TCM 797F Test PDF

797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-...
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Product: TRUCK
Model: 797F TRUCK WSP
Configuration: 797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine
Troubleshooting
C175-16 and C175-20 Engines for 793F and 797F Off-Highway Trucks
Media Number -KENR5398-05 Publication Date -01/04/2011 Date Updated -20/04/2011
i03996408
Coolant Temperature Control Module - Test

SMCS - 135V-038
System Operation Description:
Use this procedure to troubleshoot the electrical system if a problem is suspected with the
Temperature Control Module (TCM). Also, use this procedure if one of the diagnostic codes in
Table 1 is active.
Table 1
Diagnostic Codes Table
System Response
Description Conditions which Generate this Code
168-3 Battery Potential / The supply voltage to the TCM has exceeded
The code is
Power Input 1 : Voltage 33.5 V. This code is reported by the TCM over
logged.
Above Normal the CAN data link (MID No. 094).
168-4 Battery Potential / The supply voltage to the TCM has dropped
The code is
Power Input 1 : Voltage below 16 V. This code is reported by the TCM
logged.
Below Normal over the CAN data link (MID No. 094).
The code is
2349-19 Engine Coolant The TCM reported that there is a problem with logged.
Pump Outlet the circuit that is for the coolant temperature The TCM
Temperature Sensor : sensor. The problem is communicated to the commands the
Data Error ECM via the CAN data link. valve to the full
open position.
The code is
2854-9 Coolant
The engine ECM did not receive the expected logged.
Temperature Control
data link information from the controller for Control for the
Module : Abnormal
the TCM. TCM reverts to the
Update Rate
PWM signal.
4193-2 Engine Coolant The TCM detects an intermittent problem in The code is
Pump Outlet the circuit for the coolant temperature sensor. logged.
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Temperature : Erratic,
This code is reported by the TCM over the
Intermittent, or Incorrect
CAN data link (MID No. 094).
The TCM detects an open circuit or a short to

+Battery in the harness for the coolant
The code is
temperature sensor. The three-way valve is
4193-3 Engine Coolant logged.
commanded to the fault position. This code
Pump Outlet The three-way
may be generated if the coolant temperature is
Temperature : Voltage valve is
less than
Above Normal commanded to the
−25° C (−13° F). This code is reported by the
fault position.
TCM over the CAN data link (MID No. 094).
The code is
4193-4 Engine Coolant The TCM detects a short to ground in the logged.
Pump Outlet harness for the coolant temperature sensor. The three-way
Temperature : Voltage This code is reported by the TCM over the valve is
Below Normal CAN data link (MID No. 094). commanded to the
fault position.
This engine is equipped with an electronic fluid temperature control system. The system is used to
control the flow of coolant through the cooling system. There are two basic components of the
system:
Illustration 1 g01661653
Location of the electronic fluid temperature control for the cooling system on the 793F (left front view)
Location of the electronic fluid temperature control for the cooling system on the 797F (right front view)
Components of the electronic fluid temperature control
(1) TCM
(2) Variable position electric motor
(3) Three-way valve
Temperature Control Module (TCM) - The TCM receives a coolant temperature signal from
the coolant temperature sensor that is installed in the outlet of the coolant pump. The TCM
processes this input signal and outputs a voltage that is used to control the position of the coolant
valve.
Three-way Valve - The valve assembly consists of a fixed housing, a piston plate, and a variable
position electric motor. The valve housing has inlet piping and outlet piping that attaches to the
cooling system. The piston plate is internal to the valve and rides on a lead screw. The variable
position electric motor drives the lead screw in order to adjust the piston within the housing. The
electric motor receives a voltage signal from the TCM in order to turn the lead screw and adjust
the coolant flow through the valve.
For this application, the electronic fluid temperature control operates in a stand-alone mode. The
temperature control module regulates the engine temperature to a default temperature of 78° C
(172° F). The control system for the unit is preprogrammed to control the temperature of the
engine coolant during all of the possible engine operating conditions. The unit regulates the flow
of coolant through the engine and the radiator in order to regulate the temperature of the engine
coolant.
The TCM communicates diagnostic codes to the service tool over the CAN data link. The TCM
also communicates data that is related to the engine coolant temperature and fault conditions to the
engine ECM via the CAN data link. If an electrical fault occurs in the circuit for the coolant
temperature sensor, the temperature control module communicates the condition to the ECM.
When an electrical fault is received by the ECM, a 2349-19 diagnostic code is activated.
Note: Use Cat ET in order to clear diagnostic codes. Keyswitch power to the engine must be
cycled in order to complete clearing of the codes from the TCM.
Illustration 4
Schematic for the TCM
Fuse panel that is in the cab of the machine
(4) 10 amp fuse for the keyswitch power to the TCM
(5) 15 amp fuse for the battery power to the TCM
Location of the machine interface connectors (typical left rear engine view)
(6) Machine interface connector
Location of the temperature sensor at the outlet of the coolant pump (left front engine view)
(7) Temperature sensor at the outlet of the coolant pump
Location of the harness connectors at the TCM
(8) Harness connectors at the TCM
Location of the interface connector at the cab of the machine for the TCM
(9) Interface connector at the cab of the machine
797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C17... Página 10 de 14
Terminal locations for the electronic fluid temperature control at the harness connector for the TCM
(Terminal 1) +Battery
(Terminal 3) Return
(Terminal 5) −Battery
(Terminal 8) Keyswitch
(Terminal 10) Sensor signal
Terminal locations at the machine interface connector for the temperature sensor at the outlet of the coolant pump
(Terminal 34) Return
Terminal locations at the temperature sensor at the outlet of the coolant pump
(Terminal 2) Return
Test Step 1. Check for an Active Diagnostic Code
A. Connect Cat ET to the service tool connector.
B. Restore the electrical power to the ECM.
C. Monitor the diagnostic codes on Cat ET. Check and record any diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
D. Determine if a diagnostic code has occurred several times.
Note: A diagnostic code that is logged several times is an indication of an intermittent

problem. Most intermittent problems are the result of a bad connection between a socket
and pin in the connector. An intermittent problem may also be caused by a poor connection
between a wire and terminal.
E. Look for the following diagnostic codes that are active or logged:
◦ 168-3
◦ 168-4
◦ 2349-19
◦ 2854-9
◦ 4193-2
◦ 4193-3
◦ 4193-4
F. Remove the electrical power from the ECM.
Expected Result:
No diagnostic codes are active for the TCM.
Results:
• OK - No diagnostic codes are active.
Repair: There may be an intermittent problem in the harness or in a connector. If an

intermittent problem is suspected, refer to Troubleshooting, "Electrical Connectors -
Inspect" for the correct procedures for inspecting electrical connectors.
STOP
• 168-3 or 168-4 Code is Active - A 168-3 or 168-4 diagnostic code is active. The TCM has
detected a problem with the supply voltage to the unit. Proceed to Test Step 2.
• 2854-9 Code is Active - A 2854-9 diagnostic code is active. The ECM detects a problem
with data link communications for the TCM. Proceed to Test Step 2.
• 2349-19 Code is Active - The 2349-19 diagnostic code is active. The ECM is reporting that
the TCM detects a problem in the circuit for the temperature sensor at the coolant pump.
Proceed to Test Step 4.
• 4193-2, 4193-3, or 4193-4 Code is Active - A 4193 diagnostic code is active. The TCM
detects a problem in the circuit for the temperature sensor at the coolant pump. Proceed to
Test Step 4.
Test Step 2. Check the Supply Voltage at the TCM
A. Disconnect the harness connector at the TCM.
B. Restore the electrical power to the ECM. Ensure that the keyswitch is in the ON position.
C. Use a multimeter to measure the supply voltage between terminal 1 (+Battery) and terminal
5 (−Battery) on the harness side of the connector.
D. Remove the electrical power from the ECM.
Expected Result:
The supply voltage that is measured at the connector is between 18 V and 32 V.
Results:
• OK - The supply voltage is between 18 V and 32 V. The supply voltage is correct at the
TCM. Proceed to Test Step 3.
• Not OK - The supply voltage is not between 18 V and 32 V. Check the condition of the 15
Amp fuse that is in the fuse panel in the cab of the machine.
Test Step 3. Check for Keyswitch Power at the TCM
A. Ensure that the harness connector for the TCM has been disconnected.
B. Restore the electrical power to the ECM. Ensure that the disconnect switch is in the ON
position.
C. Use a multimeter to measure the keyswitch power between terminal 8 (keyswitch) on the
harness side of the connector and the chassis ground.
D. Remove the electrical power from the ECM. Restore the wiring to the original
configuration.
Expected Result:
The voltage at the keyswitch input is 24.0 ± 3.0 V.
Results:
• OK - The voltage at the keyswitch input is 24.0 ± 3.0 V.
Repair: The voltage for the keyswitch and the supply is correct at the TCM.There may be a
problem with the wiring for the CAN data link. Repair the CAN data link. Refer to
Troubleshooting, "Data Link - Test" for information that is related to troubleshooting the
circuit.
STOP
• Not OK - The voltage at the keyswitch input is not 24.0 ± 3.0 V.
Repair: The keyswitch power is not reaching the controller for the TCM. There is a
problem in the keyswitch circuit. Repair the circuit. Refer to Troubleshooting, "Electrical
Power Supply - Test" for information that is related to troubleshooting the keyswitch circuit.
STOP
Test Step 4. Check the Resistance of the Wiring Harness for the Sensor Circuit
A. Ensure that the battery disconnect switch is in the OFF position.
B. Fabricate a jumper wire that is long enough to create a short circuit at the sensor connector.
Crimp connector pins to each end of the jumper wire.
C. Check for an open circuit in the harness wiring:
a. Disconnect the connector from the suspect sensor.
b. Use the jumper wire to create a short circuit on the harness side of the sensor
connector.
c. Disconnect the engine harness connector at the TCM.
d. Use a multimeter to check for continuity between terminal 3 and terminal 10 of the
harness connector at the TCM.
e. Remove the jumper wire from the sensor connector. Leave the sensor disconnected.
The correct measurement shows continuity while the wires are jumpered.
D. Check for a short circuit to another wire in the harness:
a. Disconnect the engine harness connector at the TCM.
b. Use a multimeter to check for continuity between terminal 3 and all of the other
terminals in the harness connector.
Note: The return circuit for the sensor will show continuity to the circuit for the
−Battery.
c. Use a multimeter to check for continuity between terminal 10 and all of the other
terminals in the harness connector.
The correct measurement shows that the circuit does not have continuity to any other
wires that are in the harness.
E. Restore all of the wiring to the original configuration.
Expected Result:
The measurements show that the sensor circuit is not open or shorted.
Results:
• OK - The sensor circuit is not open or shorted.
Repair: The circuit for the temperature sensor that is at the outlet of the coolant pump is
OK. There is a problem with the temperature sensor. There may be a problem with the
TCM. Perform the following procedure:Temporarily connect a new sensor to the harness,
but do not install the new sensor in the engine. Verify that the original diagnostic code is no
longer active. If the code is no longer active, permanently install the new sensor. Clear any
logged diagnostic codes.If the original diagnostic code remains active, reconnect the old
sensor. The problem is with the TCM. Replace the TCM. Verify that there are no active
diagnostic codes. Verify that the repair has resolved the original problem.
STOP
• Not OK - The sensor harness has an open or short circuit.
Repair: There is a problem in the wiring harness. Repair the wiring harness or replace the
wiring harness. Verify that the original problem has been resolved.
STOP
Copyright 1993 - 2011 Caterpillar Inc. Tue Dec 27 13:52:50 EST 2011
All Rights Reserved.
Private Network For SIS Licensees.

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-...

Coolant Temperature Control Module - Test

System Operation Description:

The TCM detects an open circuit or a short to

Components of the electronic fluid temperature control

(2) Variable position electric motor

(3) Three-way valve

Schematic for the TCM

Fuse panel that is in the cab of the machine

(4) 10 amp fuse for the keyswitch power to the TCM

(5) 15 amp fuse for the battery power to the TCM

(6) Machine interface connector

(7) Temperature sensor at the outlet of the coolant pump

Location of the harness connectors at the TCM

(8) Harness connectors at the TCM

(9) Interface connector at the cab of the machine

(Terminal 10) Sensor signal

(Terminal 28) Sensor signal

(Terminal 34) Return

(Terminal 1) Sensor signal

Test Step 1. Check for an Active Diagnostic Code

A. Connect Cat ET to the service tool connector.

B. Restore the electrical power to the ECM.

D. Determine if a diagnostic code has occurred several times.

Note: A diagnostic code that is logged several times is an indication of an intermittent

F. Remove the electrical power from the ECM.

No diagnostic codes are active for the TCM.

• OK - No diagnostic codes are active.

Repair: There may be an intermittent problem in the harness or in a connector. If an

Test Step 2. Check the Supply Voltage at the TCM

A. Disconnect the harness connector at the TCM.

D. Remove the electrical power from the ECM.

The supply voltage that is measured at the connector is between 18 V and 32 V.

Test Step 3. Check for Keyswitch Power at the TCM

The voltage at the keyswitch input is 24.0 ± 3.0 V.

• OK - The voltage at the keyswitch input is 24.0 ± 3.0 V.

• Not OK - The voltage at the keyswitch input is not 24.0 ± 3.0 V.

A. Ensure that the battery disconnect switch is in the OFF position.

C. Check for an open circuit in the harness wiring:

a. Disconnect the connector from the suspect sensor.

c. Disconnect the engine harness connector at the TCM.

D. Check for a short circuit to another wire in the harness:

a. Disconnect the engine harness connector at the TCM.

E. Restore all of the wiring to the original configuration.

• OK - The sensor circuit is not open or shorted.

• Not OK - The sensor harness has an open or short circuit.

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