DIAGRAMA 3406E

SENR5574-04 January 1999

Engine Sensor Open or Short Circuit Test Connect Electronic Service Tool to Cab Data Link and check for ACTIVE Engine Sensor Open or Short Circuit Code. If the code is not ACTIVE and the Engine is not running properly, refer to Troubleshooting Without A Diagnostic Code. ACTIVE Open or Short Circuit Code

NOT OK

Check Electrical Connectors and Wiring.

ACTIVE Open Circuit Code

ACTIVE Short Circuit Code With the ignition key OFF, disconnect the Sensor Connector with the ACTIVE Short Circuit Code. Does the Short Circuit Code remain Active? Code Changes To Open Circuit

Refer to PB-10

Short Circuit Code Remains

If a Short Circuit code was Active before the sensor was disconnected, but an Open Circuit code became Active after the sensor was disconnected then thoroughly inspect the connector for moisture. Inspect the seals and connect the sensor. If the code reappears, the sensor or pigtail harness is the problem. Temporarily replace the sensor (connect sensor to harness but do not install into engine) and ensure the code is no longer Active. If the code disappears with a new sensor, replace the old sensor. STOP.

Measure the Sensor Supply Voltage with a Voltmeter. Reading should be within the range of 4.5 VDC to 5.5 VDC.

NOT OK Refer to PC-34

OK Install a short circuit between pin-C and pin-B of the sensor harness connector and check for an ACTIVE Short Circuit Diagnostic Code. Does the Open Circuit Code remain Active? Open Circuit Code Active with Jumper

Short Circuit Code Active with Jumper

If a Short Circuit Code appears, temporarily connect the suspect sensor. If the Open Circuit code returns Active, replace the sensor and verify the diagnostic code does not return.

Disconnect the ECM Connector J2/P2 and check for Active Diagnostic Codes. The Open Circuit Diagnostic Code should be Active without the harness connected. Install a jumper between the Sensor signal pin and pin-30 (Sensor Common). A Short Circuit Code should be Active with the jumper in place. OK

Restart Test

NOT OK

NOT OK If the Open Circuit Diagnostic Code is not active without the harness connected, or the Short Circuit Diagnostic Code does not appear with the short circuit in place, temporarily install another ECM. Repeat this test step. If the problem is resolved with the new ECM, verify the problem returns with the old ECM. If the new ECM works and the one on the engine did not, replace the ECM. STOP.

Install Sensor Bypass Wiring. Disconnect J2/P2 and remove the sensor signal wire from P2. Install a 125-3662 3-Pin Engine Sensor Harness Bypass, or make a bypass and route the bypass wire directly from the ECM Connector P2 to the Sensor.

OK

Repair or Replace Harness

5EK1-UP 9CK1-UP 1YN1-UP 2PN1-UP 6TS1-UP

Diagnostic Code Listing Code 1-11 2-11 3-11 4-11 5-11 6-11 22-13 26-05 26-06 30-08 30-13 40-05 40-06 41-03 41-04 51-05 51-06 71-00 71-01 71-14 84-00 84-01 84-02 84-08 84-10 84-14 91-08 91-13 100-01 100-03 100-04 100-11 102-00 102-03 102-04 102-13 105-00 105-03 105-04 105-11 108-03 108-04 110-00 110-03 110-04 110-11 111-01 111-02 111-11 121-05 121-06 122-05 122-06 168-02 171-03 171-04 171-11 174-00 174-03 174-04 190-00 190-02 228-03 231-11 232-03 232-04 244-02 249-11 252-11 253-02 253-11 254-12

Description

Flash Code

Troubleshooting Guide Procedure

Cylinder 1 Fault Cylinder 2 Fault Cylinder 3 Fault Cylinder 4 Fault Cylinder 5 Fault Cylinder 6 Fault Check Timing Sensor Calibration Multi-Function Output #1 Open Circuit Multi-Function Output #1 Short Circuit Invalid PTO Throttle Signal PTO Throttle Sensor Calibration Multi-Function Output #2 Open Circuit Mulit-Function Output #2 Short Circuit 8 Volt Supply Above Normal 8 Volt Supply Below Normal Multi-Function Output #3 Open Circuit Multi-Function Output #3 Short Circuit Idle Shutdown Override Idle Shutdown Occurrence PTO Shutdown Occurrence Vehicle Overspeed Warning Loss of Vehicle Speed Signal Invalid Vehicle Speed Signal Vehicle Speed Out of Range Vehicle Speed Rate of Change Quick Stop Occurrence Invalid Throttle Signal Throttle Sensor Calibration Low Oil Pressure Warning Oil Pressure Sensor Open Circuit Oil Pressure Sensor Short Circuit Very Low Oil Pressure Boost Pressure Reading Stuck High Boost Pressure Sensor Open Circuit Boost Pressure Sensor Short Circuit Boost Pressure Sensor Calibration High Intake Manifold Temp Warning Intake Manifold Temp Sensor Open Circuit Intake Manifold Temp Sensor Short Circuit Very High Intake Manifold Temp Atmospheric Pr Sensor Open Circuit Atmospheric Pr Sensor Short Circuit High Coolant Temperature Warning Coolant Temp Sensor Open Circuit Coolant Temp Sensor Short Circuit Very High Coolant Temperature Low Coolant Level Warning Coolant Level Sensor Fault Very Low Coolant Level Retarder Solenoid Lo/Hi Open Circuit Retarder Solenoid Lo/Hi Short Circuit Retarder Solenoid Med/Hi Open Circuit Retarder Solenoid Med/Hi Short Circuit Low or Intermittent Battery Outside Air Temp Sensor Open Circuit Outside Air Temp Sensor Short Circuit No Ambient Air Temperature Data High Fuel Temp Warning Fuel Temp Sensor Open Circuit Fuel Temp Sensor Short Circuit Engine Overspeed Warning Loss of Engine RPM Signal A/C High Pressure Sw Open Circuit J1939 Data Link Fault 5 Volt Supply Above Normal 5 Volt Supply Below Normal Event Recorder Data Lost J1922 Data Link Fault Incorrect Engine Software Check Customer or System Parameters Check Transmission Customer Parameters ECM Fault

72 72 73 73 74 74 42 69 69 29 29 66 66 21 21 67 67 01 47 47 41 31 36 36 36 00 32 28 46 24 24 46 25 25 25 42 64 38 38 64 26 26 61 27 27 61 62 12 62 14 14 14 14 51 00 00 00 65 13 13 35 34 19 58 21 21 02 58 59 56 56 53

PC-33 PC-33 PC-33 PC-33 PC-33 PC-33 PC-32 PB-25 PB-25 PB-12 PB-12 PB-25 PB-25 PB-12 PB-12 PB-25 PB-25 PB-21 PB-21 PB-21 PC-36 PB-14 PB-14 PB-14 PB-14 PB-36 PB-12 PB-12 PC-36 PC-35 PC-35 PC-36 PC-35 PC-35 PC-35 PC-37 PC-36 PC-35 PC-35 PC-36 PC-35 PC-35 PC-36 PC-35 PC-35 PC-36 PC-36 PB-17 PC-36 PB-20 PB-20 PB-20 PB-20 PB-11 PC-35 PC-35 PB-21 PC-36 PC-35 PC-35 PC-36 PC-31 PB-18 PB-24 PC-34 PC-34 PB-11 PB-24 PC-30 PC-30 PC-30 PC-30

©1999 Caterpillar All Rights Reserved

Cooling Fan Always ON Check the following on an Electronic Service Tool: 1. Cooling Fan Type Customer Parameter must be programmed to "On-Off" or "Three Speed Fan". If programmed to "None" the fan may always be ON. 2. For AUG96 and later Personality Modules, Multi-Function Output #4 Customer Parameter must be programmed to "Cooling Fan". If both of the above are correctly programmed, inspect ECM Connector J1/P1 for wire connected to pin-28. If no wire is present at pin-28 then the ECM is not used to control the Cooling Fan System. The problem is in the OEM Vehicle System. ECM is used to control the Cooling Fan System

Turn ignition key ON, engine OFF. Access the Cooling Fan Driver Special Test on an Electronic Service Tool. Make the test Active and Not Active while listening for the solenoid and/or relay to click as test status changes. Is clicking detected? NO Refer to PB-18

YES

1.

2. 3.

Check A/C Fan status parameter on Electronic Service Tool. If A/C Fan status indicates "DISABLED" then the ECM does not use and A/C High Pressure Switch to control the Cooling Fan System. If parameter indicates "OFF" at any time and the fan is still ON then the A/C High Pressure circuit is not the reason the Fan is ON. If parameter indicates "ACTIVE DIAG", "ON", or "COUNTING" the fan is ON because of the A/C High Pressure circuit. "OFF" at any time or "DISABLED"

"ACTIVE DIAG", "ON"Or "COUNTING" Refer to PB-18

Check for logged or active diagnostic codes as follows: 1. 110-00 High Coolant Temp Warning 2. 110-03 Coolant Temp Sensor Open 3. 110-04 Coolant Temp Sensor Shorted 4. 110-11 Very High Coolant Temp 5. 105-00 High Manifold Temp Warning 6. 105-11 Very High Manifold Temp For codes 110-03 and 110-04 refer to procedure PC-35. For codes 105-00, 105-11, 110-00 and 110-11 refer to procedure PC-36. No Listed Codes

The following conditions will turn Fan ON if engine speed < 2250 rpm: 1. Engine not running. 2. During engine cranking. 3. Coolant sensor temp > 205°F (96°C). 4. Coolant temp sensor diagnostic active. 5. Intake manifold air temp > 189°F (87°C). 6. Intake manifold air temp > 162°F (72°C) with boost pressure > 10 psi (70 kPa). 7. Retarder solenoid ON in high mode > 10 seconds. 8. A/C high pressure switch open or ECM counting. 9. A/C high pressure switch diagnostic active. 10. PTO On/Off switch in ON position. If no listed condition exists then check for an open circuit in the solenoid or ECM fan relay circuit. If problem can not be found refer to procedure PB-18.

Printed in U.S.A.

CYL NO.2

CYL NO.4

CYL NO.5

CYL NO.6

C A746-PK B 993-BR A 997-OR J3

GN YL OR P3

WH C A751-YL BK B 993-BR OR A 997-OR J23 P23

WH C C967-BU BK B 993-BR OR A 997-OR J21 P21

WH C 995-BU BK B 993-BR OR A 997-OR J10 P10

GN C 994-GY YL B 993-BR OR A 997-OR P17 J17

GN C A747-GY YL B 993-BR OR A 997-OR P22 J22

A 996-GN B 998-BR C 999-WH J9

OR BK WH P9

ENGINE RETR SOL CYL 1&2

ENGINE RETR SOL CYL 5&6

ENGINE RETR SOL CYL 3&4

29

23

19

13

7

35

1

37

36

5

39

4

38

A

Harness Side

3

2

1 2 J24 P24

C

40

6

34

28

22

18

12

B

Jack

Engine Harness ECM Connector

Plug

VOLTAGE SUPPLY WIRES COMMON WIRES INPUT SIGNAL WIRES OUTPUT SIGNALS WIRES

J5 P5 12 10 8 6 5 4 3 2 1 11 9 7

21 27 33 39

22 28 34 40

B

17

18

4

38

32

26

16

10

37

31

25

15

9

3

C

A

ECM Side

5 11

6 12

36

30

24

20

14

8

2

35

29

23

19

13

7

1

995-BU C967-BU A751-YL 993-BR 997-OR

996-GN 998-BR 999-WH A746-PK A747-GY 994-GY

5 17 27 34 28 22 18 12 6 13 19 7 40 39 4 10 16 35 11 32 26 38 1 29 37 23 20 8 15 14 2 3 30 36 21 31 25 9 24 33

P2 J2 D789-WH D790-OR D791-YL A706-GY A705-BU A704-GN A703-BR A702-PU A701-GY D786-BR D787-GN D788-BK D784-BU D810-PU D811-YL D785-GN

E971-GN

A/C HIGH PRESS. SW N/C

- 12V +

THROTTLE POSITION SENSOR

+8 V THROTTLE POSITION SENSOR COMMON

RD WH BK

C D A B

C997-OR C983-WH C984-YL C993-BR

J11 P11 C985-BU A C986-BR C B C993-BR

+5V COOL LEVEL NORMAL COOL LEVEL LOW SENSOR COMMON

COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED

ENG GND STUD

C988-BK

- 12V +

BATTERY 3 BATTERY 2 BATTERY 1

- 12V +

STARTER MOTOR (12V)

E715-RD

COOLANT LEVEL SENSOR

GND

ALTERNATOR

G BAT MTR

S

C987-RD

ENGINE CYL HEAD

R

15

KEY SWITCH

B

OFF C ON ST S

N/O RELAY

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

ATA+ ATA-

+BAT. -BAT.

D784-BU D785-GN

LO MED HI LO MED HI

E717-GN

E716-GY

C978-BR C979-OR

TO J1922 DATA LINK CONNECTOR TO J1922 DATA LINK CONNECTOR

TO J1939 DATA LINK CONNECTOR TO J1939 DATA LINK CONNECTOR TO J1939 DATA LINK CONNECTOR

ENGINE RETARDER SOLENOID SELECTOR SW

C993-BR

ENGINE RETARDER SOLENOID ON/OFF SW

C993-BR

C977-BU

SET/RESUME

C993-BR (PEDAL RELEASED POSITION)

CLUTCH N/C

SERVICE BRAKE N/C C993-BR C992-PU (PEDAL RELEASED POSITION)

C975-WH

SIGNAL+ SIGNAL-

C974-PU

CRUISE ON/OFF C993-BR

PASSIVE MAGNETIC VEHICLE SPEED SENSOR

659-PK

D799-GN

C973-GN

TACHOMETER

SIGNAL+

SIGNAL-

WARNING LAMP

CHECK ENGINE LAMP

SPEEDOMETER

DASH DATA LINK

B793-YL B792-BU

C E D F A B

451-BR

450-YL

40

39

38

37

OEM INSTALLED

22 27 10 16 17 11 18 12 20 14 24 25 15 19 13 1 7 6 4 28 40 38 26 39 33 36 2 23 9 3 5 34 35 37 29 8 32 31 30 21

P1 J1

34

28

22

18

12

B

Jack

ECM

Plug

OEM Vehicle Harness ECM Connector

35

B

29 36

38

39

40

23 30

32

33

24 34

19

20 26

27

28

21

22

C

TO ECM MOUNTING BOLT

A

ECM Side

37

31

25

15

7

1

13

2

14

16

17

18

9

3

TO ECM MOUNTING BOLT

8

4 10

5 11

6 12

CHECK ENGINE LAMP WARNING LAMP SPEEDOMETERECM GND STRAP SPEEDOMETER+ TACHOMETER+ TACHOMETERVEHICLE SPEED IN+ VEHICLE SPEED INCRUISE CONT ON/OFF SW SERVICE BRAKE SW CLUTCH SW SET RESUME RETARDER SOLENOID LO/HI SW RETARDER SOLENOID MED/HI SW ATA DATA LINK- (J1587) ATA DATA LINK+ (J1587) +BATTERY UNSWITCHED +BATTERY MULTI-FUNCTION OUTPUT #4 (NOTE B) MULTI-FUNCTION OUTPUT #2 A/C HIGH PRESSURE SW J1939 DATA LINK SHIELD (NOTE K) J1939 DATA LINK- (NOTE K) J1939 DATA LINK+ (NOTE K) +5V COOLANT LEVEL NORMAL COOLANT LEVEL LOW J1922 DATA LINK+ J1922 DATA LINK-BATTERY MULTI-FUNCTION OUTPUT #3 +8V THROTTLE POSITION SENSOR COMMON MULTI-FUNCTION INPUT #1 MULTI-FUNCTION INPUT #2 MULTI-FUNCTION INPUT #3 MULTI-FUNCTION SENSOR COMMON MULTI-FUNCTION OUTPUT #1

C

6

5

4

3

A

ECM

ECM GND STRAP

VOLTAGE SUPPLY WIRES COMMON WIRES INPUT SIGNAL WIRES OUTPUT SIGNALS WIRES

OUTSIDE AIR TEMP

COOLANT TEMP INTAKE MANF AIR TEMP FUEL TEMP SENSOR COMMON +5V

+V ENG SP/TMG ENG SP/TMG COMMON ENG SP/TMG BOOST PRESSURE ATM PRESSURE OIL PRESSURE

INJECTOR COMMON 1 & 2 INJECTOR COMMON 3 & 4 INJECTOR COMMON 5 & 6 INJECTOR 6 INJECTOR 5 INJECTOR 4 INJECTOR 3 INJECTOR 2 INJECTOR 1 RETARDER SOLENOID MED/HI RETARDER SOLENOID LO/HI RETARDER SOLENOID COMMON VEHICLE SPEED OUT+ (NOTE A) TDC PROBE+/VEH SP IN+ (NOTE A) TDC PROBE-/VEH SP IN- (NOTE A) VEHICLE SPEED OUT - (NOTE A)

Harness Side

36

35

D799-GN 659-PK C973-GN C974-PU 450-YL 451-BR D784-BU D785-GN C975-WH C992-PU C977-BU C978-BR C979-OR E716-GY E717-GN B792-BU B793-YL C987-RD E715-RD D745-YL E718-PK E971-GN A249-BK K990-GN K900-YL C997-OR C983-WH C984-YL E721-PK E720-WH C988-BK E991-GY C985-BU C986-BR C993-BR K999-GN K980-PK K982-YL L901-GY K998-BU

29

23

19

13

7

2

1

3176B, C-10, C-12, & 3406E OEM Vehicle Harness Wiring Diagram

FUEL TEMP SENSOR COMMON +5V

INTAKE MANF AIR TEMP SENSOR

FUEL TEMP SENSOR

INTAKE MANF AIR TEMP SENSOR COMMON +5V

COOLANT TEMP SENSOR

OIL PRESSURE SENSOR COMMON +5V

ATM PRESSURE SENSOR COMMON +5V

BOOST PRESS. SENSOR COMMON +5V

+V ENG SP/TMG ENG SP/TMG COMMON ENG SP/TMG

CYL NO.3

COOLANT TEMP SENSOR COMMON +5V

OIL PRESSURE SENSOR

ATM PRESSURE SENSOR

BOOST PRESSURE SENSOR

SPEED/TIMING SENSOR

CYL NO.1

D789-WH D790-OR D791-YL A706-GY A705-BU A704-GN A703-BR A702-PU A701-GY D786-BR D787-GN D788-BK

3176B, C-10, C-12, & 3406E Engine Harness Wiring Diagram

ECM CKT BKR

Electronic Service Tool Will Not Communicate with the ECM

Does not crank, refer to PA-18 OK

Repair Service Tool OK

Repair Cables

NOT OK

Refer to PC-30

ATA DATA LINKATA DATA LINK+

+BATTERY - BATTERY

+ BATTERY

H J E D F C G A B P1 J1 1 7 6 5

-

Dashed in Area is Cable Shown Below ATA DATA LINK +

ATA DATA LINK Caterpillar Harness Bypass Service Tool P/N 129-2018

Caterpillar Service Tool "T" Cable P/N 8T5275 or 139-4166 Cable

- BATTERY - 12V +

Engine Cranks, But Will Not Start

Try to Start the Engine.

Does not start

Engine Starts, but ECM does not communicate with the Service Tool.

Connect Another Service Tool to the ECM, but use the same Service Tool Cables as in the previous step.

No Communications

Disconnect ECM Connector P1 from the ECM. Install a Caterpillar 129-2018 Harness Bypass. Connect the Bypass directly to the Electronic Service Tool Harness and ECM as shown below. No Communications

ECM and Service Tool Communicate

Either the vehicle wiring or another device on the vehicle is causing the communication problem. If ECM Serial Number ends in "CA", ensure the Personality Module Chip is completely snapped into the ECM socket.

Harness Bypass Diagram ECM ATA DATA LINK - (J1587) ATA DATA LINK + (J1587) +BATTERY - BATTERY

12V +

Connect Electronic Service Tool to Cab Data Link, turn ignition key ON, engine OFF. Attempt to access Truck Functions. ECM does not communicate

No Communications

Connect the Service Tool Using a completely different set of Service Tool Cables.

NOT OK

Refer to PC-30 NOT OK

Refer to PC-33 NOT OK

Refer to PC-31 NOT OK

Refer to PC-30

ECM Communicates

Ensure after-market engine protection devices (not installed by Caterpillar) are not active, preventing the ECM from receiving battery power. OK

NOT OK

Check ECM power and ground connections with the ignition key switch ON. Battery voltage at the ECM Refer Connector P1/J1 pin-6 +Battery to pin-5 to PB-11 -Battery should be 11.0 - 13.5 Volts DC. OK

If ECM Serial Number ends in "CA", ensure the Personality Module Chip is completely snapped into the ECM socket. OK

Ensure the Fuel Injector Connector (J5/P5) is fully connected and free of corrosion. OK

Observe engine rpm from Electronic Service Tool while cranking the engine. OK

If the Personality Module has been recently replaced/updated, connect and check for an active 252-11 Incorrect Engine Software. OK

If the Truck is equipped with a CAT ID, ensure Theft Deterrent is not Active. Turn the ignition key ON, engine OFF, the CAT ID will indicate Theft Deterrent Active. OK

Monitor the exhaust stack while cranking - if no smoke is present there may be a fuel supply or fuel quality problem. Check fuel pressure, fuel priming, and fuel filters. OK

Check for combustion problems, mechanical problems or extreme cold.