3/3/23, 10:24 AM SIS 2.

2005/04/27 Coolant Level Sensor Circuit - Test (RENR1367-20)

SMCS - 1439, 5574 i02303749

System Operation Description:

PPI
Use this procedure under the following situation:

202 -0007
Use this procedure if any of the following diagnostic codes are active or easily repeatable:

3
15: 03/0 0CA
111-02 Coolant Level signal invalid (12)
/ 4
2
RE 4:23- 3
111-03 Coolant Level voltage high (12)

N
111-04 Coolant Level voltage low (12)

0
©2 R 136 5:00
Do not use this procedure for either of the following diagnostic codes:

023
111-01 Low Coolant Level Warning (62)
7
111-11 Very Low Coolant Level (62) Cat
erp
111-14 Low Coolant Level Warning
illa
r In
These diagnostic codes indicate a low coolant level but not an electrical system malfunction. Refer to

c.
Troubleshooting, "111-01 Low Coolant Level Warning", Troubleshooting, "111-11 Very Low Coolant
Level" or Troubleshooting, "111-14 Low Coolant Level Warning" for the proper troubleshooting
procedure.

The following background information is related to this procedure:

The coolant level sensor is installed by the vehicle's Original Equipment Manufacturer (OEM). This
sensor is an optional sensor for "Engine Monitoring". Engine monitoring is a programmable feature of
the Caterpillar Engine Control Module (ECM). The sensor is selectable through a customer
programmable parameter and the customer programmable parameter may be protected by customer
passwords. Some OEM installed coolant level sensors are not connected to the ECM. Do not confuse
an OEM installed coolant level sensor that is independent of engine monitoring with the coolant level
sensor that is used for engine monitoring.

The customer programmable parameter for the coolant level sensor can be programmed to "4-Pin", "2-
wire float sensor", or "2-pin switch". Also, the customer programmable parameter for the coolant level
sensor can be programmed to "NO" if the option for the coolant level sensor is not being used.

If the parameter "Coolant Level Sensor" is programmed to "NO", the coolant level sensor is ignored by
the ECM. Conversely, if the parameter is set, then a sensor must be installed. The coolant level is

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monitored by the engine monitoring system when the parameter "Coolant Level Sensor" is programmed
to "4-Pin" or "2-wire float sensor".

4-Pin Sensor

The sensor indicates the presence or the absence of coolant at the sensor probe. A sensor with a 4-pin
connector that requires a +5 VDC connection to a power supply must be used. The sensor is powered
from the ECM through the ECM vehicle harness connector J1/P1 terminal 2 (+5 VDC). The ECM
vehicle harness connector has 70 terminals. The signal wires for the coolant level sensor are connected
at J1/P1-54 (coolant level low) and at J1/P1-49 (coolant level normal). The common wire for the sensor
is connected to the J1/P1 ECM connector through terminal 5 (AP sensor/switch common).

Note: If both parameters are set and a sensor is not installed, 111-02 diagnostic code will be logged.

Table 1

ECM Output for the 4-Pin Sensor

Pin location Engine coolant level normal Engine coolant level low
J1-49 5 VDC 0 VDC
J1-54 0 VDC 5 VDC

2-Wire Float Sensor

To use a 2-wire float sensor, the parameter "Coolant Level Sensor" must be programmed to "2-wire float
sensor". The sensor is connected to P1/J1-26 (sensor input) and to P1/J1-5 (AP sensor/switch
common). The sensor will provide information to the ECM at P1/J1-26 that will enable the ECM to
determine if the coolant level is normal, low, or extremely low.

If this parameter is set and a sensor is not installed, 111-02 diagnostic code will be logged.

"2-Pin Switch" (GMT-560)

The "2-pin switch" is a switch that is provided by the OEM for the vehicle. The switch is also installed by
the OEM. This coolant level switch is available only for the GMT-560 application.

The ECM detects closed contacts for a coolant level that is present "2-pin switch" and open contacts
when a coolant level is not present. Terminals J1/P1-49 and J1/P1-3 are used for the "2-pin switch".

Refer to OEM information for the proper troubleshooting procedure for the "2-Pin Switch".

Test Step 1. USE CATERPILLAR ELECTRONIC TECHNICIAN (ET) TO CHECK FOR AN ACTIVE
COOLANT LEVEL SENSOR FAULT

A. Connect Cat ET to the data link connector.

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B. Turn the keyswitch to the ON position.

C. Access the active diagnostic screen on Cat ET.

D. Verify that a diagnostic code that is related to the coolant level switch is active.

Expected Result:

Result 1 111-02 diagnostic code is active. This fault indicates that a problem exists with the 4-pin
sensor. Ensure that the vehicle is equipped with a 4-pin sensor.

Result 2 111-03 diagnostic code or 111-04 diagnostic code is active. These faults indicate that a
problem exists with the 2-wire float sensor. Ensure that the vehicle is equipped with a 2-wire float
sensor.

Result 3 111-01, 111-11, or 111-14 diagnostic code is active.

Results:

Result 1 - Proceed to Test Step 2.

Result 2 - Proceed to Test Step 8.

Result 3 -
Repair: Refer to Troubleshooting, "111-01 Low Coolant Level Warning", Troubleshooting, "111-11
Very Low Coolant Level" or Troubleshooting, "111-14 Low Coolant Level Warning" for the proper
troubleshooting procedure.

STOP

Test Step 2. INSPECT ELECTRICAL CONNECTORS AND WIRING FOR THE 4-PIN SENSOR

Illustration 1 g01118000
This is a typical schematic for the 4-pin sensor.
The return wire may be connected to P1-3, P1-5, or P1-18.

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Illustration 2 g01153498
Pin locations on ECM connector
(P1-2) +5V supply
(P1-5) AP sensor/switch common
(P1-49) Coolant level normal
(P1-54) Coolant level low

A. Thoroughly inspect J1/P1 ECM connector, the connector for the extension harness for the coolant
level and the terminals for the coolant level sensor in the connectors. The connector for the
extension harness for the coolant level connects the coolant level sensor to the vehicle harness in
the engine compartment of some chassis. Refer to Troubleshooting, "Electrical Connectors -
Inspect" for details.

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B. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with
the following connections:

P1-2 +5V supply

P1-5 AP sensor/switch common

P1-49 Coolant level normal

P1-54 Coolant level low

Refer to Illustration 2.

C. Check the ECM connector (allen head screw) for the proper torque. Refer to Troubleshooting,
"Electrical Connectors - Inspect" for details.

D. Check the harness and wiring for abrasion and pinch points from the sensor to the ECM.

Expected Result:

All connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are
free of corrosion, of abrasion or of pinch points.

Results:

OK - Proceed to Test Step 3.

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. Clear all diagnostic codes.

STOP

Test Step 3. DISCONNECT THE COOLANT LEVEL SENSOR AND CHECK THE SUPPLY VOLTAGE
(+5 VDC)

A. Turn the keyswitch to the OFF position.

B. Disconnect the coolant level sensor from the harness.

C. Use a multimeter to measure the voltage at the harness connector from terminal C (+ 5 VDC) to
terminal B (AP sensor/switch common).

D. Turn the keyswitch to the ON position.

Expected Result:
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The measured voltage is 5.0 ± 0.2 VDC.

Results:

OK - Proceed to Test Step 4.

Not OK - Proceed to Test Step 5.

Test Step 4. DISCONNECT THE COOLANT LEVEL SENSOR AND CHECK THE COOLANT LEVEL
HARNESS

Illustration 3 g00651005
Jumper wire

A. Turn the keyswitch to the OFF position.

B. Disconnect the coolant level sensor from the harness.

C. Use a jumper wire in order to connect terminal D (coolant level normal) to terminal B (AP
sensor/switch common) at the harness connector.
Refer to Illustration 3.

D. Turn the keyswitch to the ON position.

E. While the jumper wire is in place, access the status screen that indicates the coolant level status.

F. Wait for 30 seconds. Read the status and record the status.

Expected Result:

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PPI
The coolant level status indicates "LOW" with the jumper in place.

Results:
-
202 0007
Proceed to Test Step 6. 3
15: 03/0 0CA
/ 4
OK - Leave the jumper wire in place. If a breakout T is installed, leave the breakout T in place also.

Not OK - Proceed to Test Step 7.

RE 2 4 : 3
N 2 3-0
Test Step 5. DISCONNECT THE TERMINAL FOR THE SENSOR SUPPLY (+5 VDC) FROM THE ECM
CONNECTOR
© 2 R13 5:00
023 67
Cat
erp
illa
r In
c.

Illustration 4 g01118013
Breakout T
(2) +5V supply
(5) AP sensor/switch common

A. Turn the keyswitch to the OFF position.

B. Disconnect the J1/P1 ECM connector.

C. Install a breakout T between the J1 and the P1 ECM connector.

D. Turn the keyswitch to the ON position.

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E. Measure the voltage at the breakout T from terminal 2 to terminal 5.

Refer to Illustration 4.

Expected Result:

The measured voltage is 5.0 ± 0.2 VDC.

Results:

OK - The problem is located in the harness wiring.

Repair: Repair the wiring or replace the wiring, as required.

Verify that the repair eliminates the problem.

STOP

Not OK - The problem is on the ECM side.

Repair: Temporarily connect a test ECM. Ensure that the "Coolant Level Sensor" is programmed to
match the old ECM. Check the test ECM by measuring the voltage at the breakout T from terminal
2 to terminal 5 again. If the problem is resolved with the test ECM, reconnect the suspect ECM. If
the problem returns with the suspect ECM, replace the ECM.

STOP

Test Step 6. CHECK THE WIRE HARNESS FOR THE COOLANT LEVEL LOW

Illustration 5 g00651008
Jumper wires

A. Turn the keyswitch to the OFF position.

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B. Use two jumper wires to connect terminal A (coolant level low) and terminal D (coolant level
normal) to terminal B (sensor common) at the harness connector.
Refer to Illustration 5.

C. Turn the keyswitch to the ON position.

D. While the jumper wires are in place, access the active diagnostic code screen on Cat ET.

E. Verify that 111-02 diagnostic code is active.

Note: Wait for 30 seconds for the activation of the diagnostic code.

Expected Result:

111-02 diagnostic code is active while the jumper wires are in place.

Results:

OK - The harness and the ECM are working correctly.

Repair: Remove the jumpers. Replace the sensor and ensure that 111-02 diagnostic code
disappears with the new sensor.

Verify that the repair eliminates the problem. Clear all diagnostic codes.

STOP

Not OK - Proceed to Test Step 7.

Test Step 7. CHECK THE ECM

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Illustration 6 g01118015
Breakout T
(5) AP sensor/switch common
(18) Input sensor common 1
(49) Coolant level normal
(54) Coolant level low

A. Turn the keyswitch to the OFF position.

B. Fabricate two jumper wires 100 mm (4 inch) long. Crimp a Deutsch pin to both ends of each wire.

C. Turn the keyswitch to the ON position.

D. Observe the coolant level sensor status on Cat ET. Install the jumper into the breakout T in order to
connect terminal 49 (coolant level normal) to terminal 5 (AP sensor/switch common).

E. Monitor the coolant level sensor status while the jumper is being inserted and removed. Wait for 30
seconds between the insertion of the jumper and the removal of the jumper. Waiting for 30 seconds
allows the ECM to acknowledge the change. While the jumper remains in place, a 111-01
diagnostic code should be active.

F. Record the result.

G. Leave the jumper installed in the breakout T.

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H. Install a jumper wire from 54 coolant level low to 18 input sensor common 1 of the breakout T.

I. While both jumper wires are in place, access the active diagnostic code screen. Verify that 111-02
diagnostic code is active.
Wait for 30 seconds for the activation of the diagnostic code.

Refer to Illustration 6.

Expected Result:

The coolant level sensor status behaves in the following manner:

The Coolant Level Sensor Status indicates "OK" before the jumper wire is installed between
terminal 49 and terminal 5. 111-02 diagnostic code may be active.

The coolant level sensor status changes to "LOW" after the jumper wire is installed between
terminal 49 and terminal 5. Also, the diagnostic code 111-01 is active.

111-02 diagnostic code is active when both jumper wires are installed.

Results:

OK - The ECM is functioning properly.

Repair: Repair the harness or replace the harness, as required.

Verify that the repair eliminates the problem. Clear all diagnostic codes.

STOP

Not OK -
Repair: Temporarily connect a test ECM. Ensure that the "Coolant Level Sensor" is programmed to
match the old ECM. If the problem is resolved with the test ECM, reconnect the suspect ECM. If the
problem returns with the suspect ECM, replace the ECM.

STOP

Test Step 8. INSPECT ELECTRICAL CONNECTORS AND WIRING FOR THE 2-WIRE FLOAT
SENSOR

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Illustration 7 g00882602
This is a typical schematic for the 2-wire float sensor.
The return wire may be connected to P1-3, P1-5, or P1-18.

Illustration 8 g01153501
Pin locations on ECM connector
(P1-5) AP sensor/switch common
(P1-26) Coolant level input

A. Thoroughly inspect the J1/P1 ECM connector, the connector for the coolant level sensor and the
terminals for the coolant level sensor in the connectors. Refer to Troubleshooting, "Electrical
Connectors - Inspect" for details.

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B. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with
the following connections:

P1-26 coolant level input

P1-5 AP sensor/switch common

Refer to Illustration 8.

C. Check the ECM connector (allen head screw) for the proper torque. Refer to Troubleshooting,
"Electrical Connectors - Inspect" for details.

D. Check the harness and wiring for abrasion and pinch points from the sensor to the ECM.

Expected Result:

All connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are
free of corrosion, of abrasion or of pinch points.

Results:

OK - Proceed to Test Step 9.

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. Clear all diagnostic codes.

STOP

Test Step 9. DISCONNECT THE COOLANT LEVEL SENSOR AND CHECK THE SUPPLY VOLTAGE
(+5 VDC)

A. Turn the keyswitch to the OFF position.

B. Disconnect the coolant level sensor from the harness.

C. Use a multimeter to measure the voltage at the harness connector.

D. Turn the keyswitch to the ON position.

Expected Result:

The measured voltage is 5.0 ± 0.2 VDC.

Results:

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OK - The correct voltage is reaching the sensor.

Repair: Replace the sensor.

STOP
PPI
Not OK - Proceed to Test Step 10. -
202 0007
3
15: 03/0 0CA
/ 4
Test Step 10. DISCONNECT THE TERMINAL FOR THE SENSOR SUPPLY (+5 VDC) FROM THE
ECM CONNECTOR

2
RE 4:23- 3
N 0
©2 R 136 5:00
023 7
Cat
erp
illa
r In
c.

Illustration 9 g01118029
Breakout T
(5) AP sensor/switch common
(26) Coolant level input

A. Turn the keyswitch to the OFF position.

B. Disconnect the J1/P1 ECM connector.

C. Install a breakout T between the J1 and P1 ECM connector.

D. Turn the keyswitch to the ON position.

E. Measure the voltage at the breakout T from terminal 26 to terminal 5.

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Refer to Illustration 9.

Expected Result:

The measured voltage is 5.0 ± 0.2 VDC.

Results:

OK - The problem is located in the harness wiring.

Repair: Repair the wiring or replace the wiring, as required.

Verify that the repair eliminates the problem.

STOP

Not OK - The problem is on the ECM side.

Repair: Temporarily connect a test ECM. Ensure that the "Coolant Level Sensor" is programmed to
match the old ECM. Check the test ECM by measuring the voltage at the breakout T from terminal
26 to terminal 5 again. If the problem is resolved with the test ECM, reconnect the suspect ECM. If
the problem returns with the suspect ECM, replace the ECM.

STOP

PPI-000740CA
2023/03/03
15:18:23-05:00
i01808160
© 2023 Caterpillar Inc.

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