Cat Electronic Technician Course 3-1-1 Module Three

01/04 Lesson One

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Lesson One: Cat ET Engine Diagnostic Functions

Introduction
This lesson covers the use of Cat ET for diagnosing electrical and
mechanical problems on Caterpillar engines. This information is generic
in nature unless otherwise indicated.
The subjects covered are:
• Diagnostic topics - Electronic Unit Injector Testing

- System Component Calibrations

- Miscellaneous Diagnostic Routines

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Electronic Unit Injector Testing

Accessing Diagnostic Routines

• Accessing injector Access to Cat ET Injector Tests is reached only through the Diagnostics
tests pull down menu as follows:
Diagnostics / Diagnostic Tests

• Two injector tests There are two basic injector tests which can be accessed from this menu
available depending on the application selected:
Injector Solenoid Test
Cylinder Cutout Test
There are a variety of methods of testing injectors within the two
categories listed above, these will be covered later.

The Injector Solenoid Test is accessed through the Diagnostics pull down
menu using the following menu sequence:

Diagnostics / Diagnostic Tests / Injector Solenoid Test

NOTE: The injection actuation test, override parameters, and the wiggle
test can also be accessed from the diagnostic tests menu and will be
covered later in the presentation.
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Injector Solenoid Tests

• Injector solenoid tests
• Automatic solenoid
test
• Faulty cylinders
identified
There are several methods of testing injectors (and cylinders) for
mechanical and electrical faults using Cat ET. The first category to be
described is the Injector Solenoid Test.
This test can be performed when troubleshooting injector open/short
diagnostic messages. The Solenoid Test is usually performed first
because it is done with the engine off.
The Injector Solenoid Test verifies that the circuits from the ECM to the
injector are currently functioning. The ECM injector power supply and
drivers, the external/internal wiring harnesses, and the injector solenoids
are tested.
If no active fault is found, the logged fault screen should be checked. It is
possible that a loose connection could cause an intermittent fault which
may not be evident at the time of testing.
There are two ways to test the solenoids. The first method, shown here, is
automatic, and tests each solenoid in sequence. Select the Test All button,
or the A key. A defective solenoid circuit will appear on the screen as
shown above. In this case, the screen shows cylinder 7 is open.
There are differences between the automatic test on highway truck and
machine engines, trucks will test the solenoids continuously in sequence
and machines will test once through the injectors and then stop.

NOTE: Striking the letter underlined on the button performs the same
function as clicking the button.
Cat Electronic Technician Course
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• Manual (individual)
injector solenoid test
• Interpretation of
solenoid test sounds
3-1-4 Module Three
Lesson One
1-4
The other method of testing injector solenoids is to individually test each
cylinder. This method is useful when an intermittent injector fault is
indicated on the Logged Fault screen. However, this method does not
work with on highway on truck engines.
With the suspect cylinder highlighted, select the Test button or the E key
on the keyboard. The solenoid can be repeatedly fired while the affected
wiring harness and connectors are manipulated. When the fault is found,
the Cat ET screen will show an open or short circuit as seen above.
In this case, the test has identified an open circuit on cylinder number 7.
This test is commonly called the "clack test" from the noise
accompanying injector solenoid actuation.
The sound, or lack of sound from the test, is not in itself, a conclusive
symptom of a faulty injector.
When testing a HEUI injector however, a dead cylinder with no sound at
all, but accompanied by a normal electrical test indication, could mean
that the poppet valve is stuck.
This condition could be caused by improper injector removal or
installation, resulting in misalignment of the poppet valve bore, and
thereby leading to a stuck poppet valve. The use of a pry bar to remove a
3408/12E HEUI injector usually causes distortion of some close tolerance
machined parts such as the poppet valve and valve body.
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Cylinder Cutout Test

• Cylinder cutout tests The Cylinder Cutout Test is the second category of injector tests. This
test can be used when no diagnostic message is present and the problem is
mechanical.

The test is accessed through the Diagnostics pull down menu using the
following menu sequence:

Diagnostics / Diagnostic Tests / Cylinder Cutout Test

Cat Electronic Technician Course
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• Automatic and manual
cylinder cutout tests
• Cutout controls
3-1-6 Module Three
Lesson One
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There are two basic Cylinder Cutout test routines, automatic and manual.
The automatic test, shown above, will test all cylinders and make a
comparison between them. The numbers are not a finite measurement but
are purely comparative. This test is performed with the engine running.
There are four buttons below the main box, at the bottom of the screen:
Change Cuts out an individual cylinder
Power All Re-powers a cutout cylinder
Start Starts the automatic sequence
Stop Stops the automatic sequence
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• Manual cutout test In the case of engines with 12 cylinders or more, it is difficult to tell if a
cylinder is misfiring. It is easier to find the defective cylinder by cutting
out one bank completely and then checking the other bank.

• Torque stall test Another method is to perform a torque stall and watch the rpm drop as
each cylinder is cutout. Typically the rpm will drop about 100 rpm as the
cylinder is cutout. A dead cylinder will show no change.

In the illustration above, the odd numbered cylinders have been cutout
and the even numbered cylinders are being tested. Cylinder No. 7 is being
manually cutout. The engine noise will change if it is a good cylinder and
will not if it is a dead cylinder.

Injection duration and fuel position will also change if it is a good

cylinder. Cutting out a bank adds a significant parasitic load to the
opposite bank and helps to show a more easily visible and audible change
when a cylinder is cutout. Adding more rpm (with a fixed throttle setting)
also helps, particularly with an eight cylinder engine.

To manually cutout a cylinder:

Highlight the desired cylinder, and

Click on the Change button or
Depress the letter C
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• Intermittent injector An intermittent injector fault can be recognized by the "Occ."

faults (occurrence) portion of the Logged Fault screen. In this case a No. 7
cylinder fault has registered 4 occurrences in about 1 hour between
33 and 34 engine hours. Usually the occurrences are much higher (around
100) and this will normally indicate that there is an intermittent problem
and is most likely caused by a loose connection.

• Locating a loose To locate this type of fault, return to the Injector Solenoid Test Screen and
connection highlight the cylinder in question. Press the Test key to perform the
"clack" test as the wiring is manipulated in various ways. Eventually, the
fault will be located as the wiring is disturbed.

The circuit should be retested and logged faults cleared. Note that an
active injector wiring fault cannot be observed on Cat ET unless the
engine is running. Conversely, a solenoid test is performed with the
engine stopped.
Cat Electronic Technician Course
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• Automatic injector
disconnect
• Cold cylinder cutout
strategy
• Cold cylinder cutout
disabled when:
- Throttle opened
- Gear selected
- Engine up to temp
- Parking brake off
3-1-9 Module Three
Lesson One
ECM Injection Strategies
If an out of normal range current flow is detected by the ECM, then the
injector will be deactivated for about 10 cycles. Thereafter, the ECM will
periodically retry the injector and disconnect if the problem is still
present. This explains why a suspect injector may be automatically
activated and deactivated at regular intervals on the cylinder cutout
screen.
Some 3500 engines employ a Cold Cylinder Cutout Strategy. This
process provides a means of reducing white smoke after a cold start. Also
some damage could be sustained by raw fuel washing down the cylinder
bore leading to a piston seizure.
During cold running conditions, the ECM determines if a cylinder is not
firing by turning off the cylinder and measuring the "rack." If there is no
change, then that cylinder is disconnected and the process moves on to the
next cylinder. The process continues until the complete engine is checked
for misfiring cylinders. The cycle repeats until the engine has warmed up.
The Cold Cylinder Cutout process is independent of cold mode. This
process is a function of coolant temperature, throttle position, parking
brake position, and some transparent parameters within the ECM. All of
the conditions have to be met in order for the strategy to be enabled.
If the throttle is opened, a gear is selected or the engine comes up to
temperature, the process is disabled. This process should not be confused
with a misfire caused by an electrical fault or other mechanical
malfunction.
NOTE: The term "rack" does not imply that a physical rack is present in
an EUI engine. The term is synonymous with that used with mechanical
fuel systems.
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System Component Calibrations

There are three components which are calibrated and covered in this
lesson:

Speed/Timing Sensors
Pressure Sensors
Injectors

• Speed/timing sensor Speed/Timing Sensor Calibration

calibration
Select the Speed/Timing Sensor calibration through the pull down menu
as follows:
Service / Calibrations / Timing Calibration
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Once the timing calibration sensor is installed, the engine is running, and
the calibration screen is initiated, press the Continue button at the lower
left hand portion of the calibration screen.
• Speed/timing sensor It is not always necessary to set the engine rpm for this procedure. This
calibration engine step is usually performed automatically by Cat ET when the timing
speed setting calibration sequence is initiated in the ECM. Engine speed is set to 800
rpm. If an error of 10º or more is detected, for example, timing
calibration is aborted. (These numbers may vary from application to
application.)
• Sensor calibration Calibration is required after an engine timing adjustment. If the ECM is
required after: replaced and the ECM Replacement Function is performed, the calibration
- ECM replacement data is copied with the other parameters to the new ECM. If not,
- Timing adjustment calibration is necessary. Most engine Service Manuals do not call for a
calibration after a Speed/Timing Sensor replacement. However, in this
case, good judgement may be the deciding factor.
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Pressure Sensor Calibration

• Two methods to There have been two methods to perform pressure sensor calibration; the
calibrate pressure key switch, and the Cat ET methods. The ET method has been deleted
sensors with some engines.

Using the same pull down menu used with Speed/Timing sensor
calibration, select:

Service / Calibrations / Pressure Sensor Calibration

• Cat ET pressure Unlike Speed/Timing Sensor Calibration, the engine cannot be running
sensor calibration during Pressure Sensor Calibration. The Pressure Sensor Calibration
feature is only present in the pull down menu if the feature applies to the
engine selected.

The atmospheric pressure sensor is used as the baseline to adjust the other
pressure sensor outputs. Other sensors with readings which do not agree
with the atmospheric sensor's output readings will be adjusted (within
limits) to agree with the atmospheric sensor.

Select Start or A to begin the sensor calibration.

Oil gauge pressure on ET is a calculation (oil pressure - atmospheric

pressure). On some engines it is possible to read absolute and gauge
pressures, they should not be confused.
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As long as the error is within the calibration range, the error will be
corrected by this process. If not, a repair is necessary.
There is a diagnostic routine built into the program which will identify a
calibration problem. It could be that a sensor is out of the normal output
range for calibration. For example, the reason for calibration may be that
oil pressure reads +4 psi (28 kPa) with the engine stopped. This means
that the oil pressure sensor absolute pressure reading is 19 psia (129 kPa).

Oil gauge pressure is a calculation (oil pressure - atmospheric pressure).

As long as the error is within the calibration range, the error will be
corrected by this process. If not, a repair is necessary.
Some engines only use the key switch method for calibration. To
calibrate the pressure sensors on most new engines, it is only necessary to
turn the keyswitch on for five seconds without starting the engine.
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• Status screen When troubleshooting a multiple pressure sensor problem, it is

configured for advantageous to create a status screen as shown above. All the sensor
troubleshooting
outputs can now be verified simultaneously.

When using the status screen to troubleshoot a problem, the oil pressure
sensor reading should agree with the atmospheric sensor reading with the
engine stopped. Most engine pressure sensors are the absolute type.

INSTRUCTOR NOTE: This scenario can be easily set up for a class

using the Training Aid simulation.

psia = pounds/sq. absolute

psig = pounds/sq. gauge
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EUI and HEUI Injector Calibration

Not all electronically controlled engines require injector calibration. In

this case, the example is a C-9 Industrial Engine (lower portion of screen).
To access Injector Calibration, use the following pull down menu
sequence:

Service / Calibrations / Injector Codes Calibration

• Injector calibration The purpose of Injector Calibration is to enable a more precise fuel flow
balances fuel flow and timing balance between cylinders. The injectors are flow checked
and timing between
and calibrated at the factory. Any minute fuel flow deviations are
cylinders
represented by a code stamped on the top of the injector. These codes are
programmed into the ECM with the injector calibration function.

If for any reason, injectors are changed, or interchanged, it is essential that

calibration is performed for the affected injectors to avoid imbalance
between cylinders.

There are two types of injector calibration.

• Two forms of injector Trim code calibration

calibration
Trim file calibration (used with ACERT engines)
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The numbers seen on the right hand side are the default values which will
be used if no values are pre-programmed.

As the values from the injectors are read, they are transferred to the ECM
using this screen. This process provides a more even flow to each
cylinder, and therefore more even, smooth power balance throughout the
engine.

To input the code:

• Input injector
calibration codes Highlight the desired injector, as seen above
Click on the Change button
Enter the new code in the change screen
Confirm the change by selecting OK
The changes are automatically saved as each injector code is entered.

• ECM replacement All the calibrations previously mentioned are copied over to a new ECM
if the Copy Configuration / ECM Replacement function is performed
when the ECM is replaced. The only parts that must be manually
performed are the loading of the flash file and rating selection.
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ACERT Injector Trim Calibration

Engines with ACERT Technology have a very different method of trim
calibration from previous engines. Injector trim calibration results in each
injector performing virtually identically within very close limits
throughout the operational envelope.

In order to reach the very finely required tolerances in injector

performance and to meet the current EPA requirements with on highway
truck engines, the injectors must be calibrated to very fine tolerances. At
every point on the operational speed curve, each of the injectors must
perform with identical timing and fuel quantity. This degree of accuracy
is only possible with a multiple point calibration, which in turn is only
possible with very sophisticated calibration data uploaded to the ECM.

Software maps were previously in the ECM. The ECM would select the
correct map using the trim code from the face of the injector. This code
was typically 4 or 6 digits.

Injector trim calibration on engines with ACERT Technology have a

greater volume of information to be uploaded to the ECM than before.
This volume precludes the use of simple trim codes normally stamped on
the injector. The trim code if used, would contain hundreds of characters,
obviously not practical in this case.
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• Trim files used for In order to accommodate this volume of data, it is loaded into a trim file
calibration which is uploaded to the Engine ECM.

Engine with ACERT Technology are also now appearing in other

applications including machines. These engines will also require injector
calibration using trim files.
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Downloading Injector Trim Files

As previously mentioned, the injectors are calibrated using data from a
file. The file is identified by the injector serial number (seen on the
following illustrations). This process is not unlike the flash program
process.

• Trim file sources: The files are stored and can be retrieved using SIS (Service Information
- SIS Windows System). The files are also provided with the replacement injectors on
- SIS Web CD.
- SIS Network
- CD ROM with
injector
At the time of writing there are two Trim File CDs supplied with SIS
Windows, by the end of the year, the files will be on 1 DVD. Also trim
files are available on a separate CD for TEPS dealers.

The injector serial number must be obtained first in order to download the
file to the PC.
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Locate the injector serial number obtained from the injector as shown
above (arrow).

• Injector confirmation Also locate the "Injector Confirmation Code" to the right of the Serial
codes Number, in this case 4382. The serial number and four digit random
- Cross checks number is printed onto the injector using a laser
injector serial
number
The four digit random number is included in the trim file. This feature is
a security measure to make sure the mechanic actually has the injector in
hand. Cat ET (Electronic Technician) cross checks the injector serial
number and code in the trim file with what is typed in. If there is not a
match, a dialog box will appear (shown later).
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• SIS Start the SIS (Service Information System) program. On the SIS main
- Source of trim files menu, locate "Injector Trim Files" (arrow).

NOTE: If this item is not on the main menu, then the Dealer SIS
Coordinator should be contacted to have the SIS Web profile changed to
turn on the "Injector Trim Files."
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• File downloads Follow the instructions on screen (left arrow) which says:

"Please enter valid search criteria to the right."

Follow the instruction on the right hand side marked:

"Injector Trim File Download"

This box is used to input the serial number (right arrow) for the injector.
This serial number is the same as the file name for the trim file.
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• Entering injector Enter the injector serial number in the box (arrow) to identify the trim file
serial number for downloading.
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• Search for trim file Click on the Search button, this action will download the file. The file
will appear on the left hand side (arrow).

Click on this file name (arrow), this will bring up the “File Download"
dialog box.

The file version number can be ignored when performing the calibration.
There is no need to perform an upgrade if the injector file is an earlier
version than the file in SIS. This information is used by the factory and
does not affect replacement or calibration of injectors.

NOTE: Only one file can be downloaded at a time.

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• Trim file download After the Search button is selected, the File Download dialog box will
appear.

- Check the button: Save this file to disk

- Click the OK button

The "Save AS" dialog box will appear.

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Using the "Save AS" dialog box:

Click on the folder Injector Trim Files

Click the Open button (opens the folder)
• Saving file to PC Click the Save button in order to save the file to the PC

Once all the files are all downloaded to the PC, they can be uploaded to
the the ECM for calibration.

NOTE: A folder called Injector Trim Files, can be created to contain the
downloaded trim files. Cat ET preferences can then be set to
automatically look to this folder for the trim files.
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Calibrating Injectors with ACERT Technology

Open Cat ET and select the following from the Service pull down menu:

• Cat ET pull down Service / Calibrations / Injector Trim Calibration

menu

NOTE: Both Dealer and Customer ET can be used to perform this

operation. No passwords are required to perform calibrations.
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• Select injector for Select the injector to program and click the Change button at the bottom
calibration of the screen. In this case injector number one is selected.

The "Open" dialog box will appear.

NOTE: There is also an Exchange button at the bottom of the screen.

This button is used to switch the position of two injector files and will be
covered later in the presentation.
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• Select file Select (highlight) the file for calibration. This file will be copied to the
ECM.

NOTE: The Cat ET preferences menu allows the Injector Trim Files
folder to be automatically located in the same way as the Flash File folder
is located.
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• Enter confirmation Enter the Confirmation Code, this code was recorded from the injector
code with the serial number. This code ensures that the correct and compatible
file is selected – a confirmation.

Cat ET determines if the Confirmation Code and the file are a valid pair.
If not, Cat ET will display an error message as shown on this slide.
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• Emissions warning A prompt Indicates emissions could be affected by an input error.

If Yes is selected, ECM programming will start.

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• Double check injector Upon successful completion, the Injector Serial Number field will have a
code new value. At this point, it is prudent to double check that the serial
number appearing against the injector represents the injector that was
installed.

NOTE: It the Serial Number field has not been programmed, an Active
Fault will be displayed. The engine will run but with a warning light.
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Injector Trim File Exchange

There are times when two injectors may be exchanged for diagnostic
purposes. In this case it is necessary that the files are also moved to their
respective new injector positions.

To facilitate this operation and to reduce the risk of an error, a file

exchange function has been added to the Injector Trim File Calibration
screen.

• Injector trim file First, highlight the first injector to be exchanged as shown above, in this
exchange procedure case number one.

Select the Exchange button.

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Select the second injector of the pair to be exchanged:

Using the lower "With Injector" box, select the number of the new
position. In this case it is number four.

Click OK.
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Upon successful completion, both Injector Serial Number fields will have
new values.

It is recommended that a final check be made to ensure that the correct

files are installed for the respective injectors. Failure to match the files to
the correct injectors may result in a customer complaint of a rough
running engine.

NOTE: The Trim Files functions described in this section are only
possible using STW/Cat ET Version 2003B or higher. If a previous
version is used, none of these functions can be accessed.
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Miscellaneous Diagnostic Routines

Injection Actuation Pressure Test
Note that Cat ET is shown connected to a 3408E HEUI engine, shown on
the lower right hand portion of the screen.

The HEUI Injection Actuation Pressure Test allows the user to override
the automatic ECM pressure control and manually change hydraulic
pressure from minimum to maximum.

• Accessing the test The test is accessed through the pull down menu as follows:

Diagnostics / Diagnostic Tests / Injection Actuation Pressure Test

The purpose of this test is to perform a functional check on all the

hydraulic components, such as: the pump, compensator valve assembly,
pump control valve, and the hydraulic oil pressure sensor.

The pressure can be lowered using the Step Down button to the minimum
permitted by the compensator valve adjustment, and has a value of about
20% pump control valve (injection actuation) current.

The maximum pressure is produced using the Step Up button with about
50% pump control valve current. These values are variable depending on
parasitic load and oil viscosity.
The Step Up function will stop when pressure reaches the maximum limit.
Also the Step Down function will not cause the pressure to pull below the
value set by the spring in the compensator valve.
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Override Parameters Function

This screen enables circuits such as the lamps highlighted to be turned on
or off for troubleshooting purposes.

• Accessing the The screen can be accessed through the pull down menu as follows:
Override parameters
Diagnostics / Diagnostic Tests / Override Parameters
function
In this case the Check Engine Lamp has been turned off for a functional
check of the ECM. The Low Oil Pressure Lamp has been grounded.
In the case of an open or a short in one of these circuits, the system can be
turned on and off to aid in tracing the fault.
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Wiggle Test
The Wiggle Test function allows the user to determine if there is an
intermittent wiring problem by indicating which parameter on the screen
has moved beyond a predetermined range while "wiggling" the wiring
harness, sensors, connectors etc.

• Accessing the Wiggle The Wiggle Test can be accessed using the following pull down menu:
Test
Diagnostics / Diagnostic Tests / Wiggle Test

Once you have selected the wiggle test through the pull down menu, a
warning box will appear. If all the conditions are met, then press the OK
button. If all the conditions are not met either complete them before
continuing with the test or press the Cancel button.
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• Screen Layout The Wiggle Test screen has the following areas:

Engine description and Group No.

Data display Area
The upper portion of the screen displays engine description and group
number chosen. This area is located in the upper-left corner of the screen.

The Wiggle Test display area is in a grid format and it displays the
description, value, and unit of predefined ECM parameters. The
Description column gives the name of the parameter. The Value column
displays the status of the selected parameter. The Unit column displays
the type of unit that the value is measured by.

If there are more parameters to view than what are shown in the display
area, a vertical scroll bar displays at the right side of the screen to view
the remaining parameters.

NOTE: If the service tool is unable to read the data, "Unavailable," "Not
Installed," or "Not Available" will display.
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On the Wiggle Test screen, each group can be viewed consecutively by

using the "Page Up" and "Page Down" keys. A specific default group can
be viewed by selecting the key number corresponding to that Group.
Groups 1 through 9 can be viewed by pressing the number keys 1 through
9. Default groups 10 through 19 can be viewed by pressing the number
keys 1 through 9 plus the ALT key. View the <TEMPORARY GROUP>
by pressing the 0 number key.

• Pushbuttons The pushbuttons available in the Wiggle Test screen are:

Groups …
Zoom In/Zoom Out
Active Codes
Start/Stop

End of Lesson One

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Lesson One Lab Exercises

Diagnostics with Cat ET

The following exercises will reinforce the material introduced in this lesson and will allow questions to
be asked:

1. Demonstrate the following methods of testing EUI or HEUI injectors:

Solenoid test
Manual cutout test
Automatic cutout test
Manually cutout one bank of a vee engine while testing the other bank

2. Calibrate injectors, record values from injectors (not ACERT):

Injector No. 1 ___________ Injector No. 5 ___________

Injector No. 2 ___________ Injector No. 6 ___________

Injector No. 3 ___________ Injector No. 7 ___________

Injector No. 4 ___________ Injector No. 8 ___________

3. Calibrate speed/timing sensors

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Notes
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4. Diagnose a HEUI hydraulic pressure problem using the Injection Actuation Pressure Test.

5. Operate the Override Parameters function to turn on and off subsystems.

6. Engine with ACERT Technology (C7, C9, C11, C13, C15)

a Record the injector serial number from an ACERT engine _____________________

b Record the injector confirmation code number _____________________

c. Access the Trim File from SIS, save the file to a directory in the PC

d. Upload the Trim File to the ECM using Cat ET

e. Input the Confirmation Code

f. Perform the injector swap function on two injectors

g. Test the engine an check for Active Faults

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