PUMP GP-WATER 0R0804 - Caterpillar

Use this procedure to troubleshoot the electrical system if a problem is suspected with the air shutoff system. Also, use this procedure if any one of the diagnostic codes in Table 1 is active or easily repeated.
Table 1
CDL Code and Description Conditions which Generate this Code System Response
337-2 Remote Emergency Stop Switch : Erratic, Intermittent, or Incorrect The two inputs from the emergency stop switch are in the opposite state. The code is logged.
446-5 Air Shutdown Relay : Current Below Normal The Electronic Control Module (ECM) detects an open circuit and/or a short to the +Battery in the solenoid circuit. The code is logged.
446-6 Air Shutoff Relay short The ECM detects a short circuit to ground in the solenoid circuit.
Illustration 1 g01827000
Schematic for the air shutoff system if equipped with an A4 ECM
Illustration 2 g06325126
Schematic for the air shutoff system if equipped with an A5 ECM
Table 2
Troubleshooting Test Step Values Results
1. Inspect the Electrical Connectors and the Wiring
A. Turn the battery disconnect switch to the OFF position.
B. Verify that the air shutoff mechanisms are set to the OPEN position.
C. Thoroughly inspect the electrical connectors and switches for the air shutoff that are on both sides of the engine. Refer to Troubleshooting, "Electrical Connectors - Inspect"
D. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the air shutoff system.
E. Check the allen head screw on each ECM connector for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
F. Check the harness and the wiring for abrasion and for pinch points from the air shutoff solenoid to the ECM.
Connectors
Results: The connectors and wiring appear to be OK.
Proceed to Test Step 2
Results: The connectors and/or wiring are not OK.
Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. Ensure that all the seals are properly in place and ensure that the connectors are coupled. Verify that the problem is resolved.
Table 3
Troubleshooting Test Step Values Results
2. Test the Operation of the Control Solenoid for the Air Shutoff Relay and Check for Logged Codes
A. Connect Cat ET to the service tool connector.
B. Turn the battery disconnect switch to the ON position.
C. Test the air shutoff system with the emergency stop switch:
a. Start the engine.
b. Place the emergency stop switch in the STOP position.
c. Check the position of the air shutoff mechanisms. Activation of the emergency stop will activate the air shutoff system and the air shutoff mechanisms will close.
Check that the solenoid has de-energized after the air shutoff mechanisms are closed.
d. Turn the battery disconnect switch to the OFF position.
D. Check the status of the "Air Intake Shutoff Position" parameter