0439954 JOHNSON RETAINER, CAM & LINK ASSY.

Illustration 1 g01190337
Schematic for the throttle position sensorTest Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Illustration 2 g01144022
P1 terminals that are associated with the throttle position sensor (P1-4) 8 volt supply (P1-5) Return (P1-66) Throttle signal
Thoroughly inspect the J1/P1 connectors and the J403/P403 connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit.
Check the torque of the allen head screws for the ECM connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the throttle position sensor to the ECM.Expected Result:All of the connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Inspect the Accelerator Pedal Assembly
Inspect the accelerator pedal assembly for components that are loose, bent, missing, or worn.
Slowly depress the accelerator and release the accelerator.Expected Result:The accelerator pedal assembly operates smoothly without excessive drag. The accelerator pedal assembly returns to the low idle position without assistance in less than one second.Results:
OK - The accelerator pedal assembly functions properly. Proceed to Test Step 3.
Not OK - The accelerator pedal assembly does not operate smoothly without excessive drag. The accelerator pedal assembly does not return to the correct position.Repair: Repair the accelerator pedal assembly.STOPTest Step 3. Check the Status for "Throttle Position"
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the keyswitch to the ON position.
Observe the status for "Throttle Position" on Cat ET while you operate the accelerator pedal.Expected Result:The status is approximately zero percent when the throttle pedal is released. The status progressively increases to approximately 100 percent when the throttle pedal is fully depressed.Results:
OK - The throttle position sensor is working properly.Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect" if the problem is intermittent.STOP
Not OK - The status is not correct on Cat ET. Proceed to Test Step 4.Test Step 4. Check for Supply Voltage at the Throttle Position Sensor
Disconnect the P403 connector.
Turn the keyswitch to the ON position. The engine should be OFF.
Measure the voltage between terminals P403-A and P403-B.Expected Result:The supply voltage is approximately 8 VDC.Results:
OK - The supply voltage is approximately 8 VDC. The supply voltage is reaching the sensor. Proceed to Test Step 5.
Not OK - The supply voltage is incorrect.Repair: The problem could be in the wiring or in a connector. Perform the necessary repairs. Verify that the problem is resolved.STOPTest Step 5. Check the Signal Wire for a Short Circuit
Turn the keyswitch to the OFF position.
Disconnect the P1 connector.Note: Be sure to wiggle the harnesses during the following measurements. Be sure to wiggle each harness near each connector.
Measure the resistance between terminal P1-66 and all of the other terminals in the P1 connector.Expected Result:Each resistance measurement indicates an open circuit.Results:
OK - Each resistance measurement indicates an open circuit. Proceed to Test Step 7.
Not OK - At least one resistance measurement does not indicate an open circuit. There is a problem with the signal wire for the throttle position sensor.Repair: The problem could be in the wiring or in a connector. Repair the wiring and/or the connector, when possible. Replace parts, if necessary. Verify that the problem is resolved.STOPTest Step 6. Check the Signal Wire for an Open CircuitNote: Be sure to wiggle the harnesses during the following measurement. Be sure to wiggle each harness near each connector.Measure the resistance between terminal P1-66 and terminal P403-C.Expected Result:The resistance measurement is less than ten Ohms.Results:
OK - The resistance measurement is less than ten Ohms. Connect the P403 connector. Proceed to Test Step 7.
Not OK - The resistance measurement is greater than ten Ohms. There is a problem with the signal wire.Repair: The problem could be in the wiring or in a connector. Repair the wiring and/or the connector, when possible. Replace parts, if necessary. Verify that the problem is resolved.STOPTest Step 7. Check the Frequency of the Throttle Position Signal at the ECM
Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Connect a 208-0059 Adapter Cable As (70-PIN BREAKOUT) between the P1 connector and the J1 connector.
Connect a multimeter between terminals 66 and 5 on the breakout t.
Turn the keyswitch to the ON position.
Measure the frequency of the throttle position signal. Slowly move the throttle from low idle to high idle and back to low idle while you measure the frequency of the signal.
Observe the "Active Diagnostic" screen on Cat ET. Slowly move the throttle from the low idle position to the high idle position. Look for a 091-08 diagnostic code while you move the throttle.Expected Result:The frequency of the signal remains between 150 Hz and 1050 Hz as you move the throttle. A 091-08 diagnostic code is not activated.Results:
OK - The frequency of the signal remains between 150 Hz and 1050 Hz as you move the throttle. A 091-08 diagnostic code is not activated.Repair: Perform the following procedure:
Turn the keyswitch to the OFF position.
Remove the 208-0059 Adapter Cable As (70-PIN BREAKOUT).
Connect the J1/P1 connectors.
Turn the keyswitch to the ON position.
Operate the throttle throughout the entire range.If the problem does not recur, the problem is resolved. The original problem was probably caused by a poor electrical connection. Return the engine to service.STOP
Not OK - The frequency of the signal is incorrect. A 091-08 diagnostic code is activated.Repair: Perform