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SPECIAL INSTRUCTION

Reference: SI E0920
June 17, 2009

Attention: This notice is being issued to advise you of new information for certain
Caterpillar (CAT) Telehandlers that were manufactured by JLG Industries,
Inc. (JLG).

TITLE:
Diagnostic Code Information for Transmission and/or Engine control systems used
on certain CAT Branded Telehandlers.

APPLICABLE PRODUCTS:

Model Serial Number Range


TH336 TDE00100 & After

TH337 TDF00100 & After

TH406 TBX00100 & After

TH407 TBY00100 & After

TH414 TBZ00100 & After

TH514 TBW00100 & After

TH417 TBT00100 & After

INTRODUCTION:
The diagnostic code information that follows is utilized by certain CAT Branded Telehandlers
that are equipped with Caterpillar electronic controls.
Component identifiers, failure mode identifiers, and module identifiers are pieces of information
that assist service personnel in diagnosing system problems of the machine.
A component identifier (CID) is a diagnostic code that informs the service personnel of the
specific circuit or system within which a problem was detected.
A failure mode identifier (FMI) is a diagnostic code that informs the service personnel of the type
of problem that has been detected within a circuit or system.
Event codes identify significant events that occur to the systems of the machine. The ECM
stores the data from the events.
This function allows tracking of the history of the machine. The data is used as an aid for
managers and maintenance personnel.

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TRANSMISSION RELATED DIAGNOSTICS
Details are following for the transmission control system related diagnostics that are
supported by the system. This system will support diagnostic reporting in SAE J1939
SPN-FMI format only.

SPN Description

FMI Description

Warning Level
SPN

FMI
678 ECU 8 Volts DC Supply 3 Voltage Above Normal 2

678 ECU 8 Volts DC Supply 4 Voltage Below Normal 2

168 Electrical Potential (voltage) 3 Valid & Above Normal Range 2

168 Electrical Potential (voltage) 4 Valid & Below Normal Range 2

639 J1939 Network #1 9 Abnormal Update 2

525 Transmission Requested Gear 19 Received Network Data in Error 2

683 Disengage Driveline Request 19 Received Network Data in Error 2

177 Transmission Oil Temperature 3 Voltage Above Normal 2

177 Transmission Oil Temperature 4 Voltage Below Normal 2

190 Engine Speed 19 Received Network Data in Error 2

191 Transmission Output Shaft Speed 2 Data Erratic, Intermittent or Incorrect 1

161 Transmission Input Shaft Speed 2 Data Erratic, Intermittent or Incorrect 1

4216 Transmission Reverse Solenoid Valve 3 Voltage Above Normal 3

4216 Transmission Reverse Solenoid Valve 5 Current Below Normal 2

4216 Transmission Reverse Solenoid Valve 6 Current Above Normal 2

741 Transmission Forward Solenoid Valve 3 Voltage Above Normal 3

741 Transmission Forward Solenoid Valve 5 Current Below Normal 2

741 Transmission Forward Solenoid Valve 6 Current Above Normal 2

734 Transmission Range Clutch Solenoid #1 3 Voltage Above Normal 3

734 Transmission Range Clutch Solenoid #1 5 Current Below Normal 2

734 Transmission Range Clutch Solenoid #1 6 Current Above Normal 2

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735 Transmission Range Clutch Solenoid #2 3 Voltage Above Normal 3

735 Transmission Range Clutch Solenoid #2 5 Current Below Normal 2

735 Transmission Range Clutch Solenoid #2 6 Current Above Normal 2

736 Transmission Range Clutch Solenoid #3 3 Voltage Above Normal 3

736 Transmission Range Clutch Solenoid #3 5 Current Below Normal 2

736 Transmission Range Clutch Solenoid #3 6 Current Above Normal 2

737 Transmission Range Clutch Solenoid #4 3 Voltage Above Normal 3

737 Transmission Range Clutch Solenoid #4 5 Current Below Normal 2

737 Transmission Range Clutch Solenoid #4 6 Current Above Normal 2

738 Transmission Range Clutch Solenoid #5 3 Voltage Above Normal 3

738 Transmission Range Clutch Solenoid #5 5 Current Below Normal 2

738 Transmission Range Clutch Solenoid #5 6 Current Above Normal 2

2827 Power Up Without Neutral 31 Not Available or Condition Exists 3

Transmission Shift Modulation Solenoid


4217 3 Voltage Above Normal 3
Valve

Transmission Shift Modulation Solenoid


4217 5 Current Below Normal 2
Valve

Transmission Shift Modulation Solenoid


4217 6 Current Above Normal 2
Valve

4218 Transmission Shift Rail 1 Position 3 Voltage Above Normal 2

4218 Transmission Shift Rail 1 Position 4 Voltage Below Normal 2

Abnormal Frequency, Pulse Width or


4218 Transmission Shift Rail 1 Position 8 2
Period

4219 Transmission Shift Rail 2 Position 3 Voltage Above Normal 2

4219 Transmission Shift Rail 2 Position 4 Voltage Below Normal 2

Abnormal Frequency, Pulse Width or


4219 Transmission Shift Rail 2 Position 8 2
Period

4220 Transmission Shift Rail 3 Position 3 Voltage Above Normal 2

4220 Transmission Shift Rail 3 Position 4 Voltage Below Normal 2

Abnormal Frequency, Pulse Width or


4220 Transmission Shift Rail 3 Position 8 2
Period

Transmission Directional Shift at High


4221 14 Special Instruction 3
Speed

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ENGINE RELATED DIAGNOSTICS
Note that in some case there are differences in the codes which are transmitted on the
J1939 bus and those are transmitted on the CDL bus. Additionally codes may be added
on later software that are not present on this table.

Lamp Flash Code

Component

Description
J1939 SPN

[ future ]
CID/EID
Type

FMI
data erratic intermittent or
Diagnostic 91 91 2 154 Throttle Position Sensor incorrect

Voltage above normal or


Diagnostic 91 91 3 154 Throttle Position Sensor shorted high

Voltage above normal or


Diagnostic 774 91 3 155 Secondary throttle position sensor shorted high

Voltage below normal or


Diagnostic 91 91 4 154 Throttle Position Sensor shorted low

Voltage below normal or


Diagnostic 774 91 4 155 Secondary throttle position sensor shorted low

abnormal frequency, pulse


Diagnostic 91 91 8 154 Throttle Position Sensor width, or period

abnormal frequency, pulse


Diagnostic 774 91 8 155 Secondary throttle position sensor width, or period

Diagnostic 91 91 12 154 Throttle Position Sensor Bad Device or component

Diagnostic 774 91 12 155 Secondary throttle position sensor Bad Device or component

voltage above normal or


Diagnostic 100 100 3 157 Engine Oil pressure Sensor shorted high

voltage below normal or


Diagnostic 100 100 4 157 Engine Oil pressure Sensor shorted low

Engine oil pressure sensor


5V supply connection open
Diagnostic 100 100 10 157 Engine Oil pressure sensor circuit

low oil pressure -


Event 360 100 17 n/a Engine Oil pressure sensor WARNING

Event 360 100 18 n/a Engine Oil pressure sensor Low oil Pressure - DERATE

Low Oil Pressure -


Event 360 100 1 n/a Engine Oil pressure sensor SHUTDOWN

High Intake manifold


Event 539 105 15 n/a Inlet Manifold Air Temp Sensor temperature - WARNING

High Intake manifold


Event 539 105 16 n/a Inlet Manifold Air Temp Sensor temperature - DERATE

voltage above normal or


Diagnostic 172 105 3 133 Inlet Manifold Air Temp Sensor shorted high

voltage below normal or


Diagnostic 172 105 4 133 Inlet Manifold Air Temp Sensor shorted low

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voltage above normal or
Diagnostic 1785 106 3 135 Inlet Manifold Pressure Sensor shorted high

voltage below normal or


Diagnostic 1785 106 4 135 Inlet Manifold Pressure Sensor shorted low

Inlet Manifold Pressure


Sensor 5V supply
Diagnostic 1785 106 10 135 Inlet Manifold Pressure Sensor connection open circuit

High coolant temp -


Event 361 110 15 n/a Engine Coolant Temp Sensor WARNING

High coolant temp -


Event 361 110 16 n/a Engine Coolant Temp Sensor DERATE

voltage above normal or


Diagnostic 110 110 3 169 Engine Coolant Temp Sensor shorted high

High coolant temp -


Event 361 110 0 n/a Engine Coolant Temp Sensor SHUTDOWN

voltage below normal or


Diagnostic 110 110 4 169 Engine Coolant Temp Sensor shorted low

Voltage above normal or


Diagnostic 1797 157 3 n/a Fuel Rail pressure sensor shorted high

Voltage below normal or


Diagnostic 1797 157 4 n/a Fuel Rail pressure sensor shorted low

data erratic, intermittent, or


Diagnostic 1834 158 2 439 Keyswitch incorrect

Diagnostic 168 168 0 422 ECM battery power Excessive battery power

Diagnostic 168 168 1 422 ECM battery power Low battery power

Diagnostic 168 168 2 422 ECM battery power intermittent

Diagnostic 190 190 8 141 Speed/Timing sensor abnormal signal frequency

Engine Overspeed -
Event 362 190 15 n/a Engine Speed WARNING

Diagnostic 91 558 2 154 Throttle Position Sensor Idle validation switch

data erratic, intermittent, or


Diagnostic 774 558 2 155 Secondary throttle position sensor incorrect

Diagnostic 268 630 2 527 Customer or system parameters data incorrect

Diagnostic 253 631 2 415 Engine software data incorrect

Diagnostic 247 639 9 514 SAE J1939 data link Abnormal update

Diagnostic 526 646 5 177 Turbo Wastegate Solenoid Current Low

Diagnostic 526 646 6 177 Turbo Wastegate Solenoid Current High

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Turbo Wastegate not
Diagnostic 526 1188 7 177 Turbo Wastegate responding

Diagnostic 1 651 2 n/a Cylinder #1 Injector Injector Data Incorrect

Diagnostic 1 651 5 n/a Cylinder #1 Injector Injector Current Low

Diagnostic 1 651 6 n/a Cylinder #1 Injector Injector Current High

Diagnostic 1 651 7 n/a Cylinder #1 Injector Injector not responding

Diagnostic 1 651 2 n/a Cylinder #2 Injector Injector Data Incorrect

Diagnostic 2 652 5 n/a Cylinder #2 Injector Injector Current Low

Diagnostic 2 652 6 n/a Cylinder #2 Injector Injector Current High

Diagnostic 2 652 7 n/a Cylinder #2 Injector Injector not responding

Diagnostic 1 651 2 n/a Cylinder #3 Injector Injector Data Incorrect

Diagnostic 3 653 5 n/a Cylinder #3 Injector Injector Current Low

Diagnostic 3 653 6 n/a Cylinder #3 Injector Injector Current High

Diagnostic 3 653 7 n/a Cylinder #3 Injector Injector not responding

Diagnostic 1 651 2 n/a Cylinder #4 Injector Injector Data Incorrect

Diagnostic 4 654 5 n/a Cylinder #4 Injector Injector Current Low

Diagnostic 4 654 6 n/a Cylinder #4 Injector Injector Current High

Diagnostic 4 654 7 n/a Cylinder #4 Injector Injector not responding

Diagnostic 1 651 2 n/a Cylinder #5 Injector Injector Data Incorrect

Diagnostic 5 655 5 n/a Cylinder #5 Injector Injector Current Low

Diagnostic 5 655 6 n/a Cylinder #5 Injector Injector Current High

Diagnostic 5 655 7 n/a Cylinder #5 Injector Injector not responding

Diagnostic 1 651 2 n/a Cylinder #6 Injector Injector Data Incorrect

Diagnostic 6 656 5 n/a Cylinder #6 Injector Injector Current Low

Diagnostic 6 656 6 n/a Cylinder #6 Injector Injector Current High

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Diagnostic 6 656 7 n/a Cylinder #6 Injector Injector not responding
ECM 8V DC supply
voltage above normal or
Diagnostic 41 678 3 517 8V DC supply shorted high
ECM 8V DC supply
voltage below normal or
Diagnostic 41 678 4 517 8V DC supply shorted low

Diagnostic 190 190 8 143 Primary Engine Speed Sensor abnormal signal frequency

Diagnostic 342 723 8 142 Secondary Engine Speed Sensor abnormal signal frequency

voltage above normal or


Diagnostic 262 1079 3 516 5V sensor DC supply shorted high

voltage below normal or


Diagnostic 262 1079 4 516 5V sensor DC supply shorted low

Diagnostic 261 637 11 143 Primary to secondary speed sig calibration fault

Diagnostic 261 637 13 143 Primary to secondary speed sig Calibration required

Diagnostic 1779 1347 5 162 Fuel Rail Pump Output current low

Diagnostic 1779 1347 6 162 Fuel Rail Pump Output current high

Diagnostic 1779 1347 7 162 Fuel Rail Pump Not responding

Diagnostic 2246 676 5 199 Glow Plug Start Aid relay Current Low

Diagnostic 2246 676 6 199 Glow Plug Start Aid relay Current High

Event 194 2789 15 185 Exhaust High Temperature

Event 398 157 18 159 Fuel Rail pressure sensor Low Fuel Rail Pressure

Event 396 157 16 159 Fuel Rail pressure sensor High Fuel Rail Pressure

Low Intake Manifold


Event 1045 102 18 135 Intake Manifold pressure sensor Pressure

High Intake Manifold


Event 1044 102 16 135 Intake Manifold pressure sensor Pressure

Pressure Abnormal Rate of


Diagnostic 1785 102 10 197 Intake Manifold pressure sensor Change

Diagnostic 1834 158 2 439 Key Switch Erratic

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