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J5 P5
D789-WH 12
D790-OR 10
D791-YL 8
A706-GY 6
A705-BU 5
A704-GN 4
A703-BR 3
A702-PU 2
A701-GY 1
D786-BR 11
D787-GN 9
ENGINE ENGINE ENGINE D788-BK 7
CYL CYL CYL CYL CYL CYL RETR RETR RETR
NO.1 NO.2 NO.3 NO.4 NO.5 NO.6 SOL CYL SOL CYL SOL CYL
1&2 5&6 3&4
VO
ATM PRESSURE GN C A747-GY CO
ATM PRESSURE SENSOR COMMON YL B 993-BR
SENSOR +5V OR A 997-OR IN
P22 J22
OU
35 36 37 3
Harness
INTAKE MANF INTAKE MANF AIR TEMP WH C C967-BU
AIR TEMP SENSOR COMMON BK B 993-BR
SENSOR OR 997-OR
ness Wiring Diagram
P2 J2
J5 P5
D789-WH 12 D789-WH 5 INJECTOR COMMON 1 & 2
D790-OR 10 D790-OR 17 INJECTOR COMMON 3 & 4
D791-YL 8 D791-YL 27 INJECTOR COMMON 5 & 6
A706-GY 6 A706-GY 34 INJECTOR 6
A705-BU 5 A705-BU 28 INJECTOR 5
A704-GN 4 A704-GN 22 INJECTOR 4
A703-BR 3 A703-BR 18 INJECTOR 3
A702-PU 2 A702-PU 12 INJECTOR 2
A701-GY 1 A701-GY 6 INJECTOR 1
D786-BR 11 D786-BR 13 RETARDER SOLENOID MED/HI
D787-GN 9 D787-GN 19 RETARDER SOLENOID LO/HI
D788-BK 7 D788-BK 7 RETARDER SOLENOID COMMON
D784-BU 40 VEHICLE SPEED OUT+ (NOTE A)
1 D810-PU 39 TDC PROBE+/VEH SP IN+ (NOTE A)
2 D811-YL 4 TDC PROBE-/VEH SP IN- (NOTE A)
J24 P24 D785-GN 10 VEHICLE SPEED OUT - (NOTE A)
16
35
11
32
26
38
996-GN 1 +V ENG SP/TMG
998-BR 29 ENG SP/TMG COMMON
999-WH 37 ENG SP/TMG
A746-PK 23 BOOST PRESSURE
A747-GY 20 ATM PRESSURE
994-GY 8 OIL PRESSURE
15
995-BU 14 COOLANT TEMP
C967-BU 2 INTAKE MANF AIR TEMP
A751-YL 3 FUEL TEMP
993-BR 30 SENSOR COMMON
997-OR 36 +5V
21
31
25
9 OUTSIDE AIR TEMP ECM GND STRAP
24
33 TO ECM
VOLTAGE SUPPLY WIRES ECM MOUNTING
BOLT
COMMON WIRES
INPUT SIGNAL WIRES
OUTPUT SIGNALS WIRES
1 2 3 4 5 6
6 5 4 3 2 1
7 12 12 11 10 9 8 7
13 18 18 17 16 15 14 13
19 22 22 21 20 19
23 28 28 27 26 25 24 23
29 34 34 33 32 31 30 29
40 39 38 37 36 35
35 36 37 38 39 40
Harness
INTAKE MANF INTAKE MANF AIR TEMP WH C C967-BU
AIR TEMP SENSOR COMMON BK B 993-BR
SENSOR +5V OR A 997-OR
J21 P21
A
FUEL TEMP WH C A751-YL
FUEL TEMP SENSOR COMMON BK B 993-BR
SENSOR +5V OR A 997-OR
J23 P23
SIG
OFF C SPEEDOMETER
15
B ON SIGN
ST S
C987-RD
R
TAC
KEY SWITCH
SENR5574-04
PASSIVE
MAGNETIC D784
VEHICLE SPEED D785
S G SENSOR
BAT MTR
6 Page, Color 2, JVD
ALTERNATOR CRUISE
STARTER
MOTOR C993-BR
GND (12V)
SERVICE B
C993-BR
(PEDAL RELEASED POSITION)
SET/R
C993-BR
E715-RD
LO
MED
C993-BR
HI
ENGINE RETARDER LO
SOLENOID MED
ON/OFF SW HI
ENGINE RE
SOLENOID
J11 P11
ENG GND STUD +8 V RD A C985-BU
THROTTLE POSITION WH C C986-BR
SENSOR COMMON BK B C993-BR
ENGINE
THROTTLE POSITION
CYL HEAD
SENSOR
-
+
40 39 38 37 36 35
35 36 37 38 39 40
A B B A
Jack Plug C
C
450-YL 1 2 3 4 5 6
SIGNAL+
TACHOMETER 6 5 4 3 2 1
SIGNAL- 451-BR
7 12 12 11 10 9 8 7
13 18 18 17 16 15 14 13
E 19 22 22 21 20 19
IC D784-BU
23 28 28 27 26 25 24 23
PEED D785-GN
R 29 34 34 33 32 31 30 29
40 39 38 37 36 35
35 36 37 38 39 40
CRUISE ON/OFF
Harness Side OEM Vehicle Harness ECM Side
C993-BR C975-WH ECM Connector
Jack Plug C
CLUTCH N/C C
C993-BR C977-BU
POSITION)
P1 J1 ECM
SET/RESUME
D799-GN 22 CHECK ENGINE LAMP
C993-BR C978-BR 659-PK 27 WARNING LAMP
C979-OR C973-GN 10 SPEEDOMETER-
C974-PU 16 SPEEDOMETER+ ECM GND STRAP
450-YL 17 TACHOMETER+
LO 451-BR 11 TACHOMETER-
E716-GY TO ECM
MED
D784-BU 18 VEHICLE SPEED IN+ MOUNTING
HI
D785-GN 12 VEHICLE SPEED IN- BOLT
R LO C975-WH 20 CRUISE CONT ON/OFF SW
D MED
E717-GN C992-PU 14 SERVICE BRAKE SW
W HI
C977-BU 24 CLUTCH SW
C978-BR 25 SET
ENGINE RETARDER
C979-OR 15 RESUME
SOLENOID SELECTOR SW
E716-GY 19 RETARDER SOLENOID LO/HI SW
E717-GN 13 RETARDER SOLENOID MED/HI SW
B792-BU 1 ATA DATA LINK- (J1587)
B793-YL 7 ATA DATA LINK+ (J1587)
C987-RD 6 +BATTERY
E715-RD 4 UNSWITCHED +BATTERY
D745-YL 28 MULTI-FUNCTION OUTPUT #4 (NOTE B)
E718-PK 40 MULTI-FUNCTION OUTPUT #2
E971-GN 38 A/C HIGH PRESSURE SW
LINK CONNECTOR A249-BK 26 J1939 DATA LINK SHIELD (NOTE K)
LINK CONNECTOR K990-GN 39 J1939 DATA LINK- (NOTE K)
LINK CONNECTOR K900-YL 33 J1939 DATA LINK+ (NOTE K)
C997-OR 36 +5V
C983-WH 2 COOLANT LEVEL NORMAL
C984-YL 23 COOLANT LEVEL LOW
LINK CONNECTOR E721-PK 9 J1922 DATA LINK+
LINK CONNECTOR E720-WH 3 J1922 DATA LINK-
C988-BK 5 -BATTERY
E991-GY 34 MULTI-FUNCTION OUTPUT #3
C985-BU 35 +8V
C986-BR 37 THROTTLE POSITION
C993-BR 29 SENSOR COMMON
K999-GN 8 MULTI-FUNCTION INPUT #1
K980-PK 32 MULTI-FUNCTION INPUT #2
K982-YL 31 MULTI-FUNCTION INPUT #3
L901-GY 30 MULTI-FUNCTION SENSOR COMMON
K998-BU 21 MULTI-FUNCTION OUTPUT #1
OEM
INSTALLED
Does not cr
refer to PA
Either th
device
the c
Ensure the Fuel Injector Connector (J5/P5)
NOT If ECM Serial Number ends in "CA", Refer is fully connected and free of corrosion.
OK ensure the Personality Module Chip is to
completely snapped into the ECM PC-33
Refer
to PC-30 socket. OK
NOT
Harness Bypass Diagram OK Observe engine rpm from Electronic
P1 J1 ECM Refer Service Tool while cranking the engine.
to
ATA DATA LINK- H 1 ATA DATA LINK - (J1587)
PC-31
ATA DATA LINK+ J 7 ATA DATA LINK + (J1587) OK
E 6 +BATTERY
NOT If the Personality Module has been
D 5 - BATTERY
OK
F recently replaced/updated, connect and
C Refer check for an active 252-11 Incorrect
G to Engine Software.
PC-30
+BATTERY A - 12V +
- BATTERY B OK
Dashed in Area is
Cable Shown Below
If the Truck is equipped with a CAT ID,
ensure Theft Deterrent is not Active.
ATA DATA LINK +
Turn the ignition key ON, engine OFF,
the CAT ID will indicate Theft Deterrent
Active.
ATA DATA LINK - OK
Caterpillar Harness Bypass Monitor the exhaust stack while
Service Tool P/N 129-2018 cranking - if no smoke is present there
Caterpillar may be a fuel supply or fuel quality
Service Tool "T" problem. Check fuel pressure, fuel
Cable P/N 8T5275 priming, and fuel filters.
or 139-4166 Cable
OK
- BATTERY
+ BATTERY - 12V + Check for combustion problems,
mechanical problems or extreme cold.
Electronic Service Tool Will Not Engine Cranks, But Will Not Start
Communicate with the ECM Connect Electronic Service Tool to Cab Data Link,
Does not crank, Does turn ignition key ON, engine OFF.
Try to Start the Engine. not start
refer to PA-18 Attempt to access Truck Functions.
Engine Starts, but ECM does not
communicate with the Service Tool. ECM Communicates
ECM does not communicate
OK
Connect Another Service Tool to the
Repair ECM, but use the same Service Tool
Service Ensure after-market engine protection
Cables as in the previous step.
Tool devices (not installed by Caterpillar)
No Communications are not active, preventing the ECM
OK Connect the Service Tool Using a from receiving battery power.
Repair completely different set of Service Tool
Cables Cables. OK
No Communications Check ECM power and ground
NOT
Disconnect ECM Connector P1 from OK connections with the ignition key switch
the ECM. Install a Caterpillar 129-2018 ON. Battery voltage at the ECM
Refer
Harness Bypass. Connect the Bypass to Connector P1/J1 pin-6 +Battery to pin-5
directly to the Electronic Service Tool -Battery should be 11.0 - 13.5 Volts DC.
PB-11
Harness and ECM as shown below.
OK
No Communications NOT
OK
If ECM Serial Number ends in "CA",
ECM and Service Tool
Communicate ensure the Personality Module Chip is
Refer completely snapped into the ECM
Either the vehicle wiring or another to
PC-30
socket.
device on the vehicle is causing
the communication problem. OK
NOT
OK Ensure the Fuel Injector Connector (J5/P5)
NOT If ECM Serial Number ends in "CA", Refer is fully connected and free of corrosion.
OK ensure the Personality Module Chip is to
completely snapped into the ECM PC-33
Refer
socket. OK
Engine Sensor Open or Short C
Connect Electronic Service Tool to Cab Data L
and check for ACTIVE Engine Sensor Open
Short Circuit Code. If the code is not ACTIVE
the Engine is not running properly, refer to
Troubleshooting Without A Diagnostic Code
ACTIVE
Open or Short
Circuit Code
Check Electrical Connectors and Wiring.
ACTIVE Short
Circuit Code
With the ignition key OFF, disconnect the Measure the Senso
Sensor Connector with the ACTIVE Short a Voltmeter. Read
Circuit Code. Does the Short Circuit the range of 4.5
Code remain Active?
Short
Code NOT
d Wiring. OK
Refer to PB-10
ACTIVE Open
Circuit Code
Circuit Code
e with Jumper
Short Circuit Code
Active with Jumper On-highway Engine
If a Short Circuit Code appears,
SENR5574-04 Diagnostic Code Listing
January 1999 Flash Troubleshooting Check the fo
Code Description Code Guide Procedure 1. Cooling Fa
1-11 Cylinder 1 Fault 72 PC-33 programme
2-11 Cylinder 2 Fault 72 PC-33 If programm
3-11 Cylinder 3 Fault 73 PC-33 2. For AUG96
4-11 Cylinder 4 Fault 73 PC-33 Multi-Funct
5-11 Cylinder 5 Fault 74 PC-33 must be pro
6-11 Cylinder 6 Fault 74 PC-33 If both of the ab
22-13 Check Timing Sensor Calibration 42 PC-32 ECM Connecto
26-05 Multi-Function Output #1 Open Circuit 69 PB-25 wire is present a
26-06 Multi-Function Output #1 Short Circuit 69 PB-25 control the Coo
30-08 Invalid PTO Throttle Signal 29 PB-12 OEM Vehicle Sy
30-13 PTO Throttle Sensor Calibration 29 PB-12
40-05 Multi-Function Output #2 Open Circuit 66 PB-25
40-06 Mulit-Function Output #2 Short Circuit 66 PB-25
41-03 8 Volt Supply Above Normal 21 PB-12
Turn ignition k
41-04 8 Volt Supply Below Normal 21 PB-12
Fan Driver Sp
51-05 Multi-Function Output #3 Open Circuit 67 PB-25
Make the test A
51-06 Multi-Function Output #3 Short Circuit 67 PB-25
71-00 Idle Shutdown Override 01 PB-21
solenoid and/
71-01 Idle Shutdown Occurrence 47 PB-21
71-14 PTO Shutdown Occurrence 47 PB-21
84-00 Vehicle Overspeed Warning 41 PC-36 YES
84-01 Loss of Vehicle Speed Signal 31 PB-14
84-02 Invalid Vehicle Speed Signal 36 PB-14 Chec
84-08 Vehicle Speed Out of Range 36 PB-14
84-10 Vehicle Speed Rate of Change 36 PB-14 1. If A/C Fan s
84-14 Quick Stop Occurrence 00 PB-36
ECM does
91-08 Invalid Throttle Signal 32 PB-12
91-13 Throttle Sensor Calibration 28 PB-12 control the
100-01 Low Oil Pressure Warning 46 PC-36 2. If paramete
100-03 Oil Pressure Sensor Open Circuit 24 PC-35 is still ON t
406E 100-04
100-11
102-00
Oil Pressure Sensor Short Circuit
Very Low Oil Pressure
Boost Pressure Reading Stuck High
24
46
25
PC-35
PC-36
PC-35
3.
the reason
If paramete
"COUNTIN
102-03 Boost Pressure Sensor Open Circuit 25 PC-35
Pressure c
102-04 Boost Pressure Sensor Short Circuit 25 PC-35
102-13 Boost Pressure Sensor Calibration 42 PC-37
105-00 High Intake Manifold Temp Warning 64 PC-36
"OFF" at any
105-03 Intake Manifold Temp Sensor Open Circuit 38 PC-35
Cooling Fan Always ON
heck the following on an Electronic Service Tool:
Cooling Fan Type Customer Parameter must be
rogrammed to "On-Off" or "Three Speed Fan".
programmed to "None" the fan may always be ON.
or AUG96 and later Personality Modules,
Multi-Function Output #4 Customer Parameter
must be programmed to "Cooling Fan".
h of the above are correctly programmed, inspect
Connector J1/P1 for wire connected to pin-28. If no
s present at pin-28 then the ECM is not used to
ol the Cooling Fan System. The problem is in the
Vehicle System.
ECM is used to control the
Cooling Fan System
sconnect J2/P2
from P2. Install OK
arness Bypass, Repair or
bypass wire Replace Harness
2 to the Sensor.
SENR55
6 Page,
Pressure c
102-04 Boost Pressure Sensor Short Circuit 25 PC-35
102-13 Boost Pressure Sensor Calibration 42 PC-37
105-00 High Intake Manifold Temp Warning 64 PC-36
"OFF" at any
105-03 Intake Manifold Temp Sensor Open Circuit 38 PC-35 or "DISABLE
105-04 Intake Manifold Temp Sensor Short Circuit 38 PC-35
105-11 Very High Intake Manifold Temp 64 PC-36
108-03 Atmospheric Pr Sensor Open Circuit 26 PC-35 Check for logg
108-04 Atmospheric Pr Sensor Short Circuit 26 PC-35 1. 110-00 Hig
110-00 High Coolant Temperature Warning 61 PC-36 2. 110-03 Co
110-03 Coolant Temp Sensor Open Circuit 27 PC-35 3. 110-04 Co
110-04 Coolant Temp Sensor Short Circuit 27 PC-35 4. 110-11 Ver
110-11 Very High Coolant Temperature 61 PC-36
5. 105-00 Hig
111-01 Low Coolant Level Warning 62 PC-36
111-02 Coolant Level Sensor Fault 12 PB-17 6. 105-11 Ve
111-11 Very Low Coolant Level 62 PC-36 For codes 1
121-05 Retarder Solenoid Lo/Hi Open Circuit 14 PB-20 PC-35. For co
121-06 Retarder Solenoid Lo/Hi Short Circuit 14 PB-20 r
122-05 Retarder Solenoid Med/Hi Open Circuit 14 PB-20
122-06 Retarder Solenoid Med/Hi Short Circuit 14 PB-20
168-02 Low or Intermittent Battery 51 PB-11
171-03 Outside Air Temp Sensor Open Circuit 00 PC-35 The following
171-04 Outside Air Temp Sensor Short Circuit 00 PC-35
171-11 No Ambient Air Temperature Data 00 PB-21 1. Engine no
174-00 High Fuel Temp Warning 65 PC-36 2. During eng
174-03 Fuel Temp Sensor Open Circuit 13 PC-35 3. Coolant se
174-04 Fuel Temp Sensor Short Circuit 13 PC-35
4. Coolant te
190-00 Engine Overspeed Warning 35 PC-36
190-02 Loss of Engine RPM Signal 34 PC-31 5. Intake ma
228-03 A/C High Pressure Sw Open Circuit 19 PB-18 6. Intake ma
231-11 J1939 Data Link Fault 58 PB-24 pressure >
232-03 5 Volt Supply Above Normal 21 PC-34 7. Retarder s
232-04 5 Volt Supply Below Normal 21 PC-34 8. A/C high p
244-02 Event Recorder Data Lost 02 PB-11 9. A/C high p
249-11 J1922 Data Link Fault 58 PB-24
252-11 Incorrect Engine Software 59 PC-30
10. PTO On/O
253-02 Check Customer or System Parameters 56 PC-30 If no listed co
253-11 Check Transmission Customer Parameters 56 PC-30 circuit in the
254-12 ECM Fault 53 PC-30 problem can n
© 1999 Caterpillar
All Rights Reserved
5574-04
ge, JVD
Pressure circuit.
"ACTIVE DIAG",
OFF" at any time "ON"Or "COUNTING"
r "DISABLED" Refer to PB-18
No Listed Codes
e following conditions will turn Fan ON if engine
speed < 2250 rpm:
Engine not running.
During engine cranking.
Coolant sensor temp > 205°F (96°C).
Coolant temp sensor diagnostic active.
Intake manifold air temp > 189°F (87°C).
Intake manifold air temp > 162°F (72°C) with boost
pressure > 10 psi (70 kPa).
Retarder solenoid ON in high mode > 10 seconds.
A/C high pressure switch open or ECM counting.
A/C high pressure switch diagnostic active.
PTO On/Off switch in ON position.
o listed condition exists then check for an open
cuit in the solenoid or ECM fan relay circuit. If
blem can not be found refer to procedure PB-18.
Printed in U.S.A.