Diagnostic Code Listing Cooling Fan Always ON

SENR5574-04 Flash Troubleshooting Check the following on an Electronic Service Tool:

Engine Sensor Open or Short Circuit Test January 1999 Code
1-11
Description
Cylinder 1 Fault
Code
72
Guide Procedure
PC-33
1. Cooling Fan Type Customer Parameter must be
programmed to "On-Off" or "Three Speed Fan".
Connect Electronic Service Tool to Cab Data Link 2-11 Cylinder 2 Fault 72 PC-33 If programmed to "None" the fan may always be ON.
and check for ACTIVE Engine Sensor Open or 3-11 Cylinder 3 Fault 73 PC-33 2. For AUG96 and later Personality Modules,
Short Circuit Code. If the code is not ACTIVE and 4-11 Cylinder 4 Fault 73 PC-33 Multi-Function Output #4 Customer Parameter
the Engine is not running properly, refer to 5-11 Cylinder 5 Fault 74 PC-33 must be programmed to "Cooling Fan".
6-11 Cylinder 6 Fault 74 PC-33 If both of the above are correctly programmed, inspect
Troubleshooting Without A Diagnostic Code. 22-13 Check Timing Sensor Calibration 42 PC-32 ECM Connector J1/P1 for wire connected to pin-28. If no
26-05 Multi-Function Output #1 Open Circuit 69 PB-25
ACTIVE wire is present at pin-28 then the ECM is not used to
26-06 Multi-Function Output #1 Short Circuit 69 PB-25 control the Cooling Fan System. The problem is in the
Open or Short 30-08 Invalid PTO Throttle Signal 29 PB-12 OEM Vehicle System.
Circuit Code NOT 30-13 PTO Throttle Sensor Calibration 29 PB-12
OK 40-05 Multi-Function Output #2 Open Circuit 66 PB-25 ECM is used to control the
Check Electrical Connectors and Wiring. Refer to PB-10 40-06 Mulit-Function Output #2 Short Circuit 66 PB-25
Cooling Fan System
41-03 8 Volt Supply Above Normal 21 PB-12
Turn ignition key ON, engine OFF. Access the Cooling
ACTIVE Short ACTIVE Open 41-04 8 Volt Supply Below Normal 21 PB-12
Fan Driver Special Test on an Electronic Service Tool.
Circuit Code Circuit Code 51-05 Multi-Function Output #3 Open Circuit 67 PB-25
Make the test Active and Not Active while listening for the
51-06 Multi-Function Output #3 Short Circuit 67 PB-25
NOT 71-00 Idle Shutdown Override 01 PB-21
solenoid and/or relay to click as test status changes.
With the ignition key OFF, disconnect the Measure the Sensor Supply Voltage with Is clicking detected?
Sensor Connector with the ACTIVE Short a Voltmeter. Reading should be within OK Refer 71-01 Idle Shutdown Occurrence 47 PB-21
to 71-14 PTO Shutdown Occurrence 47 PB-21 NO
Circuit Code. Does the Short Circuit the range of 4.5 VDC to 5.5 VDC. PC-34 84-00 Vehicle Overspeed Warning 41 PC-36 YES Refer to PB-18
Code remain Active? 84-01 Loss of Vehicle Speed Signal 31 PB-14
OK 84-02 Invalid Vehicle Speed Signal 36 PB-14 Check A/C Fan status parameter on
84-08 Vehicle Speed Out of Range 36 PB-14 Electronic Service Tool.
Code Changes Short Circuit 84-10 Vehicle Speed Rate of Change 36 PB-14 1. If A/C Fan status indicates "DISABLED" then the
To Open Circuit Install a short circuit between pin-C and 84-14 Quick Stop Occurrence 00 PB-36
Code Remains ECM does not use and A/C High Pressure Switch to
pin-B of the sensor harness connector 91-08 Invalid Throttle Signal 32 PB-12
control the Cooling Fan System.
and check for an ACTIVE Short Circuit 91-13 Throttle Sensor Calibration 28 PB-12
If a Short Circuit code was Active before 2. If parameter indicates "OFF" at any time and the fan
Diagnostic Code. Does the Open 100-01 Low Oil Pressure Warning 46 PC-36
the sensor was disconnected, but an 100-03 Oil Pressure Sensor Open Circuit 24 PC-35 is still ON then the A/C High Pressure circuit is not
Circuit Code remain Active?
Open Circuit code became Active after the 100-04 Oil Pressure Sensor Short Circuit 24 PC-35 the reason the Fan is ON.
100-11 Very Low Oil Pressure 46 PC-36 3. If parameter indicates "ACTIVE DIAG", "ON", or
sensor was disconnected then thoroughly
Open Circuit Code Short Circuit Code 102-00 Boost Pressure Reading Stuck High 25 PC-35 "COUNTING" the fan is ON because of the A/C High
inspect the connector for moisture. 102-03 Boost Pressure Sensor Open Circuit 25 PC-35
Inspect the seals and connect the sensor. Active with Jumper Active with Jumper Pressure circuit.
102-04 Boost Pressure Sensor Short Circuit 25 PC-35
If the code reappears, the sensor or pigtail 5EK1-UP 102-13 Boost Pressure Sensor Calibration 42 PC-37 "ACTIVE DIAG",
If a Short Circuit Code appears,
harness is the problem. Temporarily
temporarily connect the suspect sensor.
9CK1-UP 105-00 High Intake Manifold Temp Warning 64 PC-36
"OFF" at any time "ON"Or "COUNTING"
105-03 Intake Manifold Temp Sensor Open Circuit 38 PC-35
replace the sensor (connect sensor to
If the Open Circuit code returns Active, 1YN1-UP 105-04 Intake Manifold Temp Sensor Short Circuit 38 PC-35
or "DISABLED" Refer to PB-18
harness but do not install into engine) and
ensure the code is no longer Active. If the replace the sensor and verify the 2PN1-UP 105-11 Very High Intake Manifold Temp 64 PC-36
Check for logged or active diagnostic codes as follows:
code disappears with a new sensor, diagnostic code does not return. 6TS1-UP 108-03
108-04
Atmospheric Pr Sensor Open Circuit
Atmospheric Pr Sensor Short Circuit
26
26
PC-35
PC-35 1. 110-00 High Coolant Temp Warning
replace the old sensor. STOP. 110-00 High Coolant Temperature Warning 61 PC-36 2. 110-03 Coolant Temp Sensor Open
110-03 Coolant Temp Sensor Open Circuit 27 PC-35 3. 110-04 Coolant Temp Sensor Shorted
110-04 Coolant Temp Sensor Short Circuit 27 PC-35 4. 110-11 Very High Coolant Temp
110-11 Very High Coolant Temperature 61 PC-36
Disconnect the ECM Connector J2/P2 and check for Active 5. 105-00 High Manifold Temp Warning
111-01 Low Coolant Level Warning 62 PC-36
Diagnostic Codes. The Open Circuit Diagnostic Code 111-02 Coolant Level Sensor Fault 12 PB-17 6. 105-11 Very High Manifold Temp
should be Active without the harness connected. Install a 111-11 Very Low Coolant Level 62 PC-36 For codes 110-03 and 110-04 refer to procedure
jumper between the Sensor signal pin and pin-30 (Sensor 121-05 Retarder Solenoid Lo/Hi Open Circuit 14 PB-20 PC-35. For codes 105-00, 105-11, 110-00 and 110-11
Common). A Short Circuit Code should be Active with the 121-06 Retarder Solenoid Lo/Hi Short Circuit 14 PB-20 refer to procedure PC-36.
122-05 Retarder Solenoid Med/Hi Open Circuit 14 PB-20
jumper in place.
122-06 Retarder Solenoid Med/Hi Short Circuit 14 PB-20 No Listed Codes
OK NOT 168-02 Low or Intermittent Battery 51 PB-11
171-03 Outside Air Temp Sensor Open Circuit 00 PC-35 The following conditions will turn Fan ON if engine
OK 171-04 Outside Air Temp Sensor Short Circuit 00 PC-35 speed < 2250 rpm:
If the Open Circuit Diagnostic Code is not active without 171-11 No Ambient Air Temperature Data 00 PB-21 1. Engine not running.
the harness connected, or the Short Circuit Diagnostic 174-00 High Fuel Temp Warning 65 PC-36 2. During engine cranking.
Code does not appear with the short circuit in place, 174-03 Fuel Temp Sensor Open Circuit 13 PC-35 3. Coolant sensor temp > 205°F (96°C).
174-04 Fuel Temp Sensor Short Circuit 13 PC-35
temporarily install another ECM. Repeat this test step. If 4. Coolant temp sensor diagnostic active.
190-00 Engine Overspeed Warning 35 PC-36
the problem is resolved with the new ECM, verify the 190-02 Loss of Engine RPM Signal 34 PC-31 5. Intake manifold air temp > 189°F (87°C).
problem returns with the old ECM. If the new ECM works 228-03 A/C High Pressure Sw Open Circuit 19 PB-18 6. Intake manifold air temp > 162°F (72°C) with boost
and the one on the engine did not, replace the ECM. STOP. 231-11 J1939 Data Link Fault 58 PB-24 pressure > 10 psi (70 kPa).
232-03 5 Volt Supply Above Normal 21 PC-34 7. Retarder solenoid ON in high mode > 10 seconds.
232-04 5 Volt Supply Below Normal 21 PC-34 8. A/C high pressure switch open or ECM counting.
Install Sensor Bypass Wiring. Disconnect J2/P2 244-02 Event Recorder Data Lost 02 PB-11
NOT and remove the sensor signal wire from P2. Install 9. A/C high pressure switch diagnostic active.
OK OK 249-11 J1922 Data Link Fault 58 PB-24
10. PTO On/Off switch in ON position.
a 125-3662 3-Pin Engine Sensor Harness Bypass, Repair or 252-11 Incorrect Engine Software 59 PC-30
Restart Test If no listed condition exists then check for an open
or make a bypass and route the bypass wire Replace Harness 253-02 Check Customer or System Parameters 56 PC-30
253-11 Check Transmission Customer Parameters 56 PC-30 circuit in the solenoid or ECM fan relay circuit. If
directly from the ECM Connector P2 to the Sensor. problem can not be found refer to procedure PB-18.
254-12 ECM Fault 53 PC-30

©1999 Caterpillar
All Rights Reserved Printed in U.S.A.
 3176B, C-10, C-12, & 3406E Engine Harness 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
ENGINE ENGINE ENGINE D788-BK D788-BK 7 RETARDER SOLENOID COMMON
7
CYL CYL CYL CYL CYL CYL RETR RETR RETR D784-BU 40 VEHICLE SPEED OUT+ (NOTE A)
NO.1 NO.2 NO.3 NO.4 NO.5 NO.6 SOL CYL SOL CYL SOL CYL D810-PU 39 TDC PROBE+/VEH SP IN+ (NOTE A)
1
1&2 5&6 3&4 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
+V ENG SP/TMG OR A 996-GN A747-GY 20 ATM PRESSURE
SPEED/TIMING ENG SP/TMG COMMON BK B 998-BR 994-GY 8 OIL PRESSURE
SENSOR ENG SP/TMG WH C 999-WH 15
P9 J9 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
GN C A746-PK 21
BOOST PRESS.
BOOST PRESSURE YL B 993-BR 31
SENSOR COMMON
SENSOR OR A 997-OR 25
+5V
9 OUTSIDE AIR TEMP ECM GND STRAP
P3 J3 24
33 TO ECM
VOLTAGE SUPPLY WIRES ECM MOUNTING
BOLT
ATM PRESSURE GN C A747-GY COMMON WIRES
ATM PRESSURE SENSOR COMMON YL B 993-BR
SENSOR +5V OR A 997-OR INPUT SIGNAL WIRES
P22 J22
OUTPUT SIGNALS WIRES

OIL PRESSURE GN C 994-GY

OIL PRESSURE SENSOR COMMON YL B 993-BR
SENSOR +5V OR A 997-OR
P17 J17
1 2 3 4 5 6

6 5 4 3 2 1

7 12 12 11 10 9 8 7

COOLANT TEMP WH C 995-BU 13 18 18 17 16 15 14 13

COOLANT TEMP SENSOR COMMON BK B 993-BR 19 22 22 21 20 19
SENSOR +5V OR A 997-OR 23 28 28 27 26 25 24 23
J10 P10 29 34 34 33 32 31 30 29

40 39 38 37 36 35

35 36 37 38 39 40

Harness Side Engine Harness ECM Side

INTAKE MANF INTAKE MANF AIR TEMP WH C C967-BU ECM Connector
AIR TEMP SENSOR COMMON BK B 993-BR
SENSOR +5V OR A 997-OR
J21 P21

A B B A
FUEL TEMP WH C A751-YL
FUEL TEMP SENSOR COMMON BK B 993-BR
SENSOR +5V OR A 997-OR
J23 P23 Jack Plug C
C

3176B, C-10, C-12, & 3406E OEM Vehicle Harness Wiring Diagram
C +BAT. VOLTAGE SUPPLY WIRES
E -BAT.
D799-GN
D CHECK ENGINE LAMP COMMON WIRES
CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS F
B793-YL A ATA+ INPUT SIGNAL WIRES
B792-BU B ATA- WARNING LAMP 659-PK
N/O
RELAY DASH DATA LINK OUTPUT SIGNALS WIRES
ECM CKT BKR

C973-GN
SIGNAL-
OFF C SPEEDOMETER
15

B ON SIGNAL+ C974-PU
ST S

R 450-YL 1 2 3 4 5 6
SIGNAL+
TACHOMETER 6 5 4 3 2 1
SIGNAL- 451-BR
KEY SWITCH 7 12 12 11 10 9 8 7
C987-RD

13 18 18 17 16 15 14 13
PASSIVE 19 22 22 21 20 19
MAGNETIC D784-BU
23 28 28 27 26 25 24 23
VEHICLE SPEED D785-GN
S G SENSOR 29 34 34 33 32 31 30 29

40 39 38 37 36 35
BAT MTR
35 36 37 38 39 40
ALTERNATOR CRUISE ON/OFF
STARTER Harness Side OEM Vehicle Harness ECM Side
MOTOR C993-BR C975-WH ECM Connector
GND (12V)

SERVICE BRAKE N/C

C993-BR C992-PU A B B A
(PEDAL RELEASED POSITION)

- 12V + - 12V + - 12V +

Jack Plug C
CLUTCH N/C C
BATTERY 3 BATTERY 2 BATTERY 1
C993-BR C977-BU
(PEDAL RELEASED 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
E715-RD

MED
C993-BR D784-BU 18 VEHICLE SPEED IN+ MOUNTING
HI
D785-GN 12 VEHICLE SPEED IN- BOLT
ENGINE RETARDER LO C975-WH 20 CRUISE CONT ON/OFF SW
SOLENOID MED
E717-GN C992-PU 14 SERVICE BRAKE SW
ON/OFF SW 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
A/C HIGH PRESS. SW E715-RD 4 UNSWITCHED +BATTERY
N/C D745-YL 28 MULTI-FUNCTION OUTPUT #4 (NOTE B)
E718-PK 40 MULTI-FUNCTION OUTPUT #2
E971-GN E971-GN 38 A/C HIGH PRESSURE SW
TO J1939 DATA LINK CONNECTOR A249-BK 26 J1939 DATA LINK SHIELD (NOTE K)
TO J1939 DATA LINK CONNECTOR K990-GN 39 J1939 DATA LINK- (NOTE K)
TO J1939 DATA LINK CONNECTOR K900-YL 33 J1939 DATA LINK+ (NOTE K)
+5V C C997-OR C997-OR 36 +5V
COOL LEVEL NORMAL D C983-WH C983-WH 2 COOLANT LEVEL NORMAL
COOLANT LEVEL SENSOR
COOL LEVEL LOW A C984-YL C984-YL 23 COOLANT LEVEL LOW
SENSOR COMMON B C993-BR TO J1922 DATA LINK CONNECTOR E721-PK 9 J1922 DATA LINK+
TO J1922 DATA LINK CONNECTOR E720-WH 3 J1922 DATA LINK-
C988-BK C988-BK 5 -BATTERY
E991-GY 34 MULTI-FUNCTION OUTPUT #3
C985-BU 35 +8V
J11 P11 C986-BR 37 THROTTLE POSITION
ENG GND STUD C993-BR 29 SENSOR COMMON
+8 V RD A C985-BU
K999-GN 8 MULTI-FUNCTION INPUT #1
THROTTLE POSITION WH C C986-BR
K980-PK 32 MULTI-FUNCTION INPUT #2
SENSOR COMMON BK B C993-BR
K982-YL 31 MULTI-FUNCTION INPUT #3
ENGINE L901-GY 30 MULTI-FUNCTION SENSOR COMMON
THROTTLE POSITION
CYL HEAD K998-BU 21 MULTI-FUNCTION OUTPUT #1
SENSOR
OEM
COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED INSTALLED
refer to PA-18
Does not crank,

+ BATTERY
OK

OK
Tool
Repair

Repair
Cables
Service

ATA DATA LINK-

+BATTERY
- BATTERY
ATA DATA LINK+

- BATTERY
J

B
A
E

C
D
H

G
OK

Refer
NOT

to PC-30
Communicate

the communication problem.

ATA DATA LINK -

Caterpillar
device on the vehicle is causing

Dashed in Area is

ATA DATA LINK +

Service Tool "T"

Either the vehicle wiring or another

Cable Shown Below

Cable P/N 8T5275

or 139-4166 Cable
ECM and Service Tool

5
6
7
1
Cables.

P1 J1

- 12V +
No Communications
No Communications
Engine Starts, but ECM does not
Try to Start the Engine.

Service Tool P/N 129-2018

communicate with the Service Tool.

socket.

Caterpillar Harness Bypass

Communicate with the ECM

Cables as in the previous step.

+BATTERY
- BATTERY

-
Harness Bypass Diagram
Connect the Service Tool Using a
Electronic Service Tool Will Not

Harness and ECM as shown below.

No Communications
Connect Another Service Tool to the

Disconnect ECM Connector P1 from

ECM, but use the same Service Tool

directly to the Electronic Service Tool

Harness Bypass. Connect the Bypass
completely different set of Service Tool

the ECM. Install a Caterpillar 129-2018

ECM

12V
+
Does

completely snapped into the ECM

not start

If ECM Serial Number ends in "CA",

ATA DATA LINK - (J1587)

ATA DATA LINK + (J1587)
ensure the Personality Module Chip is

to
to
to
to
to
OK

OK
OK
OK
OK
NOT

NOT
NOT
NOT
NOT

Refer
Refer
Refer
Refer
Refer

PC-30
PC-31
PC-33
PC-30
Connector
ECM does not communicate

OK

OK
OK

OK
OK

OK
OK

OK
socket.

Active.
Engine Software.

priming, and fuel filters.

from receiving battery power.

Check ECM power and ground

ON. Battery voltage at the ECM

turn ignition key ON, engine OFF.

Monitor the exhaust stack while

Attempt to access Truck Functions.

Check for combustion problems,

are not active, preventing the ECM

completely snapped into the ECM

devices (not installed by Caterpillar)

problem. Check fuel pressure, fuel

If the Personality Module has been

may be a fuel supply or fuel quality

check for an active 252-11 Incorrect
If ECM Serial Number ends in "CA",

ensure Theft Deterrent is not Active.

Observe engine rpm from Electronic
Ensure after-market engine protection

ensure the Personality Module Chip is

Turn the ignition key ON, engine OFF,

mechanical problems or extreme cold.

If the Truck is equipped with a CAT ID,

cranking - if no smoke is present there

connections with the ignition key switch

Service Tool while cranking the engine.

PB-11 -Battery should be 11.0 - 13.5 Volts DC.

the CAT ID will indicate Theft Deterrent

P1/J1 pin-6 +Battery to pin-5

recently replaced/updated, connect and

Engine Cranks, But Will Not Start

is fully connected and free of corrosion.

ECM Communicates

Ensure the Fuel Injector Connector (J5/P5)

Connect Electronic Service Tool to Cab Data Link,