Injector Response - Test Engine Caterpillar C-4.2 & C-6.4 PDF

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Injecto Inje ctorr Respons Responsee - Tes Testt SMCS - 1290-038 System Operation Description:

Use this procedure to troubleshoot the electrical system if a problem problem is suspected with the injector response or if any one of the diagnostic codes in Table 1 is actie or easily repeated! Table 1 Diagnostic Codes Table Description

Conditions which Generate this Code

System System Response Response

(ata from the electronic electronic unit injector injector is out of limits!

The code is logged! logged! $f e)uipped' the warning light will illuminate! The engine engine will will be derated!

The electronic electronic unit injector injector is no longer capable of deliering the correct correct amount amount of fuel!

The code is logged! $f e)uipped' the warning light will illuminate! The engine will be derated!

2-2 "ylinder #2 $njector % &rratic' $ntermittent' $ntermittent' or $ncorrect

The data from the electronic unit injector is out of limits!

The code is logged! $f e)uipped' the warning light will illuminate! The engine will be derated!

2-* "ylinder #2 $njector % +ot ,esponding roperly

The electronic electronic unit unit injector injector is no longer capable of deliering the correct amount of fuel!

The code is logged! $f e)uipped' the warning light will

1-2 "ylinder #1 $njector % &rratic' $ntermittent' or $ncorrect

1-* "ylinde "ylinderr #1 $njector $njector % +ot ,esponding roperly

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illuminate. The engine will be derated.

The data from the electronic unit injector i out of limit.

The code i logged. If e!ui""ed, the warning light will illuminate. The engine will be derated.

The electronic unit injector i no longer ca"able of deli'ering the correct amount of fuel.










*-2 Cylinder #* Injector : Erratic, Intermittent, or Incorrect C6.4 only



*- Cylinder #* Injector : $ot %e"onding &ro"erly C6.4 only


The code i logged. If e!ui""ed, the warning light will

3-2 Cylinder #3 Injector : Erratic, Intermittent, or Incorrect

3- Cylinder #3 Injector : $ot %e"onding &ro"erly

(-2 Cylinder #( Injector : Erratic, Intermittent, or Incorrect

(- Cylinder #( Injector : $ot %e"onding &ro"erly

)-2 Cylinder #) Injector : Erratic, Intermittent, or Incorrect C6.4 only

)- Cylinder #) Injector : $ot %e"onding &ro"erly C6.4 only

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illuminate. The engine will be derated. The following background information is related to this procedure:

The engine has electronic unit injectors that are controlled by the Electronic Control Module (ECM). The ECM sends a pulse to each injector solenoid. The pulse is sent at the correct time and for the correct duration for a given engine load and engine speed. Use this procedure to identify the cause of the diagnostic code. Use this procedure to repair the system. f an injector is replaced! then the correct injector trim file must be programmed into the ECM. The injector trim file allows each individual injector to be fine tuned for optimum performance. The ECM will generate the following diagnostic code if the injector codes are not programmed" * #$%&'# rogrammed arameter ault erratic! intermittent! or incorrect Note: +iscard all fuel injection lines after use. Fuel injection lines must only be used one time.

,efer to service Troubleshooting! -njector Trim ile & nstall- for further information. Use the Caterpillar Electronic Technician (ET) in order to perform the -uel ystem /erification & Test.-. The -uel ystem /erification & Test.- is used to chec0 that the system operates correctly after a repair has been made.

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llustration 2

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Typical e4ample of the electronic unit injector

llustration # chematic for the C3.# injector solenoid circuit

llustration 1 chematic for the C$.3 injector solenoid circuit


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llustration 3 7 typical view of the # connector (harness side) pin locations. (AB) njector 2supply (1A) njector 2 return (A%) njector # supply (13) njector # return (A) njector 1 supply (11) njector 1 return ($3) njector 3 supply (%) njector 3 return ($1) njector A supply (C$.3 only) (B) njector A return (C$.3 only) ($#) njector $ supply (C$.3 only) ($) njector $ return (C$.3 only)

llustration A


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A typical view of the P2 connector (ECM side) pin locations.

Test Step 1. Inspect Electrical Connectors and Wiring

Electrical shock hazard. The electronic unit injector system uses 677! "olts.

A. Turn the keyswitch to the O position. A stron! electrical shock ha"ard is present if the power is not re#oved.

$llustration %

!&'2*+

Typical en!ine ECM (') ,2 ECM connector (2) ,' ECM connector

. Thorou!hly inspect connector P2. Thorou!hly inspect any wirin! or connectors that are associated with the circuit. -efer to service Trouleshootin!/ 0Electrical Connectors 1 $nspect0 for details. C. Perfor# a 3 4 ('& l) pull test on each of the wires in the ECM connector that are associated with in5ector solenoids.

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!. Check the torque of the allen head screws for the ECM connectors. Refer to service Troubleshooting, "Electrical Connectors - Insect" for the correct torque values. E. Check the harness and wiring for abrasion and for inch oints fro the in#ectors to the ECM. Expected Result:

$ll connectors, ins, and sockets are coletel% couled and&or inserted and the harness is free of corrosion, of abrasion and of inch oints. Results:

 OK - The harness is '(. )roceed to Test *te +.  Not OK - There is a roble in the connectors and&or the harness. Repair: Reair the connectors or the harness and&or relace the connectors or the harness. Ensure that all of the seals are correctl% in lace and ensure that the connectors are coletel% couled.)erfor a wiggle test with Cat ET in order to identif% interittent connections.erif% that the reair eliinates the roble. STOP Test Step 2. Check for Dia!ostic Codes That "re Related to this Procedure.

$. Connect Cat ET to the diagnostic connector. /. Turn the ke%switch to the ' osition. C. Check for logged diagnostic codes that are related to this rocedure. !. Make a note of the logged diagnostic codes. Expected Result: Expected Result #

'ne or ore diagnostic codes are logged. Expected Result 2

'n four c%linder engines, in#ectors 0 and 1 share a coon in#ector driver circuit within the ECM and in#ectors + and 2 share a coon in#ector driver circuit within the ECM. 'n si3 c%linder engines, in#ectors 0, + and 2 share a coon in#ector driver circuit within the ECM and in#ectors 1, 4 and 5 share a coon in#ector driver circuit within the ECM. Note: $ wire harness fault or a fault% in#ector driver circuit within the ECM are ossibilities that share the sae diagnostic codes. These codes can coe fro two or three in#ectors that share a coon sul%. Results:

 OK - Result 0 'ne or ore diagnostic codes are logged. )roceed to Test *te 2.

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 OK - Result 2 On four cylinder engines, the two injectors that share a common supply indicate the same diagnostic code. On six cylinder engines, the three injectors that share a common supply indicate the same diagnostic code. Proceed to Test Step 4.  Not OK - !o related diagnostic codes are logged. Repair: The pro"lem may ha#e "een intermittent. Refer to ser#ice Trou"leshooting, $%lectrical &onnectors ' (nspect$. STOP Test Step 3. Check the Faulty Cylinder Numers

+. )se the &at %T in order to ma*e a note of the logged diagnostic codes. . )se the noted diagnostic codes in order to chec* the cylinders for faulty injectors. !"pected Result:

The diagnostic codes indicate the cylinder num"ers that ha#e faulty injectors. Results:

 OK - !o related diagnostic codes are logged. Repair: The pro"lem may ha#e "een intermittent. Refer to ser#ice Trou"leshooting, $%lectrical &onnectors ' (nspect$. STOP

 Not OK - Result - + ' diagnostic code was acti#e. Proceed to Test Step /.  Not OK - Result 2 + '2 diagnostic code was logged. Proceed to Test Step 4. Test Step #. Check the $arness et%een the !C& and the 'al(e Co(er )ase *or an Open Circuit

!lectrical shock ha+ard. The electronic unit in,ector system uses -3 (olts.

+. Turn the *eyswitch to the O00 position. + strong electrical shoc* ha1ard is present if the *eyswitch is not turned O00. . isconnect the connectors from the #al#e co#er "ase. &. Turn the *eyswitch to the O! position. . 0a"ricate a jumper wire -33 mm 4 inch5 long with terminals on "oth ends of the wire.

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E. Insert one end of the jumper wire into the terminal for the suspect injector's supply. Insert the other end of the jumper wire into the terminal for the suspect injector's return circuit. F. Perform the "Injector Solenoid Test" at least two times. !. Repeat this test for each suspect injector. Stop the "Injector Solenoid Test" before handlin the jumper wires. Expected Result:

at ET displays "urrent #bo$e %ormal" for the cylinder with the jumper wire. Results:

 OK - at ET displays "urrent #bo$e %ormal" for the cylinder with the jumper wire. There is not an open circuit. Proceed to Test Step &.  Not OK - at ET does not display "urrent #bo$e %ormal" for the cylinder with the jumper wire. There may be a problem with the E( and)or the harness. Proceed to Test Step &. Test Step 5. Check the Injector Harness nder the !al"e Co"er

Electr#cal shock ha$ard. The electron#c un#t #njector s%ste& uses '(-() "olts.

#. Turn the *eyswitch to the +FF position. # stron electrical shoc* ha,ard is present if the *eyswitch is not turned +FF. -. Remo$e the $al$e co$er. . +n four cylinder enines disconnect the harness from the suspect injector. /isconnect the harness from the injector that shares the same supply circuit as the suspect injector. Note: +n four cylinder enines injectors 0 and 1 share a common injector dri$er circuit in the E(. Injectors 2 and 3 share a common injector dri$er circuit in the E(. If the two injectors that share a common supply indicate "+pen ircuit Fault odes" the open circuit is probably caused by a faulty E(.

/. +n si4 cylinder enines disconnect the harness from the suspect injector. /isconnect the harness from the injectors that shares the same supply circuit as the suspect injector. Note: +n si4 cylinder enines injectors 0 2 and 3 share a common injector dri$er circuit in the E(. Injectors 1 & and 5 share a common injector dri$er circuit in the E(. If three injectors that share a common supply indicate "+pen ircuit Fault odes" the open circuit is probably caused by a faulty E(.

E. +n four cylinder enines thorouhly clean the terminals on the two injectors and on the harness connectors.

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F. +n si4 cylinder enines thorouhly clean the terminals on the three injectors and on the harness connectors. !. +n four cylinder enines e4chane the harness between the two injectors that share the common dri$er. =. +n si4 cylinder enines e4chane the harness between two of the injectors that share the common dri$er. I. Turn the *eyswitch to the +% position. D. Perform the "Injector Solenoid Test" at least two times. Expected Result:

E4chanin the harness between the two injectors caused the fault to mo$e to the other injector. Results:

 OK - There is a fault with the injector harness under the $al$e co$er. Repa#r: Repair the injector harness or replace the injector harness under the $al$e co$er.;se the electronic ser$ice tool in order to clear all loed dianostic codes and then $erify that the repair eliminates the fault. STO*

 Not OK - The harness does not ha$e an open circuit. Proceed to Test Step 5. Test Step '. Check the Harness +et,een the EC and the !al"e Co"er ase /or a Short C#rcu#t

Electr#cal shock ha$ard. The electron#c un#t #njector s%ste& uses '(-() "olts.

#. Turn the *eyswitch to the +FF position. # stron electrical shoc* ha,ard is present if the *eyswitch is not turned +FF. -. /isconnect the connectors from the $al$e co$er base. . Turn the *eyswitch to the +% position. /. Perform the "Injector Solenoid Test" at least two times. Expected Result:

#ll cylinders indicate "urrent -elow %ormal". Results:

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• OK - All cylinders indicate "Current Below Normal". Proceed to Test Step 7. • Not OK - One or more cylinders indicate "Current Above Normal". Note te cylinders tat indicate "Current Above Normal". Proceed to Test Step !. Test Step 7. Check the Engine Harness Under the Valve Cover for a Short Circit

Electrical shock ha!ard. The electronic nit in"ector s#ste$ ses %7-7& volts.

A. Turn te eyswitc to te O## position. A stron$ electrical soc a%ard is present i& te eyswitc is not turned O##. B. 'emove te valve cover. C. (isconnect eac o& te in)ectors tat indicate a "Sort" &rom te wirin$ arness. *nsure tat eac o& te connectors &rom te disconnected in)ector arness does not touc any oter components. (. Turn te eyswitc to te ON position. *. Per&orm te "+n)ector Solenoid Test" at least two times. E'pected (eslt)

All o& te in)ectors tat were disconnected indicate "Current Below Normal". (eslts)

• OK - All o& te in)ectors tat were disconnected indicate "Current Below Normal". Proceed to Test Step !. • Not OK - One or more o& te in)ectors tat were disconnected indicate "Current Above Normal". Proceed to Test Step ,. Test Step *. Check for a Short Circit in the (etrn +ire

Electrical shock ha!ard. The electronic nit in"ector s#ste$ ses %7-7& volts.

A. Turn te eyswitc to te O## position. A stron$ electrical soc a%ard is present i& te eyswitc is not turned O##.

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B. Disconnect the connector P2 from the ECM. C. Locate the terminal for the return of the faulty injector in the connector P2. Measure the resistance from the terminal to the engine ground stud. Expected Result:

The resistance is greater than 10 hms. Results:

! OK - The resistance is greater than 10 hms. Repair: "econnect connector P2."e#lace the faulty injector.$se the electronic ser%ice tool in order to clear all logged diagnostic codes.Perform the &'njector (olenoid Test&.)erify that the re#air eliminates the fault. STOP

! Not OK - There is a short in the return line. Repair: Disconnect the connectors from the %al%e co%er *ase.Measure the resistance of the return +ire *et+een connector P2 and the engine ground stud.'f the resistance is less than 10 hms, the fault is in the return +ire *et+een the ECM and the %al%e co%er *ase.'f the resistance is greater than 10 hms, the fault is in the return +ire under the %al%e co%er."e#air the injector harness or re#lace the injector harness.$se the electronic ser%ice tool in order to clear all logged diagnostic codes and then #erform the &'njector (olenoid Test& in order to %erify that the re#air eliminates the fault. STOP Test Step 9. Check the ECM for Proper Operatio

Electrical shock ha!ard. The electroic uit i"ector s#ste$ uses %&-&' (olts.

-. "emo%e the electrical #o+er from the ECM. B. a*ricate a jum#er that is long enough to reach from the P2 ECM connector to the engine ground stud. Crim# a soc/et terminal to one end of the jum#er +ire. C. Disconnect the P2 connector. D. "emo%e the su##ly +ire for the sus#ect injector from the ECM connector. 'nstall the jum#er +ire into the soc/et. E. Connect the 2P2 ECM connector. . )erif# that the ECM *ill detect a ope circuit for the suspect i"ector:

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a. Ensure that the jumper wire is not in contact with any ground source or another circuit. Do not touch the jumper wire during the test. A strong electrical shock hazard is present at the jumper wire while the test is running. b. Restore the electrical power to the ECM. c. Perorm the !"njector #olenoid $est! at least two times. d. Remo%e the electrical power rom the ECM. For a circuit that is in good repair, Cat ET will display "Open" for the two injectors that share the supply wire.

&. Verify that the ECM detects a short circuit for the suspect injector: a. Connect the jumper wire to the engine ground stud. Do not touch the jumper wire during the test. A strong electrical shock hazard is present at the jumper wire while the test is running. b. Restore the electrical power to the ECM. c. Perorm the !"njector #olenoid $est! at least two times. d. Remo%e electrical power rom the engine ECM. For a circuit that is in good repair, Cat ET will display "hort" for the two injectors that share the supply wire. E!pected esult:

Cat E$ displays the correct status or each test circuit. esults:

' O# $ $he ECM detects the correct status o the circuit. epair: Replace the injector. Reer to the Disassembly and Assembly manual.(eriy that the problem is resol%ed. TO%

' &ot O# $ $he ECM does not detect the correct status o the circuit. epair: $here is a problem with the ECM. Perorm the ollowing procedure)

*. $emporarily connect a test ECM. Reer to $roubleshooting+ !ECM , Replace!. -. Recheck the circuit in order to ensure that the original problem has been resol%ed. " the problem is resol%ed with the test ECM+ install the suspect ECM. " the problem returns with the suspect ECM+ replace the ECM. (eriy that the problem is resol%ed. " the problem is not resol%ed with the test ECM+ install the original ECM. $here is a problem in the wiring.

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TO% Copyright 1993 - 2011 Caterpillar Inc.

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Injector Response - Test Engine Caterpillar C-4.2 & C-6.4 PDF

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