0327164 JOHNSON HANDLE, Remote control

Table 1
Diagnostic Codes Table
Code Conditions which Generate this Code System Response
109-3 Engine Coolant Outlet Pressure Sensor : Voltage Above Normal The duty cycle of the pressure sensor is outside the range of the sensor. The code is logged.
The alarm output is activated.
109-8 Engine Coolant Outlet Pressure Sensor : Abnormal Frequency, Pulse Width, or Period Refer to Troubleshooting, "Component Location" for graphics that show the location of the sensor's on the in-line engines and on the vee engines.The engine coolant pressure sensor is a Pulse Width Modulated sensor (PWM).Pulse Width Modulation (PWM) - This is a digital signal. The frequency is constant: the percent on time versus the period is called a duty cycle. If the signal is on for 50 percent of the period as an example, the duty cycle is 50 percent. This provides a more accurate status for a parameter than a signal that can only be ON or OFF.
Illustration 1 g01435459
Sample duty cycles that are low, medium, and high.
Note: Excessive pressure can generate false "noisy signal" diagnostic codes. If the actual engine coolant pressure is greater than approximately 444 kPa (64 psi), a "109-08 Engine Coolant Outlet Pressure Sensor noisy signal" diagnostic code will be generated. Although there is not a problem with the sensor, the code will be generated.If a "109-08" diagnostic code is generated, measure the absolute pressure with a pressure gauge before you troubleshoot the sensor. If the pressure is actually too high, reduce the pressure in order to avoid the false diagnostic codes from being activated.The "109-03" diagnostic code is probably caused by a problem with an electrical connector or with a harness. The next likely cause is a problem with a sensor. The least likely cause is a problem with the Electronic Control Module (ECM).Logged diagnostic codes provide a historical record. Before you begin this procedure, use Caterpillar Electronic Technician (ET) to print the logged codes to a file.This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 2 g01435426
Schematic of the circuit for the PWM sensor on the in-line engines and the vee engines
The PWM sensor is connected to the ECM via the J5/P5 connectors on the terminal box.
Test Step 1. Inspect the Electrical Connectors and Wiring
Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM to the OFF position. Note: For the following steps, refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g01431198
Terminal Box
(1) ECM connector J2/P2
(2) ECM connector J1/P1
(3) 16 amp circuit breaker
(4) Connectors J3/P3 for the customer's connector
(5) Connectors J4/P4 for the optional control panel (if equipped) or for a customer's connector
(6) J5/P5 connectors for the harness from the sensors
(7) J6/P6 connectors for the harness from the sensors
Thoroughly inspect each of the following connectors:
J2/P2 connectors for the ECM
J5/P5 connectors on the terminal box
Engine harness connectors for the sensor
Check the torque of the allen head screws for each of the ECM connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Illustration 4 g01435431
Terminal locations on the ECM P2 connector for the coolant pressure sensor on the in-line engines and the vee engines
(P2-65) +8 Volt supply
(P2-66) Sensor return
(P2-68) Signal for the engine coolant pressure
Illustration 5 g01435436
Terminal locations at the P5 connector on the terminal box that are for the circuit of the coolant pressure sensor on in-line engines
(P5-40) Shield
(P5-41) Sensor return
(P5-42) Signal for the engine coolant pressure
(P5-43) +8 Volt supply
Illustration 6 g01435442
Terminal locations at the P5 connector on the terminal box that are for the circuit of the coolant pressure sensor on vee engines
(P5-11) Shield
(P5-21) Sensor return
(P5-29) Signal for the engine coolant pressure
(P5-37) +8 Volt supply
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the PWM sensor.
Thoroughly check the harness and wiring for abrasion and for pinch points from the sensor to the ECM. Expected Result:All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.Results:
OK - All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. The components are in good condition with proper connections. Proceed to Test Step 2.
Not OK - At least one of the connectors, pins, or sockets is not connected properly. At least one connector or wire has corrosion, abrasion, and/or pinch points. The components are not in good condition and/or at least one connection is improper.Repair: Perform the necessary repairs and/or replace parts, if necessary.STOPTest Step 2. Check for Active Diagnostic Codes for the PWM Sensor
Turn on the "Active Diagnostic" screen on Cat ET. Determine if either of these diagnostic codes are active:
109-03 Coolant Outlet Pressure open/short to +batt
109-08 Engine Coolant Outlet Pressure noisy signalExpected Result:Neither of the codes are active.Results:
OK - Neither of the codes are active.Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshooting, "Symptom Troubleshooting".If the engine is runn