9101E3-5625 Tohatsu BOLT

Illustration 1 g01114146
Schematic for the bypass valve actuator circuit for engines GZJ00001-00551.
Illustration 2 g06231453
Schematic for the throttle actuator circuit for engines GZJ00552-Up.
Test Step 1. Inspect the Electrical Connectors and Wiring
Remove the electrical power from the engine.Note: For the following steps, refer to Troubleshooting, "Electrical Connectors - Inspect".
Thoroughly inspect each of the following connectors:
J1/P1 connectors
J9/P9 connectors
Connectors on the actuator for the bypass valve
Check the torque of the allen head screw for the ECM connectors.
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the actuator for the bypass valve.
Illustration 3 g00935459
Right side views
Check the wiring for abrasion and for pinch points from the actuator for the bypass valve to the master ECM.Expected Result:All of the connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.Results:
OK - The components are in good condition with proper connections. Proceed to Test Step 2.
Not OK - 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. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem.STOPTest Step 2. Check for a Diagnostic Code
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
Use Cat ET in order to determine if one of the following diagnostic codes is active:
1720-9 Turbocharger Compressor Bypass Valve Actuator : Abnormal Update Rate
1720-11 Turbocharger Compressor Bypass Valve Actuator invalid
1720-12 Turbocharger Compressor Bypass Valve Actuator : FailureExpected Result:None of the diagnostic codes are active.Results:
OK - None of the diagnostic codes are active. The communication between the master ECM and the actuator for the bypass valve appears to be OK at this time. However, diagnostic codes may be logged.Repair: If you are troubleshooting an intermittent problem, refer to Troubleshooting, "Electrical Connectors - Inspect".Terminating resistors must be connected to each end of the CAN data link. The terminating resistors improve the communication between the devices. If there is an intermittent diagnostic code for any of the devices that are connected to the CAN data link, be sure to check the terminating resistor that is inside the terminal box.The second terminating resistor is located internal to either the compressor bypass actuator or the fuel metering valve depending on the current engine configuration. Check that there is a jumper wire present at one of the following locations:
Turbocharger compressor bypass actuator terminals J and K
Raptor fuel metering valve terminals R and PMake repairs, when possible. Replace parts, if necessary.STOP
Not OK (Active 1720-9) - The master ECM has detected a problem with the communication between the master ECM and the actuator for the bypass valve. Proceed to Test Step 3.
Not OK (Active 1720-11) - There is an active 1720-11 diagnostic code. This code indicates a problem with the movement of the actuator for the compressor bypass.Repair: The actuator for the compressor bypass valve must be installed properly in order to provide stable operation. If the motion is sticky and/or rough, investigate the cause of the binding. Perform the necessary repairs.STOP
Not OK (Active 1720-12) - There is an active 1720-12 diagnostic code.Repair: The actuator for the bypass valve has detected an internal fault. Replace the actuator. Verify that the repair has eliminated the original problem.STOPTest Step 3. Check for Electrical Power at the Actuator