Speed Circuit After the kickout, review the status parameter on
- Test” Caterpillar Electronic Technician (ET). The status
parameter indicates the cause of the kickout. This
STOP. must be performed before the ignition key switch
is turned off. It is important to remember that the
• Result 2 – The engine must not be in cold mode parameter will only indicate the last kickout since the
operation while this test procedure is being ECM has been powered by the ignition key switch.
performed. Allow the engine to run until the coolant
temperature exceeds 38 °C (100 °F). Troubleshoot This parameter is blank when the ECM is first
and repair any related conditions. STOP. powered up. If this parameter is blank “Not Kicked
Out” is indicated. This parameter remains blank until
• Result 3 – Continue by testing the circuit for the the ECM detects the use of the PTO mode. Also, this
PTO on/off switch. parameter remains blank until the ECM detects the
disengagement of PTO mode. Refer to Table 187 in
Repair: Perform the following diagnostic order to interpret the status parameter.
procedure: Troubleshooting, “PTO Switch Circuit -
Test” PTO interlocks may also be connected in series with
the PTO on/off switch. The interlocks are intended to
STOP. prevent the PTO on/off circuit from activating unless
certain conditions are met.
i02375749
INPUT 2
PTO Switch Circuit - Test P1-58 input 2 is used for the PTO set switch when
SMCS Code: 7332-038 the “PTO Configuration” is programmed to “Remote
Switches” or to “Remote Throttle”. The PTO set
System Operation Description: switch can also be used to increase engine rpm.
Use this procedure under the following situation: INPUT 3
Use this procedure to determine that the vehicle P1-60 input 3 is used for the PTO resume switch
wiring and the Engine Control Module (ECM) are when the “PTO Configuration” is programmed to
functioning properly for the features of dedicated “Remote Switches” or to “Remote Throttle”. The PTO
PTO. resume switch can also be used to decrease engine
rpm.
to this procedure: The PTO Configuration Is Set To Cab Switches.
INPUT 1
RENR1367-11 331
When the “PTO Configuration” is programmed to • P1-5 (AP sensor/switch sensor common)
“Cab Switches” and the PTO on/off switch is on, the
following circuits can be used to interrupt a set rpm:
• Cruise control set/resume switch

• Service brake pedal position switch 1
• Clutch pedal position switch
• Neutral switch
• Cruise control pause switch
When the “PTO Configuration” is programmed to
“Cab Switches” and the PTO on/off switch is on, the
accelerator pedal position sensor that is located in the
cab can be limited to one of the following settings by
using the “PTO Cab Throttle RPM Limit” parameter:
• Low idle
• PTO top engine limit
• Top engine limit
The “PTO Configuration” Is Programmed To
“Remote Switches” or “Remote Throttle”.

“Remote Switches” or to “Remote Throttle” and the
PTO on/off switch is on, the following circuits are
ignored:

• Clutch pedal position switch
• Neutral switch
• Accelerator pedal position sensor
• Cruise control set/resume switch that is located
in the cab
A remote accelerator pedal position sensor is

connected to P1-68 input 8 when the “PTO
Configuration” is programmed to “Remote Throttle”.
Note: The wiring for your particular application

may be slightly different. The circuits for the sensor
common are used interchangeably by the OEM of
the vehicle. The following circuits are common within
the ECM:
• P1-18 (sensor common 1)

• P1-3 (sensor common 2)
332 RENR1367-11
Table 187
Table For The PTO Kickout Status Screen On Cat ET
Cat ET Meaning or Possible Cause Troubleshooting
The PTO on/off switch is turned off or the Proceed with this test procedure.
Switch”
The service brake pedal is depressed or the Refer to Troubleshooting, “Service Brake
“Brake Pedal Depressed” circuit for the service brake switch has an Pedal Position Switch 1 Circuit - Test”.
The clutch pedal is depressed or the circuit Refer to Troubleshooting, “Clutch Pedal
for the clutch pedal position switch has an Position Switch Circuit - Test”.
open circuit condition. Also, the switch could
be incorrectly adjusted.
The vehicle speed has exceeded the speed Refer to Troubleshooting, “Vehicle Speed
that is programmed into the “PTO vehicle and Speedometer Circuit - Test” if a problem
“Vehicle Speed ≥ Limit”
speed limit” parameter or the vehicle speed with the signal exists.
signal is erratic or intermittent.
The PTO has not been enabled since the Operate the vehicle in the PTO mode in
ECM has been powered up. order to create the problem again.
g00644420
Illustration 149
Typical circuit schematic for “Cab Switches” configuration
RENR1367-11 333
g00644427
Illustration 150
Typical circuit schematic for “Remote Switches” configuration
g00644448
Illustration 151
Typical circuit schematic for “Remote Throttle” configuration
Test Step 1. Use Cat ET to Check Expected Result:

the Programming of the Parameter
“Dedicated PTO Parameters” The “PTO Configuration” is programmed to “Cab
Switches”, to “Remote Switches”, or to “Remote
A. Connect Cat ET to the data link connector. Throttle”.
B. Turn the ignition key switch to the ON position. Results:
C. Access the “Dedicated PTO Parameters” on Cat • OK – The “PTO Configuration” is programmed.
ET. Note the programming of the parameter “PTO Proceed to Test Step 2.
Configuration”.
334 RENR1367-11
• Not OK – The Dedicated PTO features are not Test Step 3. Inspect the Electrical
programmed for this engine. If PTO operation Connectors and the Wiring
is desired, the “PTO Configuration” must be
programmed to “Cab Switches”, to “Remote
Switches”, or to “Remote Throttle”. STOP.
Test Step 2. Determine the Configuration

of the PTO Electrical System
A. From the programming of the parameter for the
“PTO Configuration”, review the configuration of
the PTO electrical system in order to determine
the method of installation of the wiring. Talk to the
driver about the operation of the PTO.
B. Check the cab glove box for any information

regarding the installation of the PTO. It is important
to understand the location and the function of the
interlock switches for the PTO.
C. Contact the installer of the components that are

used for the PTO, if necessary.
D. Determine the schematic that most closely

matches the installation. Review the schematics
in this procedure for each of the options for the
specific “PTO Configuration” of the truck.
E. Record the “PTO Configuration”.
Expected Result:
The requirements for the installation and the

g01152436
application have been reviewed. Illustration 152
P1 ECM connector
Results: (P1-3) Input sensor common number 2
(P1-5) AP sensor/switch sensor common
• OK – The requirements for the installation and the (P1-22) Clutch pedal position switch
(P1-30) Output number 1
application have been reviewed. Proceed to Test
(P1-35) Set
Step 3. (P1-44) Resume
(P1-45) Service brake pedal position switch
(P1-56) Input number 1
(P1-58) Input number 2 (remote PTO set)
(P1-60) Input number 3 (remote PTO resume)
(P1-68) Input number 8
B. Thoroughly inspect the J1/P1 ECM connector, the

firewall bulkhead connectors, and any connectors
that are used by the PTO.


with the connections for the PTO.

RENR1367-11 335
D. Check the allen head screw on each of the Result 2 The status of the PTO on/off switch on
ECM connectors for the proper torque. Refer to Cat ET changes from “OFF” to “ON” when the PTO
Troubleshooting, “Electrical Connectors - Inspect” on/off switch is turned to the OFF position and the
for details. ON position. However, the remote accelerator is not
operating correctly.
E. Check the harness and wiring for abrasion and for
pinch points from the switch to the ECM. Result 3 The status of the PTO on/off switch on Cat
ET does not change from “OFF” to “ON” when the
Expected Result: PTO on/off switch is turned to the OFF position and
to the ON position.
coupled and/or inserted and the harness and wiring Results:
• Result 1 – The status of the PTO on/off switch
Results: correctly changes but the set/resume switch is not
operating correctly. Proceed to Test Step 5.
• OK – The harness and connectors appear to be
OK. Proceed to Test Step 4. • Result 2 – The status of the PTO on/off switch
correctly changes but the remote accelerator is not
• Not OK – There is a problem with the connectors operating correctly.
and/or wiring.
Repair: Repair the connectors or wiring and/or procedure: Troubleshooting, “Remote PTO
replace the connectors or wiring. Ensure that all of Accelerator Position Sensor Circuit - Test”
connectors are completely coupled. STOP.
Verify that the repair eliminates the problem. • Result 3 – The status of the PTO on/off switch
does not change. Proceed to Test Step 6.
STOP.
Test Step 5. Use Cat ET to Check the
Test Step 4. Use Cat ET to Check the Status of the Set/Resume Input
Circuit for the PTO On/Off Switch
Note: The set/resume input increases the engine rpm
A. Turn the ignition key switch to the ON position. and the set/resume input decreases the engine rpm.
B. For the input 1 (PTO on/off switch), access the A. Find the PTO set switch. If the “PTO Configuration”
Cat ET status screens that display the following is programmed to “Cab Switches”, the cruise
status parameters: control set/resume switch will be used. If the
“PTO Configuration” is programmed to “Remote
• “PTO Config” Switches” or to “Remote Throttle”, a dedicated
PTO set switch will be used.
• “PTO On/Off Switch”
The “PTO Configuration” is programmed to
C. Verify that each of the interlocks for the PTO are “Cab Switches”.
set. Then, while the Cat ET status screen is being
monitored move the PTO on/off switch to the ON Look at the status for the “Cruise Control
position and move the PTO on/off switch to the Set/Resume Switch” parameter on Cat ET. The
OFF position. parameter is located on the same status screen
as the idle switch.
An example of an interlock for the PTO would be
a parking brake that is intended to allow the PTO B. Monitor the status screen of Cat ET. Perform the
to control the engine under specific conditions. following procedure in order:
Expected Result: • Put the cruise control set/resume switch in the

Set position.
Result 1 The status of the PTO on/off switch on Cat
ET changes from “OFF” to “ON” when the PTO on/off • Release the cruise control set/resume switch
switch is turned to the OFF position and the ON from the Set position.
position, but the set/resume switch is not operating
correctly. • Put the cruise control set/resume switch in the
Resume position.
336 RENR1367-11
• Release the cruise control set/resume switch • The status of the remote PTO resume switch
from the Resume position. changes from “OFF” to resume switch “ON” when
the remote PTO resume switch is moved to the
The “PTO Configuration” is programmed to RESUME position.
“Remote Switches” or to “Remote Throttle”.
Results:
View the status parameter on Cat ET for the
“Remote PTO Set Switch” and for the “Remote • Yes – The set circuit and the resume circuit are
PTO Resume Switch”. functioning correctly. The inputs for the PTO are
functioning properly. Continue troubleshooting if
C. While the status screen of Cat ET for the switch is the original condition is not resolved. STOP.
being monitored, perform the following procedure
in order: • No – The “PTO Configuration” is programmed to
“Cab Switches”. Proceed to Test Step 7.
• Put the remote PTO set/resume switch in the
Set position. • No – The “PTO Configuration” is programmed to
“Remote Switches” or “Remote Throttle”. Proceed
• Release the remote PTO set/resume switch to Test Step 8.
from the Set position.
Test Step 6. Use Cat ET to Check the
• Put the remote PTO set/resume switch in the Status of the PTO On/Off Switch
Resume position.
• Release the remote PTO set/resume switch

from the Resume position.
Expected Result:

“Cab Switches”, the status parameter for the cruise
control set/resume switch on Cat ET behaves in the
following manner:
• The status of the cruise control set/resume switch

will display “OFF” when the set switch is released.
g01105784
• The status of the cruise control set/resume switch Illustration 153
changes from “OFF” to “ON” when the switch is Schematic of connector for breakout T
moved to the SET position. (Terminal 3) Input sensor common number 2
(Terminal 56) Input number 1 (PTO on/off switch)
• The status of the cruise control set/resume switch
changes from “OFF” to resume switch “ON” when A. Turn the ignition key switch to the OFF position.
the resume switch is moved to the RESUME
position. B. Fabricate a jumper wire 100 mm (4 inch) long.
“Remote Switches” or to “Remote Throttle”, the status C. Disconnect vehicle harness connector P1 from
parameter for the remote PTO set switch behaves the ECM.
in the following manner:
D. Remove the wire P1-56 (input 1) from ECM
• The status screen for the remote PTO set switch connector P1.
displays “OFF” when the remote PTO set switch
is released. E. Install a 140-2266 Cable As (70-PIN
BREAKOUT) to the ECM vehicle harness
• The status of the remote PTO resume switch connector J1/P1.
displays “OFF” when the remote PTO resume
switch is released. F. Verify that Cat ET is connected to the data link
connector.
• The status of the remote PTO set switch changes
from “OFF” to set switch “ON” when the remote G. Turn the ignition key switch to the ON position.
PTO set switch is moved to the SET position.
RENR1367-11 337
H. Access the “PTO On/Off Switch” status on Cat ET. 6. If the problem returns with the suspect ECM,
replace the ECM.
I. While the switch status is being observed on Cat
ET, install the jumper into the breakout T between 7. Verify that the repair eliminates the problem.
P1-56 (input 1) and P1-3 (input sensor common
2). STOP.
The input 1 is the PTO on/off switch. Test Step 7. Use Cat ET to Check the
Status of the Cruise Control Set/Resume
Refer to Illustration 153. Switch
J. Turn the key switch to the OFF position.
K. Reconnect all wires to the original configuration.
Expected Result:
The switch status of the “PTO On/Off Switch” on Cat

ET behaves in the following manner:
• The switch status changes from “OFF” to “ON”

when the jumper is in place.
• The switch status is “OFF” when the jumper is

removed. g01105792
Illustration 154
Results: Schematic of connector for breakout T
(Terminal 5) AP sensor/switch sensor common
• OK – The input 1 (PTO on/off switch) of the ECM (Terminal 35) Cruise control set
is functioning correctly. The problem is in the (Terminal 44) Cruise control resume
switches of the vehicle or the problem is in the
wiring of the vehicle. A. Turn the ignition key switch to the OFF position.
Repair: Inspect the wiring. Select one of the B. Fabricate a jumper wire 100 mm (4 inch) long.
following options: Crimp a Deutsch pin to both ends of the wire.
• Repair the wiring or replace the wiring. C. Disconnect vehicle harness connector P1 from
the ECM.
• Send the vehicle to the OEM dealer for repair.
D. Remove the wire P1-35 (cruise control set) from
Verify that the repair eliminates the problem. the P1 ECM connector.
STOP. E. Remove the wire P1-44 (cruise control resume)

from the P1 ECM connector.
• Not OK – The ECM is not reading the switch
status change. F. Install a 140-2266 Cable As (70-PIN
BREAKOUT) to the ECM vehicle harness
Repair: Perform the following diagnostic connector J1/P1.
procedure:
G. Verify that Cat ET is connected to the data link
1. Temporarily connect a test ECM. connector.
2. Ensure that the “PTO Configuration” of the test H. Turn the ignition key switch to the ON position,
ECM matches the “PTO Configuration” of the while the engine is off.
suspect ECM.
I. Access the status of the cruise control set/resume
3. Recheck the system for active diagnostic codes. switch on Cat ET.

338 RENR1367-11
J. While the switch status is being observed on Cat • Not OK – The ECM is not reading the switch
ET, install the jumper into the breakout T in order status change.
to connect P1-35 (cruise control set) to P1-5
(AP sensor/switch sensor common). Also, while Repair: Perform the following diagnostic
the switch status is being observed on Cat ET procedure:
remove the jumper from the breakout T in order
to disconnect P1-35 (cruise control set) from P1-5 1. Temporarily connect a test ECM.
(AP sensor/switch sensor common).
2. Ensure that the “PTO Configuration” of the test
K. While the switch status is being observed on Cat ECM matches the “PTO Configuration” of the
ET, install the jumper into the breakout T. This suspect ECM.
connects P1-44 (cruise control resume) to P1-5
(AP sensor/switch sensor common). Also, while 3. Recheck the system for active diagnostic codes.
the switch status is being observed on Cat ET,
remove the jumper from the breakout T. This will 4. Repeat the test step.
disconnect P1-44 (cruise control resume) from
P1-5 (AP sensor/switch sensor common). 5. If the problem is resolved with the test ECM,
L. Turn the key switch to the OFF position. replace the ECM.
M. Reconnect all wires to the original configuration. 7. Verify that the repair eliminates the problem.
The switch status of the cruise control set/resume Test Step 8. Use Cat ET to Check the
switch on Cat ET behaves in the following manner: Status of the Remote PTO Set Switch and
the Remote PTO Resume Switch
• The switch status of the cruise control set/resume
switch changes from “OFF” to set switch “ON”
when the jumper is connected from P1-35 (cruise
control set) to P1-5 (AP sensor/switch sensor
common).

switch is “OFF” when the jumper is removed.

switch changes from “OFF” to resume switch “ON”
when the jumper is connected from P1-44 (Cruise
control resume) to P1-5 (AP sensor/switch sensor
common).
g01105788
Results: Illustration 155
Schematic of connector for breakout T
• OK – The input for the set switch and the input (Terminal 3) Input sensor common number 2
for the resume switch of the ECM are functioning (Terminal 58) Input number 2 (remote PTO set)
correctly. The problem is in the switches of the (Terminal 60) Input number 3 (remote PTO resume)
vehicle or the problem is in the wiring of the vehicle.
Repair: Inspect the wiring. Select one of the
following options: B. Fabricate a jumper wire 100 mm (4 inch) long.
• Repair the wiring or replace the wiring.
• Send the vehicle to the OEM dealer for repair. the ECM.
Verify that the repair eliminates the problem. D. Remove the wire P1-58 (input number 2 (remote
PTO set)) from ECM connector P1.
STOP.
RENR1367-11 339
E. Remove the wire P1-60 (input number 3 (remote • The switch status of the “Remote PTO Resume
PTO resume)) from ECM connector P1. Switch” changes from “OFF” to resume switch
“ON” when the jumper is connected from P1-60
F. Install a 140-2266 Cable As (70-PIN (input number 3 (remote PTO resume)) to P1-3
BREAKOUT) to the ECM vehicle harness (input sensor common 2).
connector J1/P1.
Results:
G. Verify that CatET is connected to the data link
connector. • OK – Input 2 (“remote PTO set switch”) and input
3 (“remote PTO resume switch”) of the ECM
H. Turn the ignition key switch to the ON position. are functioning correctly. The problem is in the
switches of the vehicle or the problem is in the
I. Access the “Remote PTO Set Switch” and wiring of the vehicle.
“Remote PTO Resume Switch” status on Cat ET.
Repair: Inspect the wiring. Select one of the
J. While the status of the “Remote PTO Set Switch” following options:
is being observed on Cat ET, install the jumper
into the breakout T in order to connect P1-58 • Repair the wiring or replace the wiring.
(input number 2 (remote PTO set)) to P1-3 (iInput
sensor common 2). Also, while the switch status • Send the vehicle to the OEM dealer for repair.
is being observed on Cat ET remove the jumper
from the breakout T in order to disconnect P1-58 Verify that the repair eliminates the problem.
(input number 2 (remote PTO set)) from P1-3
(input sensor common 2). STOP.
K. While the status of the “Remote PTO Resume • No – The ECM is not reading the switch status
Switch” is being observed on Cat ET, install the change.
jumper into the breakout T in order to connect
P1-60 (Input number 3 (remote PTO resume)) Repair: Perform the following diagnostic
to P1-3 (input sensor common 2). Also, while procedure:
the switch status is being observed on Cat ET
remove the jumper from the breakout T in order to 1. Temporarily connect a test ECM.
disconnect P1-60 (input number 3 (remote PTO
resume)) from P1-3 (input sensor common 2). 2. Ensure that the “PTO Configuration” of the test
ECM matches the “PTO Configuration” of the
Refer to Illustration 155. suspect ECM.
L. Turn the key switch to the OFF position. 3. Recheck the system for active diagnostic codes.
M. Reconnect all wires to the original configuration. 4. Repeat the test step.
Expected Result: 5. If the problem is resolved with the test ECM,

The switch status of the “Remote PTO Set Switch” on
Cat ET behaves in the following manner: 6. If the problem returns with the suspect ECM,
replace the ECM.
• The switch status of the “Remote PTO Set Switch”
is “OFF” when the jumper is removed. 7. Verify that the repair eliminates the problem.
• The switch status of the “Remote PTO Set Switch” STOP.

changes from “OFF” to set switch “ON” when the
jumper is connected from P1-58 (input number 2
i02336554
(remote PTO set)) to P1-3 (input sensor common
2). PTO Switch ON Lamp Circuit
The switch status of the “Remote PTO Resume - Test
Switch” on Cat ET behaves in the following manner:
SMCS Code: 7431-038
• The switch status of the “Remote PTO Resume
Switch” is “OFF” when the jumper is removed. System Operation Description:

340 RENR1367-11
Use the following information in order to determine if

the PTO switch on lamp is operating incorrectly.
Terminal 30 (Output 1)
With software that is older than OCT99, J1-30

(output 1) is dedicated for use as an output for the
PTO switch on lamp. If the “PTO Configuration” is
programmed to “Cab Switches”, “Remote Switches”,
or “Remote Throttle”, the output will turn the lamp ON
whenever the PTO switch is turned ON.
With OCT99 and newer software, J1-30 (output

1) can be used as an output for the PTO switch
on lamp or as an output for the engine coolant
level indicator lamp. The parameters should be
programmed to match the desired usage of the
terminal. If the “Engine Monitoring Lamps” parameter
is programmed to warning lamp, then output 1 is used
for the PTO switch on lamp. If the “Engine Monitoring
Lamps” parameter is programmed to Option 1and the
“Coolant Level Lamp” parameter is programmed to
“4-Pin” or “2 wire Float Sensor”, then output 1 is used
for the low coolant level warning.
Note: The “PTO Configuration” must be programmed

to “Cab Switches”, “Remote Switches”, or “Remote
Throttle” to utilize the PTO switch on lamp. Option 1
is not available for the GM truck manufacturer.
Electrical Connection of Lamps

terminal is connected to the Engine Control Module
(ECM) at terminal J1/P1-30.

on the lamp.
g00703413
Illustration 156
Typical circuit schematic for PTO switch on lamp
If terminal P1-30 is used for another function, a lamp

may be wired to a multiple pole PTO on/off switch.
RENR1367-11 341
g00834964
Illustration 157
Optional circuit for PTO switch on lamp

with the PTO switch on lamp.
C. Check the allen head screw on each ECM

connector for the proper torque. Refer to
for details.

pinch points from the battery to the ECM.
Expected Result:

Results:

• Not OK
STOP.
g01152445
Illustration 158
Terminal locations for ECM Test Step 2. Check for Normal Operation
(30) Output #1 (PTO switch ON lamp) of the PTO Switch On Lamp
Test Step 1. Inspect the Electrical A. Use the following procedure for the output 1 (PTO
Connectors and the Wiring switch on lamp).
A. Thoroughly inspect ECM connector J1/P1, the

firewall bulkhead connector, or the PTO switch
on lamp. Refer to Troubleshooting, “Electrical
342 RENR1367-11
Connect Caterpillar Electronic Technician (ET) to B. Fabricate a jumper wire 100 mm (4 inch) long.
the data link connector. Access the status screen Crimp a Deutsch pin to both ends of the wire.
that displays the “PTO Configuration” and the
PTO on/off switch. The “PTO Configuration” must C. Insert the jumper into P1-30 output 1.
indicate “Cab Switches”, “Remote Switches”, or
“Remote Throttle”. The “PTO Configuration” is D. Connect the other end of the jumper wire to one of
not programmed to turn on the PTO switch on the following terminal connections:.
lamp if the “PTO Configuration” parameter is
programmed to “OFF”. • P1-63 -Battery
While the PTO switch on lamp and the status • P1-65 -Battery
of PTO on/off switch is being monitored on the
electronic service tool, turn the PTO on/off switch • P1-67 -Battery
to the ON position and the OFF position. The PTO
switch on lamp should turn on when the PTO • P1-69 -Battery
on/off switch is in the ON position. Also, the PTO
switch on lamp should turn off when the PTO E. Turn the ignition key switch to the ON position.
on/off switch is in the OFF position.
F. While the lamp is being watched, insert the jumper
Expected Result: wire and remove the jumper wire.
The lamp turns on and the lamp turns off per the Refer to Illustration 159.
above description.
Expected Result:
Results:
Result 1 The PTO switch on lamp turns on while the
• Yes – The lamp appears to operating correctly at jumper is connected to both sockets. Also, the PTO
this time. STOP. switch on lamp turns off when the jumper is removed
from one of the sockets.
Result 2 The suspect lamp does not turn on while
Test Step 3. Test the Circuit for the PTO the jumper is connected to both sockets.
Switch On Lamp
Result 3 The lamp will stay on while the ECM
connector is disconnected.
Results:
• Result 1 – The circuit for the PTO switch on lamp

is functioning properly. Proceed to Test Step 4.
• Result 2 – The lamp did not turn on. The vehicle’s

lamp circuit is not functioning properly. The lamp
is probably burned out or there is a problem in
the wiring from the cab to either the ECM or the
+Battery connection. Repair the lamp circuit or
STOP.
g01152452
Illustration 159 • Result 3 – The lamp stayed on.
ECM connector P1
(30) Output #1 (PTO switch onlamp) Repair: Perform the following diagnostic
(48) Unswitched +Battery procedure:
(53) Unswitched +Battery The circuit between the ECM and the lamp is
(63) -Battery shorted to chassis ground. Repair the circuit or
(65) -Battery send the vehicle to the OEM dealer for repairs.
(67) -Battery
(69) -Battery STOP.
A. Disconnect the J1/P1 ECM connector .
RENR1367-11 343
Test Step 4. Use Cat ET to Check the • “Diagnostic Test”

Operation of the ECM
• “Special Test”
H. Activate the special test for the PTO switch on
lamp. Observe the voltage test lamp. The lamp
should turn on when the test is active. Also, the
lamp should turn off when the test is inactive.
Note: Perform the same test procedure with terminals

P1-52, P1-53, and P1-55 unswitched +Batt.
Expected Result:
g01152466
Illustration 160
Results:
ECM breakout T-connector
(30) Output #1 (PTO switch on lamp) • OK – The ECM is operating correctly. There is a
(48) Unswitched +Battery problem in the vehicle wiring or the lamp. STOP.
(55) Unswitched +Battery • Not OK – The test lamp does not turn on and the
(63) -Battery test lamp does not turn off.
(65) -Battery
(67) -Battery Repair: Temporarily connect a test ECM. Ensure
(69) -Battery
that the “PTO Configuration” of the test ECM
matches the “PTO Configuration” of the suspect
A. Disconnect ECM connector J1/P1.
ECM. Check the ECM output for the PTO Switch
On Lamp when the test ECM is installed. If the
B. Insert a breakout T at the J1/P1 ECM connector.
problem is resolved with the test ECM, reconnect
the suspect ECM. If the problem returns with
C. Connect one probe of the voltage test lamp to
the suspect ECM, replace the ECM. Refer to
terminal 63 (-Battery). Connect the other probe of
the voltage test lamp to terminal 48 (unswitched
+Battery) of the breakout T.
STOP.
D. The test lamp should turn on. If the test lamp does
not turn on, either the test lamp is faulty or the i02336556
wiring to the ECM is faulty. Continue with this step
if the lamp turns ON. Remote PTO Accelerator
Note: Use the same procedure to check the following:
Position Sensor Circuit - Test
SMCS Code: 1913-038
• P1-65 and P1-52
• P1-67 and P1-53
• P1-69 and P1-55
Use this procedure if any of the following diagnostic
E. Leave the probe of the test lamp connected to codes are indicated:
terminal 48 (unswitched +Battery).
F. Connect the other probe of the test lamp to

• 30-08 PTO Throttle signal invalid (29)
terminal 30 (output 1) of the breakout T.
• 30-13 PTO Throttle out of calibration (29)
Refer to Illustration 160. Also, use this procedure if the remote accelerator
position sensor is suspected of improper operation.
G. Verify that Cat ET is connected. Access the
following display screens in order: Remote Accelerator Position Sensor
344 RENR1367-11
A remote accelerator position sensor may be used This prevents the engine from experiencing
for PTO purposes. The remote accelerator position unexpected acceleration or sudden acceleration
sensor should be connected to terminal J1/P1-68 when the PTO on/off circuit is turned on. The remote
of the Engine Control Module (ECM). Before the accelerator position sensor must return to low idle
ECM will respond to the remote accelerator position before the ECM will respond. The ECM must also
sensor, the ECM “PTO Configuration” must be see a transition from the OFF position to the ON
programmed to “Remote Throttle”, and the “PTO position in the PTO on/off switch in order to allow the
On/Off Switch” must be in the ON position. other PTO speed control functions to operate. If the
engine is started with the PTO on/off switch in the ON
The remote accelerator position sensor must be position, the accelerator will respond. The response
powered from the vehicle battery (+12 V). A +12 V will occur only if the accelerator pedal is first returned
version of the accelerator position sensor must be to the low idle position. The other engine speed
used for the remote accelerator position sensor, and controls will not respond.
the +8 V version for the accelerator pedal position
sensor must be used in the cab.
The ECM will not respond to the remote accelerator

position sensor while 253-02 diagnostic code is
active. Refer to Troubleshooting, “ECM Memory -
Test” if 253-02 diagnostic code is active.
The remote accelerator position sensor provides a

throttle position signal to the ECM. The output of
the remote accelerator position sensor is a constant
frequency signal with a pulse width that varies with
the position of the sensor. This output signal is
referred to as either a duty cycle or a pulse width
modulated signal (PWM).
The output signal of the remote accelerator position

sensor is expressed as a percentage between 3
and 100 percent. The accelerator position sensor
will produce a duty cycle of 10 to 22 percent at low
idle and 75 to 90 percent when the sensor is fully
actuated. The percent of duty cycle is translated in
the ECM into a throttle position of 3 to 100 percent.
If the vehicle is using the ECM dedicated PTO

functions, the accelerator position sensor will be
ignored while the engine is in “PTO Mode” and the
“PTO Configuration” is programmed to the “Remote
Throttle” option.
The ECM is in “PTO Mode” while the PTO on/off

switch is on. This can be checked through the status
screen on Caterpillar Electronic Technician (ET).
The ECM will not respond to the remote accelerator

position sensor when both of the following conditions
are met:
• The PTO on/off circuit is switched from the OFF

position to the ON position.
• The ECM reads the remote accelerator position

sensor above low idle.
RENR1367-11 345
g01042360
Illustration 161
Typical schematic for remote accelerator pedal position sensor
346 RENR1367-11
E. Check the allen head screw on each ECM

connector for the proper torque. Refer to
for details.
F. Check the harness and wiring for abrasion and

pinch points from the remote accelerator position
sensor to the ECM.
Expected Result:

Results:

• Not OK
procedure:

STOP.
g01152475
Illustration 162
Pin locations on ECM connector Test Step 2. Check for Active Diagnostic
(P1-3) Input sensor common #2 Codes
(P1-5) AP sensor/switch sensor common
(P1-68) Input #8 (remote accelerator position sensor) A. Ensure that Cat ET is connected to the data link
connector.
Connectors and the Wiring B. Turn the ignition key switch to the ON position.
A. Connect Cat ET to the data link connector. Turn C. Monitor the active diagnostic code screen on Cat
the ignition key switch to the ON position. Verify ET. Check and record active diagnostic codes.
that the parameter for the PTO configuration is
programmed to the “Remote Throttle”.
B. Turn the ignition key switch to the OFF position.
C. Thoroughly inspect ECM vehicle harness

and the connector for the remote accelerator
position sensor. Refer to Troubleshooting,
D. Perform a 45 N (10 lb) pull test on each of the

with the remote accelerator position sensor.
RENR1367-11 347
Note: When the ECM automatically calibrates new Test Step 4. Check the Duty Cycle of
duty cycle values for the low idle throttle position the Remote Accelerator Pedal Position
and the high idle throttle position, the ECM assumes Sensor
22 percent duty cycle at low idle and 75 percent
duty cycle at high idle. As a result, you may notice A. Verify that the ignition key switch is in the ON
that the status of the throttle position reaches 100 position.
percent well before the remote accelerator position
sensor is fully actuated. This is normal. After cycling B. Monitor the duty cycle of the PTO throttle sensor
the accelerator pedal to the high idle position, the on Cat ET. Access the following display screen
ECM will adjust the calibration automatically. The in order:
ECM will adjust the calibration automatically provided
that the high idle stop position is within the 75 to 90 • “Service”
percent duty cycle range, and the low idle is in the
10 to 22 percent duty cycle range. During normal • “Calibrations”
operation, you may notice that more movement of
the remote accelerator position sensor is required for • “Monitor Throttle Position Sensor”
the status of the throttle position to increase above
three percent. You may also observe that the status Expected Result:
reaches the 100 percent value prior to the limit of the
high idle position. This is done in order to ensure that The duty cycle is between 10 and 22 percent with the
the accelerator reaches these two critical points for accelerator pedal assembly in the low idle position,
engine operation. and the duty cycle is between 75 and 90 percent
with the accelerator pedal assembly in the high idle
Expected Result: position.
Result 1 30-08 or 30-13 are active. Results:
Result 2 There are no active diagnostic codes that • OK – The remote accelerator position sensor is
are related to the remote accelerator position sensor operating correctly. Proceed to Test Step 5.
at this time, but a problem is suspected.
• Not OK – The remote accelerator position sensor
Results: is not operating correctly. Proceed to Test Step 6.
• Result 1 – 30-08 or 30-13 are active. Proceed to Test Step 5. Check the Status of the
Test Step 3. Power Train Data Link on Cat ET
• Result 2 – There are no active diagnostic codes at A. Start the engine. While the status of the “PTO
this time. Proceed to Test Step 3. Throttle Position” is being monitored on Cat ET,
actuate the remote throttle. The throttle position
Test Step 3. Check the Supply Voltage for status and the engine should respond to the
the Remote Accelerator Position Sensor change in the throttle position.
A. Verify that the ignition key switch is in the ON B. Go to the “System Troubleshooting Settings”
position. section of Cat ET and turn off the power train data
link.
B. Measure the voltage between terminal “A” (+12 V)
and terminal “B” (sensor common) at J406 remote C. While the status of the “PTO Throttle Position” is
accelerator position sensorconnector. being monitored on Cat ET, actuate the remote
throttle. Also, actuate the remote throttle while the
Expected Result: engine response is being monitored.
The measured voltage is between 11.0 VDC and Expected Result:

13.5 VDC.
The status of the “PTO Throttle Position” and the
Results: engine should respond to the change in the position
of the remote throttle position sensor.
• OK – The voltage is OK. Proceed to Test Step 4.
Result 1 The remote throttle position sensor is
• Not OK – The vehicle wiring or the battery is functioning properly.
causing the problem. Repair the wiring or the
battery. Replace the wiring or the battery. Perform Result 2 The throttle response is limited by a
the repair that is necessary. Verify that the repair message from the power train data link .
has fixed the problem. STOP.
348 RENR1367-11
Results: Test Step 7. Check the Duty Cycle of the

Remote Accelerator Position Sensor at
• Result 1 – The remote accelerator position sensor the ECM
is operating correctly. Continue troubleshooting
until the original condition is resolved. STOP. A. Turn the ignition key switch to the OFF position.
• Result 2 – If the engine responds with the power B. Remove terminal P1-68 (sensor signal) from the
train data link in the OFF position, but not with ECM connector.
the power train data link in the ON position,
a component of the power train data link is C. Connect the multimeter’s probes between the wire
causing the response problem of the remote for the remote accelerator position sensor and the
accelerator position sensor. Send the truck to the sensor common.
vehicle manufacturer in order to repair the faulty
component of the power train data link. STOP. D. Turn the ignition key switch to the ON position.
Test Step 6. Check the Duty Cycle of the E. Use the multimeter in order to display the duty
Remote Accelerator Position Sensor at cycle output of the remote accelerator position
the Sensor sensor. While the duty cycle output of the remote
accelerator position sensor is being monitored
A. Turn the ignition key switch to the OFF position. on the multimeter, actuate the remote throttle
from the low idle position to the high idle position.
B. Remove terminal J406-C (throttle position signal) Record the results.
from the connector for the remote accelerator
position sensor. This is the vehicle harness side F. Turn the ignition key switch to the OFF position.
of the connector.
Expected Result:
C. Install a breakout T at connector J406/P406.
D. Connect the multimeter probes to terminal “C” accelerator pedal assembly in the low idle position,
(throttle position signal) and terminal “B” (sensor and the duty cycle is between 75 and 90 percent
common) of the breakout T. with the accelerator pedal assembly in the high idle
position.
Results:
F. While the duty cycle is being monitored on
the multimeter, actuate the remote accelerator • OK – A good signal from the remote accelerator
position sensor. position sensor is reaching the ECM. Verify that
the ECM is receiving the proper battery voltage. If
Expected Result: the ECM is receiving the proper battery voltage,
temporarily connect a test ECM and verify that the
The duty cycle is between 10 and 22 percent with problem is resolved. If the problem disappears with
the remote accelerator position sensor in the low idle the test ECM, reconnect the suspect ECM. If the
position, and the duty cycle is between 75 and 90 problem returns with the suspect ECM, replace the
percent with the remote accelerator position sensor suspect ECM. STOP.
in the high idle position.
• Not OK – There is a problem with signal wire
Results: for the remote accelerator position sensor in the
vehicle wiring harness. Proceed to Test Step 9.
• OK – Return the J406/P406 to the original
configuration. The sensor is working correctly. Test Step 8. Remove the Remote
Proceed to Test Step 7. Accelerator Position Sensor from the
Throttle Assembly
• Not OK – Leave the PWM probe connected to the
breakout T. Insert wire C into the J406 connector. A. Turn the ignition key switch to the OFF position.
The sensor or the accelerator control is faulty.
Proceed to Test Step 8. B. Remove the remote accelerator position sensor
from the throttle assembly. Note the orientation
of the sensor in the accelerator pedal assembly,
and the sensor pigtail routing prior to sensor
removal. Thoroughly inspect the pigtail for signs
of abrasion.
RENR1367-11 349
C. Measure the PWM duty cycle to terminal “C” of

the breakout T.
E. Display the duty cycle output of the remote

accelerator position sensor while the sensor slot
is released. Use a screwdriver to advance the
sensor slot to the maximum position. Refer to
Illustration 163.
Note: When the sensor is removed from the

accelerator pedal assembly a 30-13diagnostic code
may be generated. The diagnostic code should
become inactive when the sensor is properly
assembled back into the accelerator pedal assembly.
g00642019
Illustration 163
(1) Mounting screw holes (3) Sensor housing (5) Accelerator pedal assembly
(2) Sensor slot (4) Mounting surface for sensor (6) Accelerator block assembly
350 RENR1367-11
Expected Result: • Not OK – Double check the wiring, the ECM

vehicle harness connector J1/P1 and the sensor
When the sensor is removed from the accelerator connector. If a problem still exists, restart the test
pedal assembly and the sensor slot is released, the procedure. STOP.
duty cycle is 10 percent or less. When the sensor slot
is moved to the maximum position, the duty cycle
i01858070
increases to 90 percent or more.
Results:
Service Brake Pedal Position
(Switch 1) Circuit - Test
• OK – The remote accelerator position sensor is
working correctly. Clear any diagnostic codes that SMCS Code: 1435-038-BRK
were caused by performing this test procedure.
Refer to the OEM dealer for correct replacement of System Operation Description:
the accelerator pedal assembly. STOP.
• Not OK – The remote accelerator position sensor
is faulty. Check the accelerator pedal assembly Use this procedure to determine if the Service Brake
in order to ensure that the accelerator pedal Pedal Position (Switch 1) is preventing normal
assembly is not causing damage to the sensor. If operation of cruise control, fast idle, idle set speed,
the accelerator pedal assembly is causing damage or PTO operation:
to the sensor, refer to the OEM dealer for correct
replacement of the accelerator pedal assembly. The following switch circuits can also prevent the
STOP. correct operation of the cruise control, fast idle, idle
set speed or PTO operation:
Test Step 9. Route the Supply Bypass
Wires to the Remote Accelerator Pedal • Service Brake Pedal Position (Switch 2)
Position Sensor
• Neutral switch
• Cruise Control Set/Resume Switch
B. Remove P1-66 (remote accelerator position
sensor) from the ECM connector. • Cruise Control On/Off Switch
C. Remove terminal “C” (sensor signal) from the • PTO On/Off Switch
connector for the remote accelerator position
sensor. • Cruise Control Pause Switch
D. Route new wiring from the ECM to the remote The switches are described in the respective circuit
accelerator position sensor. tests in Troubleshooting.
E. Turn the ignition key switch to the ON position. All of the following Customer Programmable
Parameters can affect cruise control, idle set speed,
F. Check the duty cycle of the remote accelerator fast idle, and PTO operation:
position sensor with Cat ET while the accelerator
pedal assembly is being moved over the full range. • “Low Cruise Control Speed Set Limit”
Expected Result: • “High Cruise Control Speed Set Limit”
The duty cycle is between 10 and 22 percent with the • “Idle Vehicle Speed Limit”
accelerator pedal assembly in the low idle position,
and the duty cycle is between 75 and 90 percent • “Fast Idle RPM #1”
with the accelerator pedal assembly in the high idle
position. • “Fast Idle RPM #2”
Results: • “Cruise/Idle/PTO Switch Configuration”
• OK – The wiring from the ECM to the accelerator • “Idle/PTO Bump rpm”
position sensor appears faulty. Permanently install
new wiring. Verify that the repair eliminates the • “Idle/PTO rpm Ramp Rate”
problem. STOP.
RENR1367-11 351
• “PTO Vehicle Speed Limit” • ECM Connector J1/P1 terminal 59 (cruise control
on/off switch)
• “Cruise Pause Switch”
• Terminal 5 (ap sensor/switch sensor common)
The vehicle speed calibration can also affect the
cruise control, fast idle, the idle set speed, and the Note: If the vehicle is programmed to use the
PTO if the vehicle speed calibration is incorrectly Dedicated PTO, the PTO On/Off switch overrides the
programmed. Refer to Troubleshooting, “Customer Cruise Control On/Off switch. The PTO On/Off switch
Specified Parameters”. overrides the Cruise Control On/Off switch when the
vehicle speed is within the range of the PTO Vehicle
Service Brake Pedal Position (Switch 1) Speed Limit that is programmed.
The switch for the Service Brake Pedal Position Set/Resume Switch
(Switch 1) is normally closed when the respective
pedal is released. Depressing the brake pedal should With the Cruise Control On/Off Switch in the ON
open the individual circuit. This switch is OEM position and the vehicle speed within the range of the
supplied. The Service Brake Pedal Position (Switch programmed Low Cruise Control Speed Set Limit and
1) is typically a pressure switch. the High Cruise Control Speed Set Limit, momentarily
pressing the Set Switch will activate cruise control
This switch may not be connected to an input on the and the ECM will maintain the current speed.
ECM. The parameter “Service Brake Pedal Position
Switch # 1” determines the input to the ECM. If the After a speed has been set and the speed is then
parameter is programmed to J1/P1:45 a switch must disengaged by using the brake, the clutch, the cruise
be connected to terminal 45. If the parameter is pause switch, or the on/off switch, the ECM will seek
programmed to one of the J1939 options, the switch the previous set speed when the resume switch
position will be transmitted to the ECM over the is toggled. This assumes that the vehicle speed is
J1939 data link. If a problem is suspected with the above the “Low Cruise Control Set Speed Limit”
J1939 data link, refer to Troubleshooting, “Powertrain for cruise control or the vehicle speed is below the
Data Link Circuit - Test”. Idle/PTO Vehicle Speed Limit for the Idle and the
PTO.
to this procedure: After a speed has been set, pressing and holding the
Set/Resume switch in position will cause the engine
The kickout switch refers to the switch that is used to establish a new set speed. The system’s reaction
to exit the Cruise Control, the PTO, fast idle, or the depends on the programming of the “Cruise/Idle/PTO
Idle Set Speed. Switch Configuration”.
The operation of the Caterpillar Electronic Engine When the Set/Resume switch is momentarily
cruise control is similar to the operation of the pressed, the cruise set point will change one mph.
cruise controls that are installed in automobiles. The The rate of change is dependent on the programmed
operation of fast idle, idle, and PTO are similar to the “Idle/PTO Bump rpm” when an idle speed is set.
operation of cruise except that the Idle and the PTO
govern engine rpm instead of vehicle speed. Cruise Pause Switch
Note: Idle in this procedure is an engine idle rpm The cruise pause switch is not a switch that is wired
above the programmed low idle rpm. Idle is set to an input. The switch position is broadcast over
by using the Cruise Control On/Off switch and the a J1939 data link. The parameter “Cruise Pause
Set/Resume switch. Refer to Troubleshooting, “PTO Switch” must be programmed to use a cruise pause
Switch Circuit - Test” for additional information switch. After a speed has been set and the speed is
regarding the programmable options for the then disengaged by using the cruise pause switch,
Dedicated PTO. the ECM will seek the previous set speed when the
resume switch is toggled. This assumes that the
Note: Fast idle in this procedure is an engine idle vehicle speed is above the “Low Cruise Control
rpm above the programmed low idle rpm. Fast idle is Speed Set Limit” for cruise control or the vehicle
set by using a dedicated fast idle switch. speed is below the “Idle/PTO Vehicle Speed Limit”
for the idle and the PTO.
Kickout Switches
This switch must be ON before cruise control or
controlled idle can be activated. This switch is ON
when the switch is closed. When the switch is closed
352 RENR1367-11
The service brake pedal position switches, the neutral If the “Transmission Style” parameter is programmed
switch and the clutch switch are used in the Cruise to one of the following options, the input for the Clutch
Control mode, the PTO mode, the Fast Idle mode, Pedal Position Switch is not used.
and the Idle mode in order to discontinue the Cruise
operation, the PTO operation, the Fast Idle mode, • “Automatic Options 1”
or the Idle operation. The capability to override the
Idle Shutdown Timer is determined by the “Allow Idle • “Automatic Option 2”
Shutdown Override” parameter setting. The “Allow
Idle Shutdown Override” is a Customer Parameter. • “Automatic Option 3”
Usage of Transmission Style Switches • “Automatic Option 4”
The “Transmission Style” parameter determines the • “AT/MT/HT Option 1”
can be used with being dependent on the parameter • “AT/MT/HT Option 2”
setting:
• Clutch Pedal Position
• Neutral
A Service Brake Pedal Position (Switch 1) is required
• Service Brake Pedal Position (Switch 1) for all configurations. The Service Brake Pedal
Position (Switch 1) connects to the ECM through
• Service Brake Pedal Position (Switch 2) connector P1 terminal 45. The Service Brake Pedal
Position (Switch 2) connects to the ECM through
Refer to Table 188 for additional information. Connector P1 terminal 64. The clutch pedal position
Table 188 terminal 22. The neutral switch connects to the ECM
Switch Usage. through connector P1 terminal 62.
Setting For
Transmission Service Service
Style Brake Brake
Clutch Neutral
1 2
“Manual
X X
Option 1”
“Manual
X X X
Option 2”
“Automatic
X
Option 1”
“Automatic
X X
Option 2”
“Automatic
X X X
Option 3”
“Automatic
X X
Option 4”
“AT/MT/HT
X
Option 1”
“AT/MT/HT
X X
Option 2”
“AT/MT/HT
X X X
Option 3”
“AT/MT/HT
X X
Option 4”
“Universal
X X X
Option”
RENR1367-11 353
Some engines that were built before JULY 1999 • “Idle Kickout”
may have a Basic ECM. The Basic ECM was used
only on General Motors chassis. Other chassis used • “PTO Kickout”
Basic ECM software does not have the parameter • “Fast Idle Kickout”
of the vehicle.

procedure:
After the kickout, review the status parameter on ET.

The status parameter for the kickout indicates the
cause. This must be performed before the ignition
key switch is turned OFF. It is important to remember
that the parameter will only indicate the last kickout
since the ECM has been powered by the input of the
ignition key switch.

powered up. If this parameter is blank, No Occurrence
is indicated. This parameter remains blank until the
ECM detects the use of the Cruise/Idle/PTO Mode.
Also, this parameter remains blank until the ECM
detects the disengagement of the Cruise/Idle/PTO
Mode. Refer to Tables 189, 190, and 191 in order to
interpret the status screen kickout status parameter.

available:
354 RENR1367-11
Table 189
condition.
The cruise pause switch is depressed or Refer to Troubleshooting, “Powertrain Data
there is an illegal message on the J1939 Link Circuit - Test”.
Switch”
data link.
The service brake pedal is depressed or Proceed with the test procedure.
“Brake Pedal Depressed” the service brake switch circuit has an open
circuit condition.
circuit condition.
exists.
circuit condition.
RENR1367-11 355
Table 190
condition.
circuit condition.
circuit condition.
Table 191

The fast idle on/off switch is turned off or the Refer to Troubleshooting, “Cruise Control
circuit condition.
356 RENR1367-11
Table 192
No Engine Speed
The PTO On/Off switch is turned OFF or the Refer to Troubleshooting, “Clutch Pedal
Switch Turned Off
switch circuit has an open circuit condition. Position Switch Circuit - Test”.
circuit condition.
g00643881
Illustration 164
Schematic for cruise control switch, service brake pedal position (switch 1) and clutch pedal position switch
Test Step 1. Determine the Type of Cruise Control Parameters

Problem.
Idle Parameters
C. If the vehicle will not allow setting a cruise speed,
an idle speed or a PTO speed, check the following • “Fast Idle RPM #1”
RENR1367-11 357

PTO Parameters
necessary.
E. Check the ET status screen that indicates the last

cause of a kickout for one of the following items:
• Cruise Control Kickout

• Idle Kickout
• PTO Kickout
meaning of the ET status parameter.
Expected Result:

Results:

the driver. STOP.
• No
Repair: Refer to tables 189, 190, 191, and 192 for
If a problem is still suspected with the circuit for the

Service Brake Pedal Position (Switch 1), perform
the following procedure:

358 RENR1367-11

and Wiring.
g00702676
Illustration 165
A. Thoroughly inspect ECM vehicle harness Expected Result:

and the terminals for the following switches in the All connectors, pins and sockets should be completely
connectors: coupled and/or inserted and the harness and wiring
• AP Sensor/Switch Sensor Common (terminal 5)
Results:
• Service Brake Pedal Position (Switch 1)
(terminal 45) • OK – Proceed to Test Step 3.
Refer to Troubleshooting, “Electrical Connectors - • Not OK
wires in the ECM connector that are associated Repair the connectors or wiring and/or replace
with the switches. the connectors or wiring. Ensure that all of the
Refer to Illustration 165. connectors are completely coupled.
C. Check the ECM connector (allen head screw) for Verify that the repair eliminates the problem.
STOP.
RENR1367-11 359
Test Step 3. Check the Service Brake B. For an intermittent Idle Kickout, talk to the driver
Switch Status on ET. in order to determine the conditions when the
kickout occurs. A topic of examination could be
Table 193 the following example:
Table for Status of the Service Brake Pedal Position
• Specific engine rpm
Switch Position or
Status Circuit
Pedal Position Start the engine. Duplicate these conditions and
The Service Brake Pedal set the idle rpm. Operate the vehicle in idle until
ON Open the problem reoccurs.
is DEPRESSED.
The Service Brake Pedal Note: The ET status screen will only indicate the
OFF Closed
is RELEASED.
last kickout. The ET status screen will lose this
information if the ignition key switch is turned OFF.
A. Access the ET status screen.
C. Connect ET and check the status screen for the
B. Turn the ignition key switch to the ON position. last cause of the kickout. Refer to Tables 189,
190, 191, and 192 for an explanation of the status
C. Depress the service brake while the status of the parameter.
service brake pedal position (switch 1) is being
observed. Also, release the service brake while D. If the ET status screen is blank, then either there
the status of the service brake pedal position was no kickout of the cruise control, or the power
(switch 1) is being observed. to the ECM was turned off before the information
Refer to Table 193 for the status of the switch or
for the status of the pedal position. Note: An ET status screen that is blank indicates No
Occurrence.
Expected Result:
Expected Result:
Table 193. RESULT 1 The ET Kickout Status displays the
following result:
Results:
• “Brake”
• Yes – The switch is operating normally. STOP.
• Intermittent Problem Suspected – Proceed to Test following result:
Step 4.
• “Switch Turned Off”
change. Proceed to Test Step 5. RESULT 3 The ET Kickout Status displays the
following result:
Test Step 4. Operate the Vehicle and
Check the Kickout Status Parameter. • “Cruise Control PAUSE Switch”
A. For an intermittent Cruise Control Kickout, talk RESULT 4 The ET Kickout Status displays the
to the driver in order to determine the conditions following result:
could be the following examples: • “Clutch”
• specific speed RESULT 5 The ET Kickout Status displays the
following result:
• road conditions
• “Vehicle Speed < Limit”
Take the vehicle for a road test in order to
duplicate these conditions and set the cruise • “Vehicle Speed ≥ Limit”
the problem reoccurs. RESULT 6 The ET Kickout Status displays the
following result:

360 RENR1367-11
RESULT 7 The ET Kickout Status displays the • Result 6

following result:
• “Neutral” procedure:
RESULT 8 The ET Kickout Status displays the Troubleshooting, “PTO Switch Circuit - Test”
following result:
STOP.
• “No Engine Speed”
• Result 7
procedure:
• “Ser Switch Timeout”
Troubleshooting, “Neutral Switch Circuit - Test”
• “Resume Switch Timeout”
STOP.
Results:
• Result 8
• Result 2 procedure:
Repair: Perform the following diagnostic Troubleshooting, “Engine Speed/Timing Sensor

procedure: Circuit - Test”
Troubleshooting, “Cruise Control Switch Circuit - STOP.

Test”
• Result 9
STOP.
• Result 3 procedure:
Repair: Perform the following diagnostic Troubleshooting, “Cruise Control Switch Circuit -
procedure: Test”.
Troubleshooting, “Powertrain Data Link Circuit - STOP.

Test”
STOP.
• Result 5
procedure:
Troubleshooting, “Clutch Pedal Position Switch

Circuit - Test”
STOP.
• Result 5
procedures:

Circuit - Test”
STOP.
RENR1367-11 361
Test Step 5. Check the Switch Circuit. 3. Recheck the system for active diagnostic codes.
Table 194 4. Repeat the test step.

Table for Status of Service Brake Pedal
Position (Switch 1) 5. If the problem is resolved with the test ECM,
Condition of Switch
Circuit
Terminal 45 is Open. ON Open replace the ECM.
Terminal 45 connected
OFF Shorted 7. Verify that the repair eliminates the problem.
to terminal 5.
STOP.
B. Fabricate a jumper wire 100 mm (4 inch) long. Service Brake Pedal Position (Switch 1).
Crimp a Deutsch Pin to both ends of the wires.
Table 195
C. Disconnect vehicle harness connector P1 from Table for Status of the Service Brake Pedal
the ECM. Position (Switch 1)
D. Connect a breakout T to ECM Connector J1 and Condition of Switch Switch

Circuit
connect P1 to the breakout T. Circuit Status
Service Brake Pedal
E. Install the jumper into terminal 45 Service Brake Position Switch 1 Wires ON Open
Pedal Position Switch 1 of the Breakout T. Connect are Disconnected.
the other end of the jumper to ECM Connector
Service Brake Pedal
P1 terminal 5 (AP sensor/switch sensor common) Position Switch 1 Wires OFF Shorted
of the Breakout T. Connected.

G. Connect an electronic service tool to the cab data
link connector. B. Ensure that ECM vehicle harness connector J1/P1
is connected.
H. Access the electronic service tool status screen.
C. Find the switch for the Service Brake Pedal
I. While the status of the Service Brake Pedal Position (Switch 1) in the vehicle.
Position (Switch 1) is being monitored on the
electronic service tool status screen slowly remove D. Disconnect the wires from the switch terminals.
the jumper from terminal 5 and slowly insert the
jumper from terminal 5 (AP sensor/switch sensor E. Turn the ignition key switch to the ON position.
common).
Refer to Table 194. link connector.
Expected Result: G. Access the electronic service tool status screen.
The switch status changes per the information in H. While the switch status is being monitored on
Table 194. the electronic service tool status screen slowly
connect the switch wires and slowly disconnect
Results: the switch wires.
• Yes – The ECM is functioning properly. Proceed Refer to Table 195.

to Test Step 6.
Expected Result:
• No – The ECM is NOT functioning properly.
Repair: Perform the following repair: Table 195.
1. Temporarily connect a test ECM. Results:
2. Remove all jumpers and replace all connectors. • Yes

362 RENR1367-11
Repair: Perform the following repair: Results:
Replace the faulty switch. • Yes – The problem is in the vehicle wiring between
STOP.
Inspect the vehicle wiring and repair the vehicle
• No – There is a problem in the harness between wiring, as required. If the problem still exists with
the switch and the ECM. Proceed to Test Step 7. the wiring, send the vehicle to the OEM dealer.
Test Step 7. Insert a Jumper at the STOP.

Bulkhead Connector.
Table 196 the bulkhead connector and the ECM.
Table for Status of the Service Brake Pedal
Position (Switch 1) Repair: Perform the following repair:
Switch Position or Inspect the vehicle wiring and repair the vehicle
Pedal Position
Service Brake Pedal the wiring, send the vehicle to the OEM dealer.
Position Switch 1 Wire is ON Open
Disconnected. STOP.
Service Brake Pedal
Position Switch 1 Wire OFF Shorted i01858135
Connected.
Service Brake Pedal Position
A. Turn the ignition key switch to the OFF position. (Switch 2) Circuit - Test
B. Fabricate a jumper wire 100 mm (4 inch) long. SMCS Code: 1435-038-BRK
Crimp a Deutsch Pin to each end of the wires.
C. Find the switch for the terminal for the Service
Brake Pedal Position (Switch 1). Also find the Use this procedure under the following situation:
terminal for the sensor common for the AP
Sensor/Switch in the engine side of the bulkhead Use this procedure to determine if the Service Brake
connector for the vehicle harness. Pedal Position (Switch 2) is preventing normal
operation of cruise control, fast idle, idle set speed,
D. Insert the jumper wire between the two terminals or PTO operation:
E. Turn the ignition key switch to the ON position. correct operation of the cruise control, fast idle, idle
set speed or PTO operation:
link connector. • Service brake pedal position (switch 1)
G. Access the electronic service tool status screen. • Neutral switch
H. While the switch status is being monitored • Cruise control set/resume switch
on the electronic service tool status screen
alternately remove the jumper wire between the • Cruise control on/off switch
two terminals, and alternately insert the jumper
wire between the two terminals. • PTO on/off switch
Refer to Table 196. • Cruise control pause switch
Expected Result: The switches are described in the respective circuit
tests in Troubleshooting.
Table 196.
RENR1367-11 363
All of the following Customer Programmable Note: Fast idle in this procedure is an engine idle
Parameters can affect cruise control, idle set speed, rpm above the programmed low idle rpm. Fast idle is
fast idle, and PTO operation: set by using a dedicated fast idle switch.
• “Low Cruise Control Speed Set Limit” Cruise Control On/Off Switch
• “High Cruise Control Speed Set Limit” This switch must be ON before cruise control or
controlled idle can be activated. This switch is ON
• “Idle Vehicle Speed Limit” when the switch is closed. When the switch is closed
• “Fast Idle RPM #2” on/off switch)
• “Cruise/Idle/PTO Switch Configuration” • Terminal 5 (AP sensor/switch sensor common)

• “Idle/PTO Bump rpm” Note: If the vehicle is programmed to use the
Dedicated PTO, the PTO on/off switch overrides the
• “Idle/PTO rpm Ramp Rate” cruise control on/off switch. The PTO on/off switch
overrides the cruise control on/off switch when the
• “PTO Vehicle Speed Limit” vehicle speed is within the range of the “PTO Vehicle
Speed Limit” that is programmed.
• “Cruise control pause switch”
Set/Resume Switch
The vehicle speed calibration can also affect the
cruise control, fast idle, the idle set speed, and the With the cruise control on/off switch in the ON
PTO if the vehicle speed calibration is incorrectly position and the vehicle speed within the range of the
programmed. Refer to Troubleshooting, “Customer programmed Low Cruise Control Speed Set Limit and
Specified Parameters”. the High Cruise Control Speed Set Limit, momentarily
pressing the set switch will activate cruise control and
Service Brake Pedal Position (Switch 2) the ECM will maintain the current speed.
The switch for the service brake pedal position After a speed has been set and the speed is then
(switch 2) is normally open when the respective pedal disengaged by using the brake, the clutch, the cruise
is released. Depressing the brake pedal should close control pause switch, or the on/off switch, the ECM
the individual circuit. This switch is OEM supplied. will seek the previous set speed when the resume
The service brake pedal position (switch 2) is typically switch is toggled. This assumes that the vehicle
a pressure switch. speed is above the “Low Cruise Control Set Speed
Limit” for cruise control or the vehicle speed is below
The following background information is related the “Idle/PTO Vehicle Speed Limit” for the idle and
to this procedure: the PTO.
The kickout switch refers to the switch that is used to After a speed has been set, pressing and holding the
exit the cruise control, the PTO, fast idle, or the idle set/resume switch in position will cause the engine
set speed. to establish a new set speed. The system’s reaction
depends on the programming of the “Cruise/Idle/PTO
The operation of the Caterpillar electronic engine Switch Configuration”.
cruise controls that are installed in automobiles. The When the set/resume switch is momentarily pressed,
operation of fast idle, idle, and PTO are similar to the the cruise set point will change one mph. The rate of
operation of cruise except that the Idle and the PTO change is dependent on the programmed “Idle/PTO
govern engine rpm instead of vehicle speed. Bump rpm” when an idle speed is set.
Note: Idle in this procedure is an engine idle rpm Cruise Control Pause Switch
by using the Cruise Control On/Off switch and the
Set/Resume switch. Refer to Troubleshooting, “PTO
Switch Circuit - Test” for additional information
regarding the programmable options for the
Dedicated PTO.
364 RENR1367-11
The cruise control pause switch is not a switch that Table 197
is wired to an input. The switch position is broadcast Switch Usage.
over a J1939 data link. The parameter “Cruise Pause Setting For
Switch” must be programmed to use a cruise control Transmission Service Service
pause switch. After a speed has been set and the Style Brake Brake
Clutch Neutral
speed is then disengaged by using the cruise control Parameter Switch Switch
pause switch, the ECM will seek the previous set 1 2
speed when the resume switch is toggled. This “Manual” X X
Cruise Control Speed Set Limit” for cruise control “Automatic
X
Option 1”
Speed Limit” for the idle and the PTO. “Automatic
X X
Option 2”
Kickout Switches
“Automatic
X X X
Option 3”
The service brake pedal position switches, the neutral
switch and the clutch switch are used in the cruise “Automatic
X X
control mode, the PTO mode, the fast idle mode, Option 4”
and the idle mode in order to discontinue the cruise “AT/MT/HT
operation, the PTO operation, the fast idle mode, X
Option 1”
or the idle operation. The capability to override the
idle shutdown timer is determined by the “Allow Idle “AT/MT/HT
X X
Shutdown Override” parameter setting. The “Allow Option 2”
Idle Shutdown Override” is a Customer Parameter. “AT/MT/HT
X X X
Option 3”
Usage of Transmission Style Switches
“AT/MT/HT
X X
Option 4”
The “Transmission Style” parameter determines the
switches that will be used. The following switches “Universal
X X X
can be used with being dependent on the parameter Option”
setting:
If the “Transmission Style” parameter is programmed
• Clutch pedal position to one of the following options, the input for the Clutch
Pedal Position Switch is not used.
• Neutral
Refer to Table 197 for additional information.
A service brake pedal position (switch 1) is required
for all configurations. The service brake pedal
connector P1 terminal 45. The service brake pedal
connector P1 terminal 64. The clutch pedal position
terminal 22. The neutral switch connects to the ECM
through connector P1 terminal 62.
RENR1367-11 365
Some engines that were built before JULY 1999 • “Idle Kickout”
may have a Basic ECM. The Basic ECM was used
only on General Motors chassis. Other chassis used • “PTO Kickout”
Basic ECM software does not have the parameter • “Fast Idle Kickout”
of the vehicle.

procedure:
After the kickout, review the status parameter on the

electronic service tool. The status parameter for the
kickout indicates the cause. This must be performed
before the ignition key switch is turned OFF. It is
important to remember that the parameter will only
indicate the last kickout since the ECM has been
powered by the input of the ignition key switch.

Occurrence” is indicated. This parameter remains
Cruise/Idle/PTO Mode. Also, this parameter remains
blank until the ECM detects the disengagement of
the Cruise/Idle/PTO Mode. Refer to Tables 198, 199,
200, and 201 in order to interpret the status screen
kickout status parameter.

available:
366 RENR1367-11
Table 198
Table For The Cruise Control Kickout Status Screen On The Electronic Service Tool
“Vehicle Speed < Limit”
The Cruise/Idle On/Off switch is turned Refer to Troubleshooting, “Cruise Control
“Switch Turned Off” OFF or the switch circuit has an open circuit Switch Circuit - Test”.
condition.
Switch”
data link.
The service brake pedal is depressed or Proceed with this test procedure.
“Brake Pedal Depressed” the service brake switch circuit 2 has a
short circuit condition.
circuit condition.
exists.
The PTO On/Off switch is turned ON or Refer to Troubleshooting, “PTO Switch
“PTO Switch On” the PTO On/Off switch circuit has a short Circuit - Test”.
circuit condition.
The Set/Resume switch was held in the Cruise control cannot be set until the cruise
SET position for more than 15 seconds control on/off switch is turned to the OFF
“Set Switch Timeout” (Basic) or there is a short circuit in the position and then turned to the ON position
switch circuit. again. If the circuit for the set switch is
The Set/Resume switch was held in the Cruise control cannot be set until the cruise
SET position for more than 15 seconds control on/off switch is turned to the OFF
“Resume Switch Timeout” (Basic) or there is a short circuit in the position and then turned to the ON position
switch circuit. again. If the circuit for the resume switch is
RENR1367-11 367
Table 199
Table For The Idle Kickout Status Screen On The Electronic Service Tool
The Cruise/Idle On/Off switch is turned OFF Refer to Troubleshooting, “Cruise Control
condition.
Switch”
data link.
The service brake pedal is depressed or the Proceed with the test procedure.
“Brake Pedal Depressed” service brake switch 2 circuit has a short
circuit condition.
The PTO On/Off switch is turned ON or the Refer to Troubleshooting, “PTO Switch
“PTO Switch On” PTO On/Off switch circuit has a short circuit Circuit - Test”.
condition.
“No Occurrence” Idle has not been enabled since the ECM Operate the vehicle in the Idle mode in order
or has been powered up. to create the problem again.
368 RENR1367-11
Table 200
The Fast Idle On/Off switch is turned OFF Refer to Troubleshooting, “Cruise Control
condition.
Switch”
data link.
The service brake pedal is depressed or the Proceed with the test procedure.
“Brake Pedal Depressed” service brake switch 2 circuit has a short
circuit condition.
“No Occurrence” Fast Idle set speed has not been exited Operate the vehicle in the Idle mode in order
RENR1367-11 369
Table 201
Table For The PTO Kickout Status Screen On The Electronic Service Tool
No Engine Speed
The PTO On/Off switch is turned OFF or the Refer to Troubleshooting, “Clutch Pedal
Switch Turned Off
switch circuit has an open circuit condition. Position Switch Circuit - Test”.
circuit condition.
g00770825
Illustration 166
Test Step 1. Determine the Type of • “Idle RPM Limit”

Problem.
A. Connect the electronic service tool to the data link
connector. PTO Parameters
B. Turn the ignition key switch to the ON position. • “PTO Configuration”

C. If the vehicle will not allow setting a cruise speed, • “PTO Vehicle Speed Limit”
an idle speed or a PTO speed, check the following
Customer Parameters: D. Ensure that the vehicle is not experiencing
Cruise Control Parameters Refer to Troubleshooting, “Customer Specified
• “Low Cruise Control Speed Set Limit” necessary.
• “High Cruise Control Speed Set Limit” E. Check the electronic service tool status screen
that indicates the last cause of a kickout for one
Idle Parameters of the following items:
• “Fast Idle RPM #1” • Cruise control kickout

• “Fast Idle RPM #2” • Idle kickout
• “Idle Vehicle Speed Limit” • Fast idle kickout
370 RENR1367-11
• PTO kickout Test Step 2. Inspect Electrical Connectors

and Wiring.
meaning of the status parameter.
Expected Result:

Results:

the driver. STOP.
• No
If a problem is still suspected with the circuit for the

service brake pedal position (switch 2), perform
the following procedure:
g00770850
Illustration 167

and the terminal 64 (service brake pedal position
(switch 2)).


with the switches.


RENR1367-11 371
All connectors, pins and sockets should be completely • Yes – The switch is operating normally. STOP.
should be free of corrosion, abrasion or pinch points. • Intermittent Problem Suspected – Proceed to Test
Step 4.
Results:
• OK – Proceed to Test Step 3. change. Proceed to Test Step 5.
• Not OK Test Step 4. Operate the Vehicle and

Check the Kickout Status Parameter.
A. For an intermittent cruise control kickout, talk to
Repair the connectors or wiring and/or replace the driver in order to determine the conditions
the connectors or wiring. Ensure that all of the when the kickout occurs. Topics of examination
seals are properly in place and ensure that the could be the following examples:
• specific speed
• road conditions
STOP.
Test Step 3. Check the Service Brake
Pedal Switch 2 Status on the Electronic Take the vehicle for a road test in order to
Service Tool. duplicate these conditions and set the cruise
Table 202 the problem reoccurs.
Table for Status of the Service Brake Pedal Position
B. For an intermittent idle kickout, talk to the driver
Switch Position or in order to determine the conditions when the
Status Circuit
Pedal Position kickout occurs. A topic of examination could be
The Service Brake Pedal the specific engine rpm.
OFF Open
is DEPRESSED.
The Service Brake Pedal set the idle rpm. Operate the vehicle in idle until
ON Closed
is RELEASED.
A. Access the electronic service tool status screen. Note: The electronic service tool status screen will
only indicate the last kickout. The electronic service
B. Turn the ignition key switch to the ON position. tool status screen will lose this information if the
ignition key switch is turned off.
C. Start the engine. Ensure that the air system is
charged if the vehicle is equipped with air brakes. C. Connect the electronic service tool and check the
Depress the service brake while the status of the status screen for the last cause of the kickout.
service brake pedal position (switch 2) is being Refer to Tables 198, 199, 200, and 201 for an
observed. Also, release the service brake while explanation of the status parameter.
the status of the service brake pedal position
(switch 2) is being observed. D. If the electronic service tool status screen is blank,
then either there was no kickout of the cruise
Refer to Table 202 for the status of the switch or control, or the power to the ECM was turned OFF
for the status of the pedal position. before the information could be read. Repeat this
test step.
Note: If the status indicates “Not Installed”, check
the programming of the “Transmission Style”. This Note: An electronic service tool status screen that is
parameter must be programmed to “Automatic blank indicates “No Occurrence”.
Option 2”, “Automatic Option 3”, “AT/MT/HT Option
2”, or “AT/MT/HT Option 3”. Expected Result:
Expected Result: RESULT 1 The Electronic Service Tool Kickout

Status displays the following result:
Table 202. • “Brake”
372 RENR1367-11
RESULT 2 The Electronic Service Tool Kickout Repair: Perform the following diagnostic
Status displays the following result: procedure:
• “Switch Turned Off” Troubleshooting, “Powertrain Data Link Circuit -

Test”
RESULT 3 The Electronic Service Tool Kickout
Status displays the following result: STOP.
• “Cruise Control PAUSE Switch” • Result 4

• “Clutch” Troubleshooting, “Clutch Pedal Position Switch

Circuit - Test”
• “Vehicle Speed < Limit” • Result 5

• “Bad Vehicle Speed” Repair: Perform the following diagnostic
procedures:
• “Vehicle Speed ≥ Limit”
RESULT 6 The Electronic Service Tool Kickout Circuit - Test”
Status displays the following result:
STOP.
• Result 6
Status displays the following result: Repair: Perform the following diagnostic
procedure:
• “Neutral”
• “No Engine Speed” • Result 7

• “Ser Switch Timeout” Troubleshooting, “Neutral Switch Circuit - Test”
• “Resume Switch Timeout” STOP.
Results: • Result 8
• Result 1 – Proceed to Test Step 5. Repair: Perform the following diagnostic
procedure:
• Result 2
Troubleshooting, “Engine Speed/Timing Sensor
Repair: Perform the following diagnostic Circuit - Test”
procedure:
STOP.
Test” • Result 9
STOP. Repair: Perform the following diagnostic
procedure:
• Result 3
RENR1367-11 373
Troubleshooting, “Cruise Control Switch Circuit - Repair: Perform the following repair:
Test”.
STOP.
Test Step 5. Check the Switch Circuit.
Table 203
Table for Status of Service Brake Pedal 4. Repeat the test step.
Position (Switch 2)
Condition of Switch Switch reconnect the suspect ECM.
Circuit
Circuit Status
Terminal 64 is Open. ON Open 6. If the problem returns with the suspect ECM,
replace the ECM.
Terminal 64 connected
OFF Closed
to terminal 5.
A. Turn the ignition key switch to the OFF position. STOP.
B. Fabricate a jumper wire 100 mm (4 inch) long. Test Step 6. Insert a Jumper at the
Crimp a Deutsch pin to both ends of the wires. Service Brake Pedal Position (Switch 2).
C. Disconnect vehicle harness connector P1 from Table 204
the ECM. Table for Status of the Service Brake Pedal
Position (Switch 2)
D. Connect a breakout T to ECM connector J1 and
connect P1 to the breakout T. Condition of Switch Switch
Circuit
Circuit Status
E. Install the jumper into terminal 64 (service brake Service Brake Pedal
pedal position switch 2) of the breakout T. Connect Position Switch 2 Wires OFF Open
the other end of the jumper to ECM connector P1 are Disconnected.
terminal 52 (unswitched +battery) of the breakout
Service Brake Pedal
T. Position Switch 2 Wires On Shorted
Connected.
G. Connect an electronic service tool to the cab data A. Turn the ignition key switch to the OFF position.
link connector.
H. Access the electronic service tool status screen. is connected.
I. While the status of the service brake pedal position C. Find the switch for the service brake pedal position
(switch 2) is being monitored on the electronic (switch 2) in the vehicle.
service tool status screen slowly remove the
jumper from terminal 52 (unswitched +battery). D. Disconnect the wires from the switch terminals.
Now, slowly insert the jumper into the terminal 52
(unswitched +battery). E. Turn the ignition key switch to the ON position.
Refer to Table 203. F. Connect the electronic service tool to the cab data
link connector.
Expected Result:
G. Access the electronic service tool status screen.
Table 203. H. While the switch status is being monitored on
the electronic service tool status screen slowly
Results: connect the switch wires and slowly disconnect
the switch wires.
to Test Step 6. Refer to Table 204.

374 RENR1367-11
Expected Result: H. While the switch status is being monitored

on the electronic service tool status screen
The switch status changes per the information in alternately remove the jumper wire between the
Table 204. two terminals, and alternately insert the jumper
wire between the two terminals.
Results:
Refer to Table 205.
• Yes
Expected Result:
Replace the faulty switch. Table 205.
Verify that the repair eliminates the problem. Results:
STOP. • Yes – The problem is in the vehicle wiring between

• No – There is a problem in the harness between
the switch and the ECM. Proceed to Test Step 7. Repair: Perform the following repair:
Test Step 7. Insert a Jumper at the Inspect the vehicle wiring and repair the vehicle
Bulkhead Connector. wiring, as required. If the problem still exists with
the wiring, send the vehicle to the OEM dealer.
Table 205
Table for Status of the Service Brake Pedal STOP.

Position (Switch 2)
Switch Position or the bulkhead connector and the ECM.
Pedal Position
Service Brake Pedal Repair: Perform the following repair:
Position Switch 2 Wire is OFF Open
Disconnected. Inspect the vehicle wiring and repair the vehicle
Service Brake Pedal
Position Switch 2 Wire ON Shorted the wiring, send the vehicle to the OEM dealer.
Connected.
STOP.
i01619084
Crimp a Deutsch pin to each end of the wires. Starting Aid Output Circuit -
Test
C. Find the switch for the terminal for the service
brake pedal position (switch 2). Also find the SMCS Code: 1456-038
terminal for the sensor common for the +battery
in the engine side of the bulkhead connector for System Operation Description:
the vehicle harness.
in the engine side of the bulkhead connector. Use this procedure in order to determine if the circuit
for the Starting Aid Output is operating properly.
F. Connect the electronic service tool to the cab data to this procedure:
link connector.
OCT01 Software
G. Access the electronic service tool status screen.
Starting Aid Output
RENR1367-11 375
Output 2 is available to connect a relay and/or a Test Step 1. Inspect Electrical Connectors
solenoid in order to control a starting aid system. The and Wiring.
parameter “Starting Aid Output” must be programmed
to “Automatic” in order to use output 2 as a starting
aid output.
Typical starting aid systems inject ether into the inlet

manifold in order to aid starting of the engine during
cold weather operation. The output is automatically
controlled by the ECM. The reading from the
coolant temperature sensor is used to determine
if conditions require the use of the starting aid.
If a fault condition exists with the circuit for the
coolant temperature sensor, the reading from the
inlet manifold temperature sensor will be used. The
starting aid output will be enabled for a maximum
of 30 seconds while the engine is cranking and the
temperature reading is below 0 °C (32 °F). The
starting aid output will be disabled if the engine speed
rises above 500 rpm. The starting aid output will also
be disabled if a condition that prevents fuel injection
occurs.
g00838127
Illustration 169
Pin locations for output 2
g00838120
Illustration 168
Schematic for the starting aid circuit A. Thoroughly inspect ECM vehicle harness
connector J1/P1, and the firewall bulkhead
connector.

B. Perform a 45 N (10 lb) pull test on terminal 10 in

the ECM connector.


Expected Result:

376 RENR1367-11
Results: Test Step 3. Use ET to Check the ECM.

• Not OK

STOP.
Test Step 2. Use ET to Check the Relay.


g00838135
Illustration 170
C. Access the special test“Starting Aid Output” on ET.
The “Starting Aid Output” test will enable output 2 Breakout T
when the test is active.
D. Begin the “Starting Aid Output” test and listen for
the relay to “click”. You may need to be near the B. Turn the ignition key switch to the OFF position.
engine in order to hear the “click”.
Expected Result: J1/P1.
The relay activates when the special test is enabled. D. Connect a breakout T between ECM connectorsJ1
and P1.
Results:
E. Connect a voltage test lamp to terminal 10 (output
• Yes – The ECM and vehicle components are 2) and terminal 65 (-battery) of the breakout T.
operating correctly. STOP.
G. Access the special test “Starting Aid Output” on
ET.
H. Cycle the special test “Starting Aid Output” to

“Active” and to “Not Active” and watch the voltage
test lamp.
I. Stop the special test.
Note: A multimeter can not be used in place of the

voltage test lamp when the ECM outputs are being
tested.
Expected Result:
The voltage test lamp turns ON when the test is

active. The voltage test lamp turns OFF when the
test is not active.
RENR1367-11 377
Results: Note: A problem with the tachometer circuit does

not indicate that there is a problem with the engine
• Yes – The ECM is OK. The problem is in the speed/timing sensors. Any problem that is associated
vehicle wiring. Inspect the vehicle wiring and then with the engine speed/timing sensors will also affect
repair the vehicle wiring. Otherwise, send the the operation of the engine. An electrical problem
vehicle to the OEM dealer for repair. Verify that the with the engine speed/timing sensors will generate
original condition is resolved. STOP. a diagnostic code. If a code that is related to the
engine speed/timing sensors is present, refer to
• No – Temporarily connect a test ECM. Use the Troubleshooting, “Engine Speed/Timing Sensor
“Starting Aid Output Special Test” on ET to check Circuit - Test”.
the ECM. If the problem is resolved with the test
ECM, install the suspect ECM. If the problem
returns with the suspect ECM, replace the ECM.
Verify that the repair eliminates the problem. STOP.
i02378211
Tachometer Circuit - Test

SMCS Code: 7462-038
Use this procedure when the Engine Control Module

(ECM) provides a signal to the tachometer and there
is a problem with the indication on the tachometer.
Background Information
The vehicle’s tachometer is connected to terminal

J1/P1-38 and/or terminal J1/P1-39 of the ECM
connector. Some tachometers require only one of
the signal lines to operate while other tachometers
require both signal lines to operate. The ECM can
also send the signal to the tachometer via the SAE
J1587 data link.
The ECM uses the signal from the engine

speed/timing sensor in order to determine engine
speed. The ECM converts the signal from the engine
speed/timing sensor into engine rpm. The ECM
creates an equivalent signal in pulses per revolution
that is output to the tachometer.
The ECM must know the tachometer’s conversion

factor in order to develop an accurate signal for
the tachometer. The conversion factor is usually
marked on the tachometer. The conversion factor
is programmed into the “Tachometer Calibration”
parameter. The parameter is programmable from
12.0 to 500.0 pulses per revolution in 0.1 increments.
The most likely source of a tachometer circuit

problem is the vehicle wiring. The second most
likely source of a tachometer circuit problem is the
tachometer. The least likely source of a tachometer
circuit problem is the ECM.
378 RENR1367-11
g00649121
Illustration 171
Schematic No. 1 for the tachometer circuit
g00649123
Illustration 172
Schematic No. 2 for the tachometer circuit
Test Step 1. Inspect the Electrical A. Thoroughly inspect ECM vehicle harness
Connectors and the Wiring connector J1/P1, the firewall bulkhead connector,
and the terminals for the tachometer in the
connectors. Refer to Troubleshooting, “Electrical
B. Refer to Illustration 173. Perform a 45 N (10 lb)

pull test on each of the wires in the ECM connector
that are associated with the terminals for the
tachometer:
C. Check the allen head screw on each of the

ECM connectors for the proper torque. Refer to
for details.

pinch points from the tachometer to the ECM.
Expected Result:

Results:
• Yes – The wiring is OK. Proceed to Test Step 2.

• Not OK – The wiring is not OK.
Illustration 173
g01152498 connectors are completely coupled. Verify that the
Terminal locations on the P1 connector repair eliminates the problem.
(P1-38) Tachometer+
(P1-39) Tachometer- STOP.
RENR1367-11 379
Test Step 2. Check the ECM Connection Results:

to the Tachometer
• Result 1 – The ECM and the tachometer are OK.
Note: Some tachometers require only one signal
line in order to operate. Either of the ECM terminals Repair: There may be an intermittent problem in
can be used for this type of tachometer. The other the harness and/or in the connectors. Repair the
wire should be left disconnected. If both wires are harness and the connectors. Verify that the original
connected, and one indicates an open circuit, repair problem has been resolved.
this open wire.
STOP.
Verify that the connections for the tachometer are
correct at the P1 connector. • Result 2 – The engine rpm is not indicated or the
engine rpm is erratic. Proceed to Test Step 4.
Expected Result:
• Result 3 – The engine rpm is not within 50 rpm of
The P1 connections are correct. 1500 rpm. Proceed to Test Step 5.
Results: Test Step 4. Check the Tachometer Signal

• OK – The P1 connections are correct. Proceed
to Test Step 3.
• Not OK – The P1 connections are not correct.

Repair: Repair the connections, when possible.
Send the vehicle to an OEM dealer for repair, if
necessary.
STOP.
Test Step 3. Use Caterpillar Electronic

Technician (ET) to Check the Tachometer
Signal g01152502
Illustration 174
A. Establish communication between Cat ET and the ECM breakout T-connector

ECM. (38) Tachometer+
(39) Tachometer-
B. Access the tachometer special test. Access the
following display screens in order: Note: Performing certain steps within this procedure
requires the use of a multimeter that is capable of
• “Diagnostics” measuring a PWM duty cycle.
• “Diagnostic Tests” A. Disconnect the P1 connector.
• “Special Test” B. Connect a breakout T to ECM vehicle harness

connector P1.
C. While the dash tachometer is being monitored,
begin the test. C. Fabricate two jumper wires 100 mm (4 inch) long.
Crimp a Deutsch Pin to one end of each wire.
Expected Result:
D. Refer to Illustration 174. Insert one of the jumper
RESULT 1 The dash tachometer indicates wires into terminal P1-39 of the breakout T and
approximately 1500 ± 150 rpm and the dash insert the other jumper wire into terminal P1-38
tachometer is stable. of the breakout T.
RESULT 2 The tachometer does not indicate an E. Access the tachometer special test. Access the
engine rpm or the tachometer is erratic. following display screens in order:
RESULT 3 The tachometer rpm is stable but the • “Diagnostics”

tachometer rpm is not within 50 rpm of 1500 rpm.
• “Special Test”
380 RENR1367-11
F. Attach one of the multimeter leads to the jumper Results:

wire from P1-38.
• OK – The parameter is programmed correctly.
G. Attach the other multimeter lead to the jumper
wire from P1-39. Repair: Replace the tachometer or send the
vehicle to an OEM dealer for repair. Verify that the
H. While the tachometer special test is being run, repair eliminates the problem.
observe the reading on the multimeter.
STOP.
Expected Result:
• Not OK – The parameter is not programmed
The multimeter indicates a duty cycle from 30 to 70 correctly.
percent from each of the terminals for the tachometer
while the engine is running. Repair: Program the parameter with the correct
value. Verify that the repair eliminates the problem.
Results:
STOP.
• OK – The multimeter indicates a duty cycle from
30 to 70 percent. The ECM tachometer output is Test Step 6. Check the ECM Connection
OK. Return the wiring to the original configuration. to the Tachometer
A. Refer to Illustration 174. Remove the appropriate
• Not OK – The duty cycle is not within the terminals from the P1 connector. Also, disconnect
specification. the signal wires at the tachometer.
Repair: Perform the following repair: B. Check each wire for continuity.
1. Restore the wiring to the original configuration. Expected Result:
2. Temporarily connect a test ECM. The wiring is OK.
3. Check the system for active diagnostic codes. Results:
4. If the problem is resolved with the test ECM, • Yes – The wiring is OK. Restore the wiring to the
connect the original ECM. Test the tachometer original configuration. Proceed to Test Step 7.
again.
• No – The wiring is not OK.
5. If the problem returns with the original ECM,
replace the ECM. Repair: Repair the wiring or send the vehicle to
an OEM dealer.
STOP.
STOP.
Test Step 7. Check the Supply Voltage for
Test Step 5. Check the Tachometer the Tachometer
Calibration
Check the connections to the tachometer for the
A. Determine the tachometer engine speed +Battery and the −Battery. Also check the fuses and
calibration setting in pulses per revolution. You the circuit protection.
may be required to contact the OEM dealer or you
may be required to send the vehicle to the OEM Expected Result:
dealer for this information.
The tachometer is receiving the correct supply
B. Verify that the value of the “Tachometer voltage.
Calibration” parameter matches the requirements
of the tachometer. Results:
Expected Result: • OK – The tachometer is receiving the correct

supply voltage.
The parameter is programmed correctly.
RENR1367-11 381
Replace the tachometer if the tachometer does • The engine is not running.
not work. Send the vehicle to an OEM dealer for
repair, if necessary. • The transmission is in neutral and the speed of the
vehicle is less than 24 km/h (15 mph) (NOV99 and
STOP. older Personality Modules).
• Not OK – The tachometer is not receiving the • The accelerator pedal position is less than 65
correct supply voltage. percent of the programmed value. Refer to the
note below.
Repair: Correct the problem. Replace parts, if
necessary. Verify that the repair eliminates the Note: JUL99 and newer Personality Modules have
problem. a programmable “AT/MT/HT Part Throttle Shift
Speed” parameter that provides three different shift
STOP. modulation settings for the transmission. The “Low”
setting will disable the relay below 65 percent throttle,
the “Medium” setting below 55 percent throttle, and
i01611424
the “High” setting below 45 percent throttle.
Transmission (AT/MT/HT) The AT/MT/HT transmission interface relay will be
Relay Circuit - Test enabled under any the following conditions:
SMCS Code: 4493-038-T3 • The engine is running.

System Operation Description: • The transmission is in gear or the speed of the
vehicle is greater than 24 km/h (15 mph) (NOV99
Use this procedure under the following situation: and older Personality Modules).
Use this procedure to determine if the AT/MT/HT • The accelerator pedal position is greater than 80
transmission interface relay (output #7) is operating percent of the programmed value. Refer to the
correctly. note below.
The following background information is related Note: JUL99 and newer Personality Modules have
to this procedure: a programmable “AT/MT/HT Part Throttle Shift
Speed” parameter that provides three different shift
Allison AT/MT/HT transmissions require an input modulation settings for the transmission. The “Low”
from the ECM to regulate the transmission shifting. setting will enable the relay above 80 percent throttle,
The ECM monitors various operating parameters the “Medium” setting above 70 percent throttle, and
in order to determine if the transmission should the “High” setting above 60 percent throttle.
use closed throttle shift modulation or full throttle
shift modulation. Programming the “Transmission Cruise Control or Vehicle Speed Limiting is
Style” parameter to “AT/MT/HT Option1”, “AT/MT/HT active.
Option2”, “AT/MT/HT Option3”, or “AT/MT/HT
Option4” activates ECM Output #7 in order to control The AT/MT/HT transmission interface relay will be
a shift interface relay that is connected to the Allison disabled when all of the following conditions occur:
transmission.
• The speed of the vehicle is greater than 2 km/h
Transmission Style (1 mph) of the cruise set speed or the vehicle
speed limit.
For engines that have a Full Feature ECM, the
“Transmission Style” must be programmed to one • The load factor is less than 75 percent.
of the AT/MT/HT options in order for Output #7 to
control the AT/MT/HT transmission relay. For the • The engine speed is greater than 2000 rpm.
“Basic (GM) System”, Output #7 is always available.
The transmission interface relay will be enabled when
Note: The ECM does not communicate with the the load factor is greater than 98 percent.
Allison AT/MT/HT Transmission through a data link.
Cruise Control or Vehicle Speed Limiting is NOT

active.
The AT/MT/HT transmission interface relay will be

disabled if any of the following conditions occur:
382 RENR1367-11
g00729187
Illustration 175
Schematic for the AT/MT/HT Transmission Relay
Test Step 1. Check Electrical Connectors

and Wiring.
A. Thoroughly inspect ECM connectors J1/P1
and the firewall bulkhead connector. Refer to
for details.

wires that go to P1:20 or P1:12.


Expected Result:

Results:

• Not OK

Illustration 176
g00729188 connectors are completely coupled.
ECM terminal
RENR1367-11 383
Verify that the repair eliminates the problem. • “Special Tests”

STOP. Note: The “Transmission Style” must be programmed
to “AT/MT/HT Option 1”, “AT/MT/HT Option 2”,
Test Step 2. Use ET to Check the “AT/MT/HT Option 3”, or “AT/MT/HT Option 4” for the
Accelerator Pedal Position Sensor. “AT/MT/HT XMission Interface Test” to be available.
This will allow output 7 to control the AT/MT/HT
A. Ensure that the cruise control switch is off. transmission relay.
B. Connect ET to the cab data link connector. D. Begin the “AT/MT/HT XMission Interface Test”
while you listen for the solenoids to click. You may
C. Turn the ignition key switch to the ON position. need to be closer to the transmission in order to
hear the click of the relay.
D. Use the following procedure to check the
accelerator pedal position sensor: Expected Result:
a. Monitor the duty cycle of the throttle sensor on The relay activates when the test is enabled.
ET. Access the display screens in the following
order: Results:
• “Service” • Yes – The ECM is functioning properly at this time.

STOP.
• “Calibrations”
• “Throttle Position”
Test Step 4. Use ET to Check the ECM.
b. While the duty cycle is being monitored on ET,
depress the accelerator pedal and release the
accelerator pedal. Repeat this action several
times.
Expected Result:
The duty cycle of the accelerator pedal position

sensor is between 3 percent and 100 percent.
Results:

• Not OK
procedure:
Troubleshooting, “Accelerator Pedal (Throttle)

Position Sensor Circuit - Test”
g00770060
Illustration 177
STOP.
Breakout T
Test Step 3. Use ET to Check the
Solenoids and the Relays. A. Turn the ignition key switch to the OFF position.
A. Connect ET to the cab data link connector. B. Disconnect the ECM engine harness connector
J1/P1.
C. Connect a breakout T to the ECM connector
C. Access the “AT/MT/HT XMission Interface Test” J1/P1.
through the following menus:
D. Connect a voltage test lamp to terminal 20 (Output
• “Diagnostics” 7) and terminal 65 (-Battery) of the breakout T.
• “Diagnostic Tests” E. Turn the ignition key switch to the ON position.

384 RENR1367-11
F. Access the “AT/MT/HT XMission Interface Test” 5. If the problem is resolved with the test ECM,
through the following menus: reconnect the suspect ECM.
• “Diagnostics” 6. If the problem returns with the suspect ECM,

replace the ECM.
• “Special Tests”
STOP.
Note: The “Transmission Style” must be programmed
to “AT/MT/HT Option 1”, “AT/MT/HT Option 2”,
i01632415
“AT/MT/HT Option 3”, or “AT/MT/HT Option 4” for the
“AT/MT/HT XMission Interface Test” to be available.
This will allow output 7 to control the AT/MT/HT
Vehicle Speed and
transmission relay. Speedometer Circuit - Test
G. While the voltage test lamp is being observed, SMCS Code: 7463-038
cycle the special test on and off.
H. Stop the special test.
Expected Result:
Use this procedure to troubleshoot the system only
The voltage test lamp behaves in the following under the following conditions:
manner:
• There is an active diagnostic code.
• The voltage test lamp turns on when the test is
active. • There is an easily repeated diagnostic code that is
associated with the vehicle speed circuit.
• The voltage test lamp turns off when the test is
not active. Refer to Troubleshooting, “Vehicle Speed Circuit -
Calibrate” if the vehicle speed is being calibrated
Results: in ppm (pulses per mile) or PPKM (pulses per
kilometer).
• Yes – The ECM is OK. There is a problem in the
harness. The following background information is related
to this procedure:
The vehicle speed circuit consists of the vehicle
Repair the engine harness or replace the engine speed source and associated wiring. The vehicle
harness. Verify that the repair eliminates the speed source is installed by the vehicle OEM. Usually,
problem. a sensor reads movement of the transmission output
shaft from the teeth on a chopper wheel. The ECM
STOP. converts the signal from the vehicle speed source
into vehicle speed for the following functions:
• No – Temporarily connect a test ECM. Repeat this
test step. If the problem is resolved with the test • Cruise control
ECM, reconnect the suspect ECM. If the problem
returns with the suspect ECM, replace the ECM. • Fast idle
Repair: Perform the following repair: • Idle speed control
1. Temporarily connect a test ECM. • Progressive shift
2. Remove all jumpers and replace all connectors. • Speedometer
3. Recheck the system for active diagnostic codes. • PTO operation
4. Repeat the test step. • Vehicle speed limiting
• Idle shutdown
RENR1367-11 385
• Operation of the air inlet heater Speedometer Connection
• Secure idle theft deterrent If the vehicle speedometer is driven by the ECM
output, the vehicle speedometer will be connected to
• Trip data the ECM vehicle harness connector J1/P1 terminal
36 and/or terminal 37. Some speedometers require
• Maintenance data only one of the ECM signal lines to operate. Other
speedometers may require both of the ECM signal
To begin troubleshooting a vehicle speed problem, lines to operate.
the following information must be determined:
Speedometer Special Test
The problem is electrical or the problem is a
calibration problem. If the vehicle speedometer is driven by ECM output,
the speedometer circuit can be checked by using ET.
Electrical problems would be an erratic speed signal The “55 mph VSP/Speedometer Test” will drive the
or no speed signal. A calibration problem would speedometer to approximately 55 mph under the
be a stable ECM speed, but an inaccurate ECM following conditions:
speed. Another calibration problem would be a stable
Speedometer speed, but an inaccurate speedometer • The “55 mph VSP/Speedometer Test” is activated.
speed.
• The circuit is operating properly.
If the problem is related to vehicle speed calibration,
refer to Troubleshooting, “Vehicle Speed Circuit - • The speedometer is operating properly.
Calibration” for calibrating the vehicle speed in PPKM
(pulses per kilometer) or ppm (pulses per mile). The Note: While the test is active, the odometer will
ECM speedometer output signal is set to 18,600 increment mileage.
PPKM (30,000 ppm) for most configurations. For “GM
Truck Manufacturer” configurations with SEP00 or Magnetic Sensors
newer software, the output of the speedometer is set
to 2,485 PPKM (4,000 ppm). The ECM speedometer A magnetic pickup will have only two wires if the
output signal cannot be changed. All speedometers magnetic pickup is a single coil magnetic sensor.
that are driven by the ECM output (J1/P1 terminal 36 Also, a magnetic pickup will have four wires if the
and terminal 37) must match the fixed output of the magnetic pickup is a dual coil magnetic sensor. The
ECM for proper operation. magnetic pickup sensor does not require a power
connection or a ground connection.
The type of vehicle speed sensor that is installed on
the vehicle must be determined. Vehicles with Electronic Vehicle Speed Sources
Both single coil magnetic sensors and dual coil For these vehicles, the vehicle speed signal is
magnetic sensors are commonly used. Caterpillar provided by an electronic source. The signal is
recommends single coil magnetic sensors. Some of received over a single wire that is connected to
the vehicles may provide the vehicle speed through ECM vehicle harness connector J1/P1 terminal 32
the Transmission ECM. (vehicle speed in positive). No other connection
should be made to this line. A speedometer is an
You must determine if the vehicle speedometer is example of a connection that should not be made
driven from the ECM. to this line. For this type of signal, the ECM vehicle
harness connector J1/P1 terminal 33 (vehicle speed
The ECM can drive the speedometer through in negative) should not be connected to the ECM in
the connection to ECM connector J1 terminal order to prevent introducing electrical noise into the
36 (speedometer positive) and/or terminal 37 circuit.
(speedometer negative).
For vehicle speed problems on trucks that are
Note: The ECM may also drive the speedometer equipped with either of these vehicle speed sources,
by a connection to the J1587 ATA data link, if the first inspect the wiring from the electronic source to
instrument cluster is capable of interpreting the the engine ECM for open circuits or short circuits.
signal.
Vehicle Speed Circuit Wiring
The vehicle speed signal is routed directly into the

ECM at ECM vehicle harness connector J1/P1
terminal 32 (vehicle speed in positive) and terminal
33 (“vehicle speed in negative”).
386 RENR1367-11
With SEP00 and newer software, the ECM can be

configured to receive vehicle speed information
from an Electronic Transmission Control Unit via the
J1939 data link. The transmission must be capable
of supporting the “J1939 ETC1 Broadcast Message
(PGN 61,442 Bytes 2 & 3)”. This message provides
the speed of the transmission output shaft. This
feature requires the hardware for the J1939 data
link to be installed in the chassis of the vehicle. This
also requires a transmission that is electronically
controlled and capable of supporting the necessary
J1939 protocol.
When the engine is configured for the J1939 option,

the circuit for the ECM vehicle speed input (terminals
32 and 33) will be ignored. The ECM uses the
“Vehicle Speed Cal (J1939-Trans)” parameter value
in order to calculate vehicle speed. The ECM uses
the parameter value and the speed of the output
shaft that is received over the J1939 data link to
calculate the vehicle speed. The “Vehicle Speed Cal
(J1939-Trans)” parameter is based on the revolutions
per mile of the output shaft. There are several
methods that can be used to arrive at this calibration
value. Refer to Troubleshooting, “Vehicle Speed
Circuit - Calibrate” for details.
Regardless of the source that is used to determine

vehicle speed, the ECM uses the calculated value
for the vehicle speed in the same manner to control
several features and functions. The diagnostics for
vehicle speed function very similarly when either
a hard-wired signal is provided to the ECM from a
speed sensor, or a message is sent to the ECM via
the J1939 data link. If the ECM detects a loss of
vehicle speed or a value that is invalid, a fault code
will be logged in order to alert the operator or the
technician of the presence of a problem.
g00643046
Illustration 178
Schematic for a single coil speed sensor and an ECM driven speedometer
RENR1367-11 387
g00643048
Illustration 179
Schematic for a single coil speed sensor and a second single coil sensor for a speedometer
g00643050
Illustration 180
Schematic for a single coil speed sensor and a Data Link driven speedometer
g00643051
Illustration 181
Schematic for an Electronic vehicle speed source and an ECM driven speedometer
388 RENR1367-11
g00643052
Illustration 182
Schematic for an Electronic vehicle speed source and a speedometer
g00643054
Illustration 183
Test Step 1. Inspect Electrical Connectors Refer to Illustration 183.

and Wiring.
A. Thoroughly inspect ECM vehicle harness the proper torque of 6.0 N·m (55 lb in).
and the terminals for vehicle speed (terminals D. Check the harness and wiring for abrasion and
32 and 33) in the connectors. Refer to pinch points from the sensor to the ECM.
for details. Expected Result:
B. Perform a 45 N (10 lb) pull test on each of the All connectors, pins and sockets should be completely
wires in the ECM connector that are associated coupled and/or inserted and the harness and wiring
with the vehicle speed sensor. should be free of corrosion, abrasion or pinch points.
RENR1367-11 389
Results: Result 4 The speed that is displayed on the ET

status screen is not present, unstable, or erratic.
Results:
• Not OK
• Result 1 – There is not a vehicle speed problem
Repair: Perform the following repair: at this time. If a problem still exists, continue
troubleshooting until the condition is resolved.
Repair the connectors or wiring and/or replace STOP.
seals are properly in place and ensure that the • Result 2 – Proceed with vehicle speed calibration
connectors are completely coupled. and adjustment.
Verify that the repair eliminates the problem. Repair: Perform the following diagnostic
procedure:
STOP.
Troubleshooting, “Vehicle Speed Circuit - Calibrate”
Test Step 2. Determine the Type of
Vehicle Speed Problem. STOP.
A. Perform a dynamometer test on the vehicle or • Result 3 – Proceed to Test Step 3.

perform a road test on the vehicle. Compare the
vehicle speed on the ET status screen against the • Result 4 – Proceed to Test Step 4.
speedometer. Also, compare the vehicle speed on
the ET status screen against the actual vehicle
speed. The actual vehicle speed can be measured
on a dynamometer or the actual vehicle speed
can be measured by a stopwatch.
B. Monitor the vehicle speed status on ET while the

vehicle is parked and the engine is running.
C. Operate various electrical devices in the vehicle

while the vehicle speed is being monitored. In
order to operate the various electrical devices,
cycle the electrical devices to the ON position and
the OFF position.
D. Increase the engine rpm a few times and decrease

the engine rpm a few times.
Note: If the operation of a specific electrical device

is producing a vehicle speed problem, the electrical
device may be the source of an electrical noise
problem. An electrical noise problem is also a
possibility if increasing the engine rpm on a stationary
vehicle produces a vehicle speed problem.
Expected Result:
Result 1 The speed that is displayed on the ET

status screen and the speed of the ECM driven
speedometer are stable and both speeds agree with
the actual speed.
Result 2 The ET status screen and speed is stable,

but incorrect.
Result 3 The ET status screen agrees with the actual

speed, but the ECM driven speedometer is incorrect
or inoperable.
390 RENR1367-11
Test Step 3. Use ET to Check the

Speedometer.
g00723985
Illustration 184
A. Inspect vehicle harness connector P1. Observe Repair: Perform the following repair:
whether connections are present to terminal
36 (speedometer positive) and/or terminal 37 If the ECM is not connected to the OEM
(speedometer negative). speedometer, send the vehicle to the OEM dealer
for repair of the speedometer.
If there is a connection to either of the speedometer
terminals continue with the procedure. STOP.
B. Connect ET to the cab data link connector. • No speed indicated – If OEM truck wiring diagrams
are available, trace the wiring to the speedometer
C. Access the “55 mph VSP/Speedometer Test” by and repair the speedometer, as required. STOP.
Accessing the following display screens in order:
• Speed present, but not in range
• “Diagnostic Tests” procedure:
• “Special Test menu” Troubleshooting, “Vehicle Speed Circuit - Calibrate”
D. Activate the test and observe the speedometer. STOP.
Note: Some types of speedometers only require one Test Step 4. Determine the Type of
ECM signal line to be connected to the speedometer. Vehicle Speed Circuit.
Either of the ECM terminals can be used for these
speedometers. A. Inspect the vehicle wiring for the type of vehicle
speed circuit that is being used.
Compare the vehicle speed circuit with the
Expected Result: detailed circuit schematics:
The speedometer indicates 80 to 96 km/h (50 to 60 Schematic 1 Refer to Illustration 178.

mph).
Schematic 2 Refer to Illustration 179.
Results:
Schematic 3 Refer to Illustration 180.
• Yes – The ECM is providing the signal for the
speedometer and the wiring and the speed are Schematic 4 Refer to Illustration 181.
OK. Send the vehicle to the OEM dealer for repair
of the speedometer. STOP. Schematic 5 Refer to Illustration 182.
• ECM not connected to speedometer Select the schematic that is similar to the circuit
that is being repaired.
RENR1367-11 391
Expected Result: Verify that any repair eliminates the problem.
RESULT 1 The vehicle speed circuit is similar to STOP.

Schematic 1, 2, or 3.
Test Step 6. Inspect the Passive Magnetic
RESULT 2 The vehicle speed circuit is similar to Speed Sensor for Vehicle Speed.
Schematic 4 or 5.
A. Remove the vehicle speed sensor from the
RESULT 3 The ECM is configured for the “J1939 transmission and inspect the vehicle speed sensor
Trans” option. for steel shavings, debris, or damage.
Results: Note: Shavings and debris on the sensor may occur

unless the transmission fluid is drained and replaced
• Result 1 – Proceed to Test Step 5. according to the maintenance schedule.
• Result 2 – The vehicle speed circuit is similar to B. Wipe off the sensor until the sensor is clean.
Schematic 4 or 5. Proceed to Test Step 7. Test the sensor according to the manufacturer’s
instructions. The sensor is OEM supplied.
Note: If the gap between the vehicle speed sensor
Test Step 5. Measure Vehicle Speed and the chopper wheel is too small, the sensor may
Sensor Resistance at the Sensor. be damaged. Also if the gap between the vehicle
speed sensor and the chopper wheel is too small, the
A. Disconnect the vehicle speed sensor from the sensor may create a signal due to the vibration of
vehicle harness. the chopper wheel. This will cause a vehicle speed
signal when the vehicle is parked. If the vehicle
B. Thoroughly inspect the connector. Ensure that is parked and a vehicle speed signal is produced,
the connector terminals are free of corrosion back out the sensor from the wheel until the signal
and ensure that the connector terminals are fully disappears. Use caution. backing out the sensor too
seated into the housing of the connector. Repair far may cause a loss of the vehicle speed signal.
the connector terminals or replace the connector Back out the sensor no more than one turn to one
terminals, as required. and one quarter turns.
C. Measure the resistance between the two terminals Expected Result:

of the sensor connector. The sensor resistance
measurement should be 100 to 4500 Ohms. The vehicle speed sensor is correctly installed and
undamaged.
D. Reverse the meter leads and measure the
resistance. Switching the probes should not Results:
change the resistance measurement by more than
10 Ohms. • OK – Proceed to Test Step 7.
Expected Result: • Not OK
The sensor resistance that is measured is between Repair: Perform the following repair:
100 and 4500 Ohms and the sensor resistance that
is measured is within 10 Ohms with the meter probes If the sensor is damaged, replace the damaged
in either position. sensor or send the vehicle to the OEM dealer for
repairs.
Results:
Verify that any repair eliminates the problem.
• OK – Reconnect the sensor to the vehicle harness.
Proceed to Test Step 6. STOP.
• Not OK
If the sensor is damaged, replace the damaged

sensor or send the vehicle to the OEM dealer for
repairs.
392 RENR1367-11
Test Step 7. Test ECM Vehicle Speed

Inputs by Using the Speedometer Special
Test.
g00643436
Illustration 185
Jumper wire locations for breakout T
A. Turn the ignition key switch to the OFF position. Expected Result:
B. Fabricate two jumper wires 100 mm (4 inch) long. ET indicates a constant vehicle speed between
Crimp a Deutsch pin to both ends of the wires. 80 to 96 km/h (50 to 60 mph) when the jumper wires
from the speedometer circuit are connected.
the ECM. Results:
D. Connect a breakout T to ECM connector J1 and • OK – The ECM is operating correctly. The source
connect P1 to the breakout T. of the problem is either the wiring or the source of
the problem is the vehicle speed sensor.
E. Install one jumper into the breakout T in order
to connect terminal 36 (speedometer positive) Repair: Perform the following repair:
to terminal 32 (vehicle speed in positive). Install
the other jumper into the breakout T in order to If the sensor is damaged, replace the damaged
connect terminal 37 (speedometer negative) to sensor or send the vehicle to the OEM dealer for
terminal 33 (vehicle speed in negative). repairs.
Refer to Illustration 185. Verify that any repair eliminates the problem.
F. Turn the ignition key switch to the ON position. STOP.
G. Connect ET to the cab data link connector. • Not OK – Recheck the connections of the jumper
wires. Leave the jumper wires installed in the
H. Access the “55 mph VSP/Speedometer Test” by breakout T. Disconnect the breakout T. Proceed
Accessing the following display screens in order: to Test Step 8.
• “Diagnostics” Test Step 8. Test the ECM Vehicle Speed

Inputs When the Test ECM is Installed.
A. Connect a test ECM and reconnect the breakout T.
• “Special Test menu”
B. Install one jumper into the breakout T in order
I. Activate the test and observe the vehicle speed to connect terminal 36 (speedometer positive)
on the vehicle speed status screen. to terminal 32 (vehicle speed in positive). Install
the other jumper into the breakout T in order to
connect terminal 37 (speedometer negative) to
terminal 33 (vehicle speed in negative).

RENR1367-11 393
C. Turn the ignition key switch to the ON position. F. Compare the Vehicle speed reading on the ET
status screen to the vehicle speedometer and the
D. Connect ET to the cab data link connector. actual vehicle speed.
E. Access the “55 mph VSP/Speedometer Test” by Expected Result:

Accessing the following display screens in order:
The “Vehicle Speed” on the ET status screen is within
• “Diagnostics” 8 km/h (5 mph) of the speedometer and the actual
vehicle speed readings.
Results:
• “Special Test menu”
• Yes – The ECM is receiving J1939 data from the
F. Activate the test and observe the vehicle speed transmission ECM. Send the vehicle to the OEM
on the vehicle speed status screen. dealer for repair of the wiring for the speedometer
or for the repair of the transmission vehicle speed
Expected Result: sensor. STOP.
ET indicates a constant vehicle speed between • No – Perform the following repair:

80 to 96 km/h (50 to 60 mph) when the jumper wires
from the speedometer circuit are connected. Repair: Connect a test ECM. Program all of the
parameters that are related to vehicle speed to
Results: the same setting as the original ECM. Repeat
the previous test step. If the test ECM functions
• OK properly and the original ECM does not function
properly, replace the ECM. If the test ECM does
Repair: Perform the following repair: not correct the problem, send the vehicle to the
OEM dealer for repair of one of the following
Reconnect the suspect ECM. If the problem returns components:
with the suspect ECM, replace the ECM.
• speedometer
STOP.
• wiring
• Not OK – Recheck the connectors. Continue
troubleshooting until original condition is resolved. • Transmission ECU
STOP.
• transmission speed sensor
Test Step 9. Verify Correct Programming
for the “J1939 Vehicle Speed Calibration” • wiring for the J1939 data link
Parameter
STOP.
i01611459
B. Access the list of “Configuration Parameters” on
the service tool and verify that the “Vehicle Speed
Input” parameter is programmed to the “J1939
Wait To Start Lamp Circuit -
Trans” option. Test
C. Verify that the “Powertrain Datalink” parameter is SMCS Code: 7431-038
programmed to “J1939”.
D. Verify that the correct value is used for the
“Vehicle Speed Cal (J1939-Trans)” parameter. Use this procedure under the following situation:
Refer to Troubleshooting, “Vehicle Speed Circuit
- Calibrate” for details. Use the following information in order to determine if
the Wait to Start Lamp is operating incorrectly.
E. Verify that the J1939 data link is connected to the
ECM and that the data link is functioning properly. Terminal 31 (Output 9)
Refer to Troubleshooting, “Powertrain Datalink
Circuit - Test”.
394 RENR1367-11
The output 9 (terminal 31) can be used as a fast idle

lamp or a Wait to Start Lamp output. The “Output
#9” parameter defaults to “Fast Idle Lamp”, but the
parameter can be programmed to operate as a wait
to start lamp.
Note: When the “Truck Manufacturer” is programmed

to “GM” configurations the “Output #9” parameter is
unavailable. The “Output #9” parameter functions as
fast idle lamp output.
If the “Output #9” parameter is programmed to “Wait

To Start Lamp”, the ECM will turn on output 9 when
the air inlet heater is operating and the engine is not
running. The wait to start lamp functions similarly to
the lamp for the air inlet heater that can be installed
in parallel with the relay for the air inlet heater circuit.
The wait to start lamp illuminates only when the
engine is not running. The lamp for the air inlet heater
illuminates when the relay for the air inlet heater is
energized.
OCT01 Software
The parameter “Output #9” is no longer available. The

parameter “Wait To Start Lamp” can be programmed
to “J1/P1:31” or “None”. When the parameter is
programmed to “J1/P1:31” a lamp circuit can be
connected to terminal 31 in order to indicate that the
air inlet heater is on and the engine is not running.
The parameter “Fast Idle Enabled Lamp” must be
programmed to “J1/P1:21” for this feature to be used.

Manufacturer” is programmed to “Other”. Illustration 187
g00770189
Electrical Connection of Lamps Test Step 1. Inspect Electrical Connectors

and Wiring.
battery voltage through the vehicle wiring. The other A. Thoroughly inspect ECM vehicle harness
terminal is connected to the ECM at the vehicle connector J1/P1, the firewall bulkhead connector,
harness connector J1/P1 at terminal 31. or the wait to start lamp. Refer to Troubleshooting,
on the lamp. B. Perform a 45 N (10 lb) pull test on each of the
with the wait to start lamp.


g00770585
Illustration 186
RENR1367-11 395
Expected Result: Test Step 3. Test the Circuit for the Wait
to Start Lamp
Results:

• Not OK
STOP.

of the Wait to Start Lamp.
A. Connect ET. Access the configuration screen
and ensure that the “Output #9” parameter g00770210
Illustration 188
is programmed to “Wait To Start Lamp”. For
OCT01 Software, ensure that “Wait to Start Vehicle harness connector P1
Lamp” is programmed to “J1/P1:31”. Also, “Fast
Idle Enabled Lamp” must be programmed to A. Disconnect ECM vehicle harness connector
“J1/P1:21”. J1/P1.
B. Turn the ignition key switch to the OFF position B. Fabricate a jumper wire 100 mm (4 inch) long.
for ten seconds. Turn the ignition key switch to Crimp a Deutsch pin to both ends of the wire.
the ON position.
C. Insert the jumper into terminal 31 of connector P1.
C. The wait to start lamp should illuminate for
approximately two seconds when the key switch is D. Connect the other end of the jumper wire to
turned on. If conditions require the air inlet heater terminal 65 (−battery) of connector P1.
to turn on, the wait to start lamp should remain
illuminated until the air inlet heater turns off or the E. Turn the ignition key switch to the ON position.
engine is started.
Expected Result: wire and remove the jumper wire.
The wait to start lamp turns on and the wait to start Refer to Illustration 188.
lamp turns off per the above description.
Expected Result:
Results:
Result 1 The wait to start lamp turns on while the
• Yes – The wait to start lamp appears to operating jumper is connected to both sockets. Also, the wait
correctly at this time. STOP. to start lamp turns off when the jumper is removed
from one of the sockets.
Result 2 The lamp does not turn on while the jumper
is connected to both sockets.
Result 3 The lamp will stay on while the ECM vehicle

harness connector is disconnected.
Results:
• Result 1 – The wait to start lamp is functioning

396 RENR1367-11
• Result 2 – The lamp did not turn on. The vehicle’s D. The test lamp should turn on. If the test lamp does
lamp circuit is not functioning properly. The lamp not turn on, either the test lamp is faulty or the
is probably burned out or there is a problem in wiring to the ECM is faulty. Continue with this step
the wiring from the cab to either the ECM or the if the lamp turns on.
+Battery connection. Repair the lamp circuit or
send the vehicle to the OEM dealer for repairs. E. Leave the probe of the test lamp connected to
STOP. terminal 52 (unswitched +battery).
• Result 3 F. Connect the other probe of the test lamp to

terminal 31 (output 9) of the breakout T.
procedure: Refer to Illustration 189.
The circuit between the ECM and the lamp is G. Turn the ignition key switch to the OFF position.
shorted to chassis ground. Repair the circuit or
send the vehicle to the OEM dealer for repairs. H. Connect ET to the cab data link connector. Access
the configuration screen and ensure that the
STOP. “Output #9” parameter is programmed to “Wait
To Start Lamp”.
Test Step 4. Check ECM Operation of
Wait to Start Lamp. I. Turn the ignition key switch to the OFF position
for ten seconds. Turn the ignition key switch to
the ON position.
J. The wait to start lamp should illuminate for

approximately two seconds when the key switch is
turned on. If conditions require the air inlet heater
to turn on, the wait to start lamp should remain
illuminated until the air inlet heater turns off or the
engine is started.
Expected Result:
Results:

problem in the vehicle wiring or the lamp. STOP.
• No
g00770221
Illustration 189
ECM breakout T-connector that the “Output #9” parameter is programmed to
“Wait To Start Lamp”. Check the ECM operation
A. Disconnect ECM vehicle harness connector of the PTO Switch ON Lamp when the test ECM
J1/P1. is installed. If the problem is resolved with the test
ECM, reconnect the suspect ECM. If the problem
B. Insert a breakout T between ECM vehicle harness returns with the suspect ECM, replace the ECM.
connector J1 and ECM vehicle harness connector
P1. STOP.
C. Connect one probe of the voltage test lamp to
terminal 65 (-battery). Connect the other probe of
the voltage test lamp to terminal 52 (unswitched
+battery) of the breakout T.
RENR1367-11 397
i01611513 If the Customer Parameter for Engine Monitoring

is programmed to “WARNING”, “DERATE”, or
Warning Lamp Circuit - Test “SHUTDOWN” the lamp will turn on when a
warning condition exists. The lamp will be turned on
SMCS Code: 7431-038 continuously while a warning condition exists.
System Operation Description: If the Customer Parameter for Engine Monitoring is
programmed to “DERATE” or “SHUTDOWN”, the
Use this procedure under the following situation: lamp flashes whenever Engine Monitoring is derating
engine speed, vehicle speed, and power.
Use the following information in order to determine if
the warning lamp is operating incorrectly: If the Customer Parameter for Engine Monitoring is
programmed to “SHUTDOWN”, the warning lamp
The following background information is related will continue flashing after the derate mode until
to the following procedure: the engine is shut down. Refer to Troubleshooting,
“System Overview”.
Warning Lamp Operation
Electrical Connection of Lamps
A warning lamp is required if the “Engine Monitoring”
feature is used. The warning lamp indicates an active One terminal of the lamp must be connected to
problem with one of the monitored conditions such battery voltage through the vehicle wiring. The other
as high coolant temperature. A flashing warning terminal is connected to the ECM at the ECM vehicle
lamp indicates that the engine is derating power. harness connector J1/P1 at terminal 29 (warning
The warning lamp will turn on for a minimum of two lamp).
seconds after the engine has started.
With SEP00 software and newer software, an the lamp ON.
option is available for the “GM Truck Manufacturer”
configuration that allows the output for warning lamp
to be configured as an output for a warning lamp for
high coolant temperature. The “Engine Monitoring
Lamps” parameter must be programmed to the
“Warning Lamp” option for standard operation of
engine monitoring. If the “Engine Monitoring Lamps”
parameter is programmed to the “HIgh Coolant
Temp Warning Lamp” option, the output is used as
an interface to the GM shutdown system. Refer to
Troubleshooting, “High Coolant Temp Warning Lamp
Output Circuit - Test” for details.
Operation Of Engine Monitoring
When the ECM has detected an engine condition Illustration 190

g00769338
that exceeds the acceptable limits, the warning lamp Schematic for the circuit of the warning lamp
will turn on. The activation of the lamp depends on
the existing conditions and the programming of the
parameter for “Engine Monitoring”. The lamp will
activate in one of the following modes:
• The lamp not only turns on, but the lamp stays on.
• The lamp will flash on and off.
If the lamp turns on continuously, the engine is in
warning mode. If the lamp begins to flash, the ECM
has begun to derate engine speed, vehicle speed,
or power.
If the parameter for Engine Monitoring is programmed

to “WARNING”, the lamp will not flash. The lamp
only flashes when the engine is programmed to
“DERATE” or “SHUTDOWN”.
398 RENR1367-11
Expected Result:

Results:

• Not OK
STOP.

of the Warning Lamp.
A. Monitor the warning lamp. Turn the ignition key
switch to the ON position, while the engine is OFF.
The lamp should turn on for five seconds. Then,
the lamp should turn off.
The lamp will continue flashing if there is an active

diagnostic code. If there is an active diagnostic
code, connect ET in order to read the active
diagnostic code. Troubleshoot the problem.
Note: The warning lamp will not turn on until the

engine is cranked.
g00769348
Illustration 191
B. Connect ETto the cab data link connector.
Pin locations for the Warning Lamp circuit
Verify that the “Engine Monitoring” has been
programmed to “WARNING”, “DERATE”,
Test Step 1. Inspect Electrical Connectors or “SHUTDOWN”. If “Engine Monitoring” is
and Wiring. programmed to “OFF”, the warning lamp is not
used and the ECM will not turn on the lamp.
connector J1/P1, the firewall bulkhead connector, While the warning lamp is being observed, start
and terminal 29. Refer to Illustration 191. Refer to the engine. The warning lamp should turn on for a
Troubleshooting, “Electrical Connectors - Inspect” minimum of two seconds after the engine starts.
for details. Then, the warning lamp should turn off. If the lamp
remains off, immediately shut down the engine.
wires in the ECM connector that is associated with Expected Result:
the suspect terminal for the lamp.
The warning lamp turns on and the warning lamp
C. Check the ECM connector (allen head screw) for turns off per the above description.
Results:
• OK – The lamp appears to operating correctly at
this time. STOP.
• Not OK – The lamp does not turn on. Proceed to

Test Step 3.
RENR1367-11 399
• Not OK – The lamp stays on. Expected Result:
Repair: Perform the following diagnostic Result 1 The warning lamp turns on while the jumper
procedure: is connected to both sockets. Also, the warning lamp
turns off when the jumper is removed from one of
Use ET to determine if an “Engine Monitoring” the sockets.
condition is causing the lamp to turn on. If an
“Engine Monitoring” condition is not present, Result 2 The lamp does not turn on while the jumper
perform the following diagnostic procedure. is connected to both sockets.
Proceed to Test Step 3. Result 3 The lamp will stay on while the ECM vehicle
harness connector is disconnected.
Test Step 3. Test the Lamp Circuit.
Results:
• Result 1 – The warning lamp circuit is functioning

• Result 2 – The lamp did not turn on. The vehicle’s

lamp circuit is not functioning properly. The lamp
is probably burned out or there is a problem in
the wiring from the cab to either the ECM or the
+battery connection. Repair the lamp circuit or
STOP.
• Result 3
procedure:
The circuit between the ECM and the lamp is

shorted to chassis ground. Repair the circuit or
g00769361
Illustration 192
STOP.
Vehicle harness connector P1
Test Step 4. Check ECM Operation of the
A. Disconnect ECM vehicle harness connector Warning Lamp.
J1/P1.

C. Insert the jumper into terminal 29 (warning lamp)

of connector P1. The jumper can be inserted
into the following terminals in order to test the
appropriate lamp circuit:
D. Connect the other side of the jumper wire to P1

terminal 65 (-battery).

wire and remove the jumper wire.
g00769368
Illustration 193
ECM breakout T-connector
400 RENR1367-11
A. Disconnect ECM vehicle harness connector

J1/P1.
B. Insert a breakout T between the ECM vehicle

harness connectors J1 and P1.
C. Connect a test light probe to terminal 65 (-battery)

and connect the other probe to terminal 52
(unswitched +battery) of the breakout T.
D. The test lamp should turn on. If the test lamp does
not turn on, either the test lamp is faulty or the
wiring to the ECM is faulty. Continue with this step
if the lamp turns on.
E. Leave the test light probe connected to terminal

52 (unswitched +battery).
F. Connect the other test light probe to terminal 29

on the breakout T.
G. Watch the voltage test lamp. Start the engine. The

lamp should turn on for a minimum of two seconds
after the engine starts. Then, the lamp should turn
off. Immediately turn the engine off if the lamp
continues to stay on. Use ET to determine the
cause of the problem.
Expected Result:
The warning lamp turns on and the warning lamp

turns off per the above description.
Results:

problem in the vehicle wiring or the lamp. Repair
the vehicle wiring or the lamp, as required. STOP.
• No – Temporarily connect a test ECM. Ensure

that the “Engine Monitoring” parameter of the test
ECM matches the “Engine Monitoring” parameter
of the suspect ECM. Check the ECM operation
of the lamp when the test ECM is installed. If the
problem is resolved with the test ECM, reconnect
the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM. STOP.
RENR1367-11 401
Calibration Procedures Test Step 1. Install the 7X-1171

Transducer Adapter
i01725180 A. Turn the ignition key switch to the OFF position.
Engine Speed/Timing Sensor - B. Remove the timing calibration plug from the left or
Calibrate right front face of the flywheel housing.
SMCS Code: 1912-524 C. Install the 7X-1171 Transducer Adapter into the
hole for the plug.
Results:
Use this procedure if any of the following conditions
exist: Test Step 2. Install the 6V-2197 Magnetic
Transducer on the Engine.
• 22-13 Check Timing Sensor Calibration (42)
A. Put a 2D-6392 O-Ring Seal on the end of the
A timing calibration must be performed under the magnetic transducer.
Note: A small amount of clean engine oil will allow
• The ECM requires replacement and the ECM the seal to slide onto the transducer more easily.
will not communicate with Caterpillar Electronic
Technician (Cat ET) in order to allow the B. Push the magnetic transducer through the adapter
timing calibration to be copied when the “Copy until the magnetic transducer comes in contact
Configuration-ECM Replacement” feature is used. with the outermost portion of the flywheel timing
calibration ring. Move the O-ring seal downward
• Work has been performed on the engine drive train against the adapter.
(front).
C. Withdraw the magnetic transducer 1.0 mm
Note: The timing calibration will not increase the (0.04 inch) and hand tighten the nut on the adapter
available engine power or the timing calibration will sleeve in order to secure the magnetic transducer
not decrease the available engine power. Do not in place.
expect an increase in power due to the performance
of the timing calibration. D. Check that the probe is properly installed and
snug. The probe should not move when the
Replacement ECM engine is started.
If a replacement ECM is required, the ECM E. Connect the 6V-2197 Magnetic Transducer to
parameters and the timing calibration can be the 7X-1695 Cable.
transferred from the suspect ECM to the replacement
ECM. Timing calibration will NOT be necessary. F. Remove the access cover from the J400 engine
This feature requires Cat ET and this feature is only timing calibration connector.
possible if the existing ECM can communicate with
Cat ET. Note: Some engines do not have a J400 engine
timing calibration connector in the engine harness.
Table 206 A 170-3519 Harness is required. Refer to Special
Required Special Tools Instruction, REHS0399, “Installation Of The 170-3519
Timing Calibration Harness Assembly On The 3126B
Part Number Description Truck Engine” for the installation procedure.
6V-2197 Magnetic Transducer
Results:
7X-1695 Cable
7X-1111 Grommet • OK – Proceed to Test Step 3.
9S-9082 Engine Turning Tool
170-3519 Harness
402 RENR1367-11
Test Step 3. Start the Engine and D. Ensure that all of the connections are made
Allow the Coolant to Reach Operating correctly.
Temperature
Results:
A. Start the engine and run at low idle until the
engine has warmed up enough to exit Cold Mode • OK – Proceed to Test Step 5.
operation. The Cat ET status screen will display
“COLD MODE” in the upper corner when Cold Test Step 5. Calibrate the Speed/Timing
Mode operation exists. The engine will adjust idle Sensor
rpm from Cold Mode idle to the programmed Low
Idle rpm when Cold Mode operation is complete. A. To calibrate the timing to the correct setting, select
“space” on Cat ET. Wait until Cat ET indicates that
B. Check for active diagnostic codes. Use the the timing is “CALIBRATED”.
procedures in this manual to troubleshoot
and repair any active diagnostic codes before Note: If the Cat ET display reads “CALIBRATION
attempting a calibration check. The engine must UNSUCCESSFUL”, the electronic injection timing
not have any diagnostic fault conditions that are has not been set. Recheck the tool installation and
present during the timing calibration except the tool operation and try again to calibrate electronic
following condition: injection timing. If the crankshaft and camshaft gears
have been reassembled incorrectly, the engine will
• 22-13 Check Timing Sensor Calibration (42) not calibrate.
C. After the engine has warmed up, set the engine If the timing calibration has been successfully
speed to 1100 rpm by using the cruise control completed, do not exit the timing calibration
switches or by using the accelerator pedal. screen on Cat ET until you have disconnected
the 7X-1695 Cable for the 6V-2197 Magnetic
Note: The engine rpm must be steady within the Transducer from the P400 Speed/Timing
1000 to 1200 rpm range in order to perform a timing Calibration Connector.
calibration.
Expected Result:
Results:
The timing calibration procedure was completed
• OK – Proceed to Test Step 4. successfully.
Test Step 4. Connect Cat ET Results:
A. Connect Cat ET to the cab data link connector. • OK – The timing calibration procedure was
completed successfully. Proceed to Test Step 6.
B. After the engine has exited Cold Mode operation,
access the “Timing Calibration Screen” on Cat ET. • Not OK
Access the following display screens in order:
Repair: Perform the following procedure:
• “Service”
1. Verify that the engine rpm was stable during
• “Calibrations” the testing (± 50 rpm). If the engine rpm
was unstable or the engine rpm could not
• “Timing Calibration” be controlled within ± 50 rpm because of
mechanical factors or electrical factors, refer to
Note: To perform a timing calibration, the engine rpm Troubleshooting, “Engine Misfires, Runs Rough
must remain as steady as possible at approximately or Is Unstable”.
1100 rpm. This can be performed by using the idle
engine governor or a steady foot on the accelerator 2. If all of the problems have been corrected but
pedal. Any changes to engine rpm that are more the timing can not be calibrated, check the
than 100 rpm will slow down the procedure. These cable of the 6V-2197 Magnetic Transducer and
changes will also reduce the accuracy of the check the 6V-2197 Magnetic Transducer in
procedure. order to verify that the Magnetic Transducer is
not bent. If the 6V-2197 Magnetic Transducer
C. Connect the 7X-1695 Cable for the 6V-2197 is not bent, restart this procedure.
Magnetic Transducer to the J400 Speed/Timing
Calibration Connector. STOP.
RENR1367-11 403
Test Step 6. Disconnect the 6V-2197 • Idle shutdown

Magnetic Transducer Before Exiting the
“Monitor/Calibrate Timing” Screen on • Operation of the air inlet heater
Cat ET
• Secure idle theft deterrent
A. Disconnect the timing probe from the J400 engine
timing calibration connector. • Trip data
B. Install the cover for the J400 connector. • Maintenance data
C. Exit the timing calibration screen on Cat ET. With SEP00 and newer software, there are two
different methods that can be used to obtain the
Note: Exiting the timing calibration screen on Cat ET information for the ECM to use for calculating vehicle
will drop the engine rpm to the programmed low idle speed. The ECM can calculate vehicle speed by
if the cruise control switches were used to maintain either of the following means:
engine rpm during calibration. This is normal.
• The ECM monitors the signal from a vehicle speed
Expected Result: sensor in pulses per kilometer (mile). The vehicle
speed sensor is connected to the ECM vehicle
The magnetic transducer was disconnected before speed input circuit (terminals 32 and 33). This is
exiting the timing calibration screen on Cat ET. the “Vehicle Speed Calibration” option.
Results: • The ECM receives a J1939 Datalink Broadcast

Message from the Transmission ECU that indicates
• OK – STOP. revolutions per kilometer (mile) of the transmission
output shaft. This option is only available with
• Not OK – If the magnetic transducer is still installed SEP00 and newer software. This is the “Vehicle
after exiting the timing calibration screen on Cat ET, Speed Cal (J1939-Trans)” option.
vehicle speed diagnostic codes may be generated.
Each of these methods require a specific calibration
Repair: If vehicle speed diagnostic codes are number to be programmed into the ECM to calculate
generated, the vehicle speed diagnostic codes vehicle speed. For the “Vehicle Speed Calibration”
should be cleared. option that uses the vehicle speed sensor, the ECM
must know the number of pulses that are produced by
STOP. the vehicle speed sensor during each kilometer (mile)
of travel by the vehicle. In order to find the number
of pulses that are produced by the sensor, multiply
i01642395 the tire size by the axle ratio. Multiply the number
Vehicle Speed Circuit - that was obtained in the previous calculation by the
number of teeth on the output shaft that is used by the
Calibrate sensor to obtain the pulses. For the “Vehicle Speed
Cal (J1939-Trans)” option, the ECM must know the
SMCS Code: 7463-524 number of times that the output shaft revolves per
kilometer (mile) of travel by the vehicle. This can be
System Operation Description: calculated by one of the following methods:
The ECM uses vehicle speed information for the • Divide the pulses per kilometer (mile) of the sensor
following features: on the transmission output shaft by the number of
teeth on the transmission output shaft.
• Cruise control
• Multiply the axle ratio by the number of revolutions
• Fast idle control per kilometer (mile) of the tire.
• Idle speed control The ECM calculates vehicle speed by converting the
vehicle speed signal to kilometers per hour (km/h)
• PTO operation or miles per hour (mph). The conversion factor is
customer programmable and the conversion factor is
• Vehicle speed limiting stored in pulses per km (PPKM) or pulses per mile
(PPM).
• Speedometer
• Progressive shift
404 RENR1367-11
The tire revolution variable could be affected by Test Step 2. Calculate the Revolutions
changing from bias ply tires to radial tires, and Per Kilometer (Mile) of the Transmission
vice versa. Also, changing to low profile radial Output Shaft
tires could affect the tire revolution variable. This
result may change the actual vehicle speed which A. The correct revolutions per kilometer (mile) of
could result in performance complaints or fuel the transmission output shaft must be entered
consumption complaints. If the tire configuration has for the “Vehicle Speed Cal J1939-Trans” setting.
been changed, determine the new tire revolution If this value is unknown, either of the following
variable. Enter the new value in pulses per km calculations can be used to obtain the correct
(PPKM) or pulses per mile (PPM). The preferred setting:
method is obtaining the data from the individual tire
manufacturers for the specific tire that is being used. • Divide the pulses per kilometer (mile) of the
sensor on the transmission output shaft by the
Note: The ECM speedometer signal is set to 18,600 number of teeth on the transmission output
pulses per km (PPKM) or 30,000 pulses per mile shaft.
(PPM). For “GM Truck Manufacturer” configurations
with SEP00 or newer software, the output of the • Multiply the axle ratio by the number of
speedometer is set to 2,485 PPKM (4,000 ppm). This revolutions per kilometer (mile) of the tire.
setting cannot be changed. All speedometers that
are driven by the ECM output (J1/P1 terminal 36 and B. Program the calculated value into the ECM.
terminal 37) must match the fixed output of the ECM
for proper operation. Expected Result:
Test Step 1. Determine if the ECM The value is within the valid range of the ECM.
Receives the Vehicle Speed Input
from the “Vehicle Speed Calibration” Results:
Option or from the “Vehicle Speed Cal
(J1939-Trans)” Option. • Yes – Once the value is entered, verify that the
ECM is accurately measuring vehicle speed.
A. Connect Caterpillar Electronic Technician (ET) to Proceed to Test Step 4.
the cab data link connector. If the software for the
ECM is older than SEP00, proceed to Test Step 3. • No – Recalculate the value and re-enter the
correct value into the ECM. STOP.
B. If SEP00 or newer software is used in the ECM,
access the “Configuration Parameter List”. View Test Step 3. Calculating Pulses Per
the “Vehicle Speed Input” parameter. Determine if Kilometer (Mile) When all the Variables
the vehicle is configured to use the “Vehicle Speed are Known.
Calibration” option, “J1/P1:32&33” or the “Vehicle
Speed Cal (J1939-Trans)” option. A. Calculate pulses per kilometer (PPKM) or pulses
per mile (PPM).
Expected Result:
PPKM = K × Ra × N.
The ECM is using software that is dated prior to
SEP00 or the ECM is configured to use the “Vehicle PPM = M × Ra × N.
Speed Calibration” option.
K – This symbol represents the tire revolutions
Results: per kilometer. This is a constant that is divided by
the tire static loaded radius.
M – This symbol represents the tire revolutions
• No – The ECM is configured to use the “Vehicle per mile. This is a constant that is divided by the
Speed Cal (J1939-Trans)” option. Proceed to Test tire static loaded radius.
Step 2.
Ra – This symbol represents the rear axle ratio.
The rear axle ratio can typically be found on the
housing of the rear axle, or the rear axle ratio can
typically be found on the specification sheet for
the vehicle.
RENR1367-11 405
N – This symbol represents the number of

chopper teeth on the transmission drive shaft.
The magnetic pickup sensor is mounted here.
The number of chopper teeth is usually 16. Some
transmissions have 11 tooth chopper wheels.
B. Use ET to enter pulses per km (PPKM) or pulses

per mile (PPM) into the ECM.
Expected Result:
This value is within the valid range of the ECM.
Results:
• OK – Once the value is entered, verify that the

ECM is accurately measuring vehicle speed.
• Not OK – Recalculate the value and re-enter the

correct value into the ECM. STOP.
Test Step 4. Inspect the Speedometer

Calibration.
Determine the speedometer’s vehicle speed
calibration setting. You may be required to contact
the OEM dealer or you may be required to send the
vehicle to the OEM dealer for this information.
Expected Result:
The speedometer must be calibrated to one of the

following values:
• For “Other Truck Manufacturer” configurations,

the value is 18,600 pulses per kilometer (30,000
pulses per mile).
• For “GM Truck Manufacturer” configurations that

have SEP00 or newer software, the value is 2,485
pulses per kilometers (4,000 pulses per mile).
The ECM can only provide the signal that is listed

above.
Results:
• OK – The speedometer is correctly calibrated.

STOP.
• Not OK
procedure:
Send the vehicle to the OEM dealer or reprogram

the OEM speedometer to the correct setting for the
pulses per kilometer (mile).
STOP.
406 RENR1367-11
Index Section
Index
Numerics 0111-01 Low Coolant Level Warning (62)............. 114
0111-02 Coolant Level signal invalid (12) ............. 115
0001-11 Cylinder #1 Injector current fault (72) ...... 92 0111-03 Coolant Level voltage high (12) .............. 115
0002-11 Cylinder #2 Injector current fault (72) ...... 92 0111-04 Coolant Level voltage low (12) ............... 116
0003-11 Cylinder #3 Injector current fault (73) ...... 93 0111-11 Very Low Coolant Level (62) ................... 116
0004-11 Cylinder #4 Injector current fault (73) ...... 93 0128-03 Secondary Fuel Level voltage high ........ 117
0005-11 Cylinder #5 Injector current fault (74) ...... 93 0128-04 Secondary Fuel Level voltage low.......... 117
0006-11 Cylinder #6 Injector current fault (74) ...... 94 0164-00 Excessive Injection Actuation Pressure
0022-11 Primary to Secondary Engine Speed Signal (17) ..................................................................... 118
Calibration (42) .................................................... 94 0164-02 Injection Actuation Pressure Signal Erratic
0022-13 Engine Speed Signal Calibration Not (15) ..................................................................... 118
Performed (42)..................................................... 95 0164-03 Injection Actuation Pressure voltage high
0030-08 PTO Throttle signal invalid (29)............... 95 (15) ..................................................................... 118
0030-13 PTO Throttle out of calibration (29) ......... 96 0164-04 Injection Actuation Pressure voltage low
0041-03 8 Volt Supply voltage high (21)................ 96 (15) ..................................................................... 119
0041-04 8 Volt Supply voltage low (21) ................. 96 0164-11 Injection Actuation Pressure system fault
0042-11 Injection Actuation Pressure output fault.. 97 (39) ..................................................................... 119
0043-02 Key Switch Fault (71) .............................. 97 0168-02 ECM Battery Power Intermittent (51) .... 120
0064-02 Secondary Engine Speed loss of signal 0186-14 PTO Engine Shutdown Switch Occurrence
(34) ...................................................................... 97 (47) .................................................................... 120
0064-11 Secondary Engine Speed no pattern 0190-00 Engine Overspeed Warning (35) ........... 120
(34) ...................................................................... 98 0190-02 Primary Engine Speed Loss of Signal
0070-05 Inlet Air Heater current low...................... 98 (34) .................................................................... 121
0070-06 Inlet Air Heater current high .................... 99 0190-11 Primary Engine Speed no pattern (34) .. 121
0071-00 Idle Shutdown Override (01) ................... 99 0224-11 Theft Deterrent Active (00) .................... 121
0071-01 Idle Shutdown (47) ................................ 100 0224-14 Theft Deterrent Active with Engine Cranking
0071-14 PTO Shutdown (47)............................... 100 (00) .................................................................... 122
0084-00 Vehicle Overspeed Warning (41) .......... 100 0231-02 J1939 Data Incorrect (58)...................... 122
0084-01 Vehicle Speed loss of signal (31) .......... 101 0231-11 J1939 Data Link Fault (58) .................... 123
0084-02 Vehicle Speed signal invalid (36) .......... 101 0231-12 J1939 Device Not Responding.............. 123
0084-08 Vehicle Speed signal out of range (36).. 102 0232-03 5 Volt Supply voltage high (21).............. 123
0084-10 Vehicle Speed signal rate of change 0232-04 5 Volt Supply voltage low (21) ............... 124
(36) .................................................................... 102 0246-11 Brake Pedal Switch #1 Fault ................. 124
0091-08 Throttle Position Invalid (32).................. 102 0247-11 Brake Pedal Switch #2 Fault ................. 125
0091-13 Throttle Position out of calibration (28).. 103 0252-11 Engine Software Incorrect (59).............. 125
0096-03 Fuel Level voltage high ......................... 103 0253-02 Check Customer or System Parameters
0096-04 Fuel Level voltage low........................... 104 (56) .................................................................... 125
0100-03 Oil Pressure voltage high (24)............... 104 0253-14 Truck Manufacturer Parameter Not
0100-04 Oil Pressure voltage low (24) ................ 104 Programed ......................................................... 126
0100-11 Very Low Oil Pressure (46).................... 105 5 Volt Engine Pressure Sensor Supply Circuit -
0102-03 Boost Pressure voltage high (25) .......... 108 Test .................................................................... 127
0102-04 Boost Pressure voltage low (25) ........... 108
0102-07 Boost Pressure not responding ............. 108
0105-00 High Intake Manifold Air Temperature A
Warning (64) ...................................................... 109
0105-03 Intake Manifold Air Temperature voltage Accelerator Pedal (Throttle) Position Sensor Circuit -
high (38).............................................................. 110 Test .................................................................... 132
0105-04 Intake Manifold Air Temperature voltage low Air Inlet Heater Circuit - Test................................ 139
(38) ..................................................................... 110 ATA (SAE J1587 / J1708) Data Link Circuit -
0105-11 Very High Intake Manifold Air Temperature Test .................................................................... 146
(64) ..................................................................... 110
0108-03 Barometric Pressure voltage high (26)... 112
0108-04 Barometric Pressure voltage low (26) .... 113 C
0110-00 High Coolant Temperature Warning
(61) ..................................................................... 113 Calibration Procedures ........................................ 401
0110-03 Coolant Temperature voltage high (27) .. 113 Can Not Reach Top Engine RPM .......................... 59
0110-04 Coolant Temperature voltage low (27).... 114 Probable Causes ............................................... 59
0110-11 Very High Coolant Temperature (61) ...... 114 Recommended Actions...................................... 59
RENR1367-11 407
Index Section
Can Not Reach Vehicle Speed Limit ..................... 60 E

Probable Causes ............................................... 60
Recommended Actions...................................... 60 ECM Date/Time Stamped Information................... 19
Change Oil Lamp Circuit - Test............................ 153 Diagnostic Clock ................................................ 20
Check Engine Lamp Circuit - Test ....................... 156 ECM Date/Time Clock ....................................... 19
Check Engine Lamp or Warning Lamp Is Total Time .......................................................... 20
Malfunctioning...................................................... 62 ECM Memory - Test............................................. 216
Check Engine Lamp........................................... 62 ECM Snapshot ...................................................... 20
Cruise Control Set/Resume Switch.................... 63 Snapshot That is Triggered by a Diagnostic
Intermittent Diagnostic Codes............................ 62 Code................................................................. 20
Probable Causes ............................................... 62 Snapshot That is Triggered by a Quick Stop ..... 21
Recommended Actions...................................... 62 Snapshot That is Triggered by the Operator...... 20
Service Engine Soon Lamp (GM) ...................... 63 Use of Snapshot Data........................................ 21
Short in Vehicle Harness.................................... 63 ECM Will Not Accept Factory Passwords.............. 69
Warning Lamp.................................................... 62 Probable Causes ............................................... 69
Clutch Pedal Position Switch Circuit - Test.......... 159 Recommended Actions...................................... 69
Coolant Level Sensor Circuit - Test ..................... 171 Electrical Connectors - Inspect............................ 219
Cooling Fan Circuit and A/C Compressor Clutch Electronic Service Tool Will Not Communicate with
Circuit - Test....................................................... 179 ECM..................................................................... 69
Cooling Fan Circuit and A/C High Pressure Switch Probable Causes ............................................... 69
Circuit - Test....................................................... 187 Recommended Actions...................................... 69
Cruise Control Parameters .................................... 34 Electronic Service Tools ........................................ 12
“Cruise/Idle/PTO Switch Configuration” ............. 35 Caterpillar Electronic Technician (ET)................ 13
“Engine Brake Mode” ......................................... 35 Optional Service Tools ....................................... 13
“High Cruise Control Speed Set Limit”............... 34 Required Service Tools ...................................... 13
“Low Cruise Control Speed Set Limit”................ 34 Electronic Troubleshooting ...................................... 5
“Soft Cruise Control” .......................................... 35 Elevated Idle.......................................................... 70
Cruise Control Switch Circuit - Test ..................... 202 Conditions .......................................................... 70
Cruise Control, Idle, or PTO Can Not Be Set ........ 63 Probable Causes ............................................... 70
Probable Causes ............................................... 63 Engine Cranks but Will Not Start ........................... 71
Recommended Actions...................................... 64 Check Communications ..................................... 72
Customer Passwords ............................................ 19 Combustion Problem ......................................... 74
Customer Specified Parameters............................ 25 ECM ................................................................... 73
Customer Parameter Lockout ............................ 25 ECM Power Supply............................................ 72
Customer Specified Parameters Table .................. 26 Engine Oil Pressure ........................................... 71
Customer Specified Parameters Worksheet ......... 31 Engine Protection Devices................................. 72
Current Totals Worksheet .................................. 34 Engine Software................................................. 74
Engine Speed/Timing Signal.............................. 73
Fuel Supply ........................................................ 74
D Hydraulic Electronic Unit Injectors ..................... 73
Ignition Key Switch............................................. 71
Data Link Parameters............................................ 35 Injection Actuation Pressure System ................. 74
Dedicated PTO Parameters .................................. 36 Personality Module ............................................ 73
“Maximum PTO Enable Speed” ......................... 38 Probable Causes ............................................... 71
“PTO Activates Cooling Fan” ............................. 38 Recommended Actions...................................... 71
“PTO Active Output ”.......................................... 39 Theft Deterrent................................................... 74
“PTO Cab Throttle RPM Limit”........................... 37 Engine Has Early Wear ......................................... 74
“PTO Configuration”........................................... 36 Probable Causes ............................................... 74
“PTO Engine RPM Set Speed” .......................... 36 Recommended Repairs ..................................... 74
“PTO Engine RPM Set Speed Input A”.............. 37 Engine Misfires, Runs Rough or Is Unstable......... 75
“PTO Engine RPM Set Speed Input B”.............. 37 Accelerator Pedal Position Sensor .................... 76
“PTO Kickout Vehicle Speed Limit ”................... 38 Camshaft Position Sensor ................................. 76
“PTO Shutdown Time” ....................................... 38 Fuel Supply ........................................................ 75
“PTO to Set Speed” ........................................... 37 Individual Cylinder Malfunction .......................... 75
“PTO Top Engine Limit”...................................... 36 Low Injection Actuation Pressure....................... 75
“Torque Limit” ..................................................... 38 Power Train Data Link ....................................... 76
Diagnostic Codes .................................................. 90 Probable Causes ............................................... 75
Diagnostic Functional Tests................................. 127 Recommended Repairs ..................................... 75
Driver Questionnaire.............................................. 67 Valve Lash ......................................................... 76
Driver Questionnaire Response ............................ 68 Engine Monitoring Parameters .............................. 42
Engine Pressure Sensor Open or Short Circuit -
Test .................................................................... 224
Engine Running Output Circuit - Test .................. 231
408 RENR1367-11
Index Section
Engine Speed/Timing Sensor - Calibrate ............ 401 Intermittent Cruise Control, Idle, or PTO Kickout .. 80
Engine Speed/Timing Sensor Circuit - Test ......... 234 Probable Causes ............................................... 80
Engine Temperature Sensor Open or Short Circuit - Recommended Actions...................................... 80
Test .................................................................... 239 Intermittent Engine Shutdown ............................... 82
Engine Vibration .................................................... 76 Aftermarket Engine Protection Devices ............. 83
Probable Causes ............................................... 76 Battery Power or Ground ................................... 82
Recommended Actions...................................... 76 Diagnostic Codes............................................... 82
Engine Will Not Crank ........................................... 77 ECM or Personality Module ............................... 83
Probable Causes ............................................... 77 Engine Speed/Timing Sensors .......................... 83
Recommended Actions...................................... 77 Fuel Supply ........................................................ 83
Engine/Gear Parameters....................................... 39 Low Injection Actuation Pressure....................... 83
Excessive Black Smoke ........................................ 77 Probable Causes ............................................... 82
Air Inlet System or Exhaust System................... 78 Recommended Actions...................................... 82
ECM or Personality Module ............................... 78 Intermittent Low Power or Power Cutout............... 83
Electronic System .............................................. 78 Accelerator Pedal Position Sensor .................... 84
Hydraulic Electronic Unit Injector ....................... 78 Battery Power or Ground to the ECM ................ 84
Probable Causes ............................................... 77 Electrical Connectors ......................................... 84
Recommended Actions...................................... 78 Electronic System .............................................. 84
Valve Lash ......................................................... 78 Engine Monitoring .............................................. 84
Excessive Valve Lash............................................ 78 Fuel Supply ........................................................ 85
Probable Causes ............................................... 78 Low Injection Actuation Pressure....................... 85
Recommended Actions...................................... 78 Power Train Data Link ....................................... 85
Excessive White Smoke ........................................ 79 Probable Causes ............................................... 83
Probable Causes ............................................... 79 Recommended Actions...................................... 83
Recommended Actions...................................... 79 Torque Limit Switch............................................ 85
Exhaust Brake Circuit - Test ................................ 245 Vehicle Speed Signal ......................................... 84
Exhaust Particulate Filter Circuit - Test................ 251
L
F
Low Power/Poor or No Response to Throttle ........ 85
Factory Passwords ................................................ 21 Probable Causes ............................................... 85
Factory Passwords Worksheet.............................. 22 Recommended Actions...................................... 86
Fast Idle Enable Circuit - Test.............................. 253
Fast Idle Lamp Circuit - Test................................ 257
Flash Programming ............................................... 22 M
Programming a Flash File.................................. 23
Fuel Level Sensor Circuit - Test........................... 260 Maintenance Parameters ...................................... 48
I N
Idle Parameters ..................................................... 43 Neutral Switch Circuit - Test ................................ 304

“Fast Idle RPM 1”............................................... 44
“Fast Idle RPM 2”............................................... 44
“Idle RPM Limit” ................................................. 43 O
“Idle Vehicle Speed Limit” .................................. 43
“Idle/PTO Bump RPM” ....................................... 44 Output Selections .................................................. 49
“Idle/PTO RPM Ramp Rate” .............................. 43
Idle Shutdown Timer - Test .................................. 264
Ignition Key Switch Circuit and Battery Supply Circuit P
- Test .................................................................. 267
Ignore Brake/Clutch Switch Circuit - Test ............ 273 Passwords ............................................................. 51
Important Safety Information ................................... 2 Customer Passwords......................................... 51
Injection Actuation Pressure - Test ...................... 277
Injection Actuation Pressure Control Valve Circuit -
Test .................................................................... 282
Injection Actuation Pressure Sensor - Test.......... 287
Injector Solenoid Circuit - Test............................. 290
Input Selection Switch Circuit - Test .................... 298
Input Selections ..................................................... 44
RENR1367-11 409
Index Section
Poor Acceleration or Response............................. 87 T

Cold Mode Operation......................................... 88
Combustion Problem ......................................... 89 Table of Contents..................................................... 3
Customer Specified Parameters ........................ 88 Tachometer Circuit - Test..................................... 377
ECM or Personality Module ............................... 89 Timer Parameters .................................................. 52
Electronic System .............................................. 88 Transmission (AT/MT/HT) Relay Circuit - Test .... 381
Individual Cylinder Malfunction .......................... 88 Trip Parameters ..................................................... 53
Injection Actuation Pressure System ................. 89 Troubleshooting Section.......................................... 5
Power Train Data Link ....................................... 89 Troubleshooting with a Diagnostic Code ............... 90
Probable Causes ............................................... 87 Troubleshooting without a Diagnostic Code .......... 59
Recommended Actions...................................... 88 Truck Manufacture Parameters ............................. 54
Theft Deterrent................................................... 89 “Truck Manufacturer” ......................................... 54
Torque Limit Switch............................................ 89 “Truck Model Type” ............................................ 54
Powertrain Data Link Circuit - Test ...................... 316
Programming Parameters ..................................... 19
PTO Engine Shutdown Switch Circuit - Test ....... 324 V
PTO Shutdown Timer - Test ................................ 328
PTO Switch Circuit - Test..................................... 330 Vehicle Speed and Speedometer Circuit - Test ... 384
PTO Switch ON Lamp Circuit - Test .................... 339 Vehicle Speed Circuit - Calibrate......................... 403
Vehicle Speed Parameters .................................... 55
“High Speed Range Axle Ratio”......................... 57
R “Low Speed Range Axle Ratio”.......................... 56
“Soft Vehicle Speed Limit”.................................. 56
Remote PTO Accelerator Position Sensor Circuit - “Tachometer Calibration”.................................... 56
Test .................................................................... 343 “Vehicle Speed Cal (J1939 ABS)”...................... 55
Replacing the ECM................................................ 15 “Vehicle Speed Cal (J1939-Trans)”.................... 55
“Vehicle Speed Calibration” ............................... 55
“Vehicle Speed Limit (VSL)”............................... 56
S “VSL Protection”................................................. 56
Selected Engine Rating ......................................... 51

ECM Identification Parameters .......................... 51 W
“Rating Number” ................................................ 51
Sensors and Electrical Connectors ....................... 16 Wait To Start Lamp Circuit - Test ......................... 393
Service Brake Pedal Position (Switch 1) Circuit - Warning Lamp Circuit - Test ................................ 397
Test .................................................................... 350
Service Brake Pedal Position (Switch 2) Circuit -
Test .................................................................... 362
Service Information Report.................................... 23
Recommendations ............................................. 23
Smart Idle Parameters........................................... 51
Starting Aid Output Circuit - Test ......................... 374
System Configuration Parameters......................... 58
“Engine Serial Number” ..................................... 58
“Full Load Setting”.............................................. 58
“Full Torque Setting”........................................... 58
Interlock Code.................................................... 58
“Personality Module Release Date” ................... 58
System Overview..................................................... 5
ECM Lifetime Totals ........................................... 10
Effect Of Diagnostic Codes on Engine
Performance....................................................... 9
Engine Monitoring ................................................ 7
Engine Snapshot Data ......................................... 9
Other Functions of the Engine Monitoring
System ............................................................... 9
Other Information That is Stored in the ECM
Memory ............................................................ 10
Passwords ......................................................... 12
Programmable Parameters................................ 12
Self-Diagnostics ................................................... 9
System Operation ................................................ 5
410 RENR1367-11
Index Section
RENR1367-11 411
Index Section
©2005 Caterpillar
All Rights Reserved Printed in U.S.A.

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RENR1367-11

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Excessive Black Smoke ........................................

Troubleshooting Section An accelerator pedal position sensor is used to

Cold mode is activated when the sum of coolant • Coolant temperature

• The service brake is depressed. Functions of the Engine Monitoring

• The automatic transmission is placed in gear. “OFF” Mode

This option is not applicable for OCT01 ECM

If the engine monitoring system is programmed to

An engine derate is provided in order to protect the

If the system is programmed to “SHUTDOWN”, the

The “SHUTDOWN” mode begins when any of the

• “Very high coolant temperature” Engine Snapshot Data

Maintenance Indicator Data Messenger provides the ability to enter an ID code

When the Caterpillar FIS downloads the information, Passwords

• Obtain retrieval. Table 2

1U-5804 Crimp Tool (12−AWG TO 18−AWG) 125-3662 Cable As (SENSOR BYPASS)

1U-5805 Wire Removal Tool 157-4829 Cable Adapter

151-6320 Wire Removal Tool 7X-1403 Adapter Cable As

167-9225 Harness (SERVICE TOOL 7X-1686 Cable Adapter

Service Tools for the Use of Cat ET

3. Connect cable (4) between the “DATA LINK” end

A test ECM can be used to determine if the ECM is NOTICE

c. Remove the fuel lines (if equipped) from the i02293867

b. Use Cat ET to match the engine application

c. If the “Copy Configuration” process from

d. If the “Copy Configuration” process from Step

e. Program the engine monitoring system, if

f. Calibrate the engine speed/timing if there is

Programming Parameters 3. Obtain the factory passwords. The information

Customer Specified Parameters – Customer i02306136

System Configuration Parameters – System ECM Date/Time Clock

• 84-00 Vehicle Overspeed Warning

2. When the “Factory Password” screen appears,

Before adjusting the ECM Date/Time Clock, ask i02305595

Use of Snapshot Data

• Program a new Electronic Control Module (ECM). i02170328

When an ECM is replaced, the system Factory Passwords Worksheet

• Read customer passwords. Engine’s Miles (km)

Since factory passwords contain alphabetic

Caterpillar Electronic Technician (ET) is used to flash i02278907

b. Press the “Browse” button in order to select the Cause of Failure

• The wiring harness was repaired.

• The Full Load Setting (FLS) was changed per the

Customer Specified If a lockable parameter is not locked out, factory

Parameters A locked out parameter also provides an audit trail.

Customer Specified Parameters allow the vehicle • Time of change

When an attempt to change a locked out parameter

Factory passwords are also required to change a

Customer Specified Parameter Table

Customer Specified Truck Manufacturer Parameters

Parameters Worksheet Truck Manufacturer

ECM Identification Parameters

Cruise/Idle/PTO Switch Engine/Gear Parameters

Fast Idle RPM (2) Top Engine Limit (TEL)

Warm Up Mode Idle Speed Ignore Brake/Clutch Switch