Injector Solenoid Circuit - Test

D7R SERIES II TRACK-TYPE TRACTOR /FINGER TIP CONTROL/ BRP00001-U...
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Product: TRACK-TYPE TRACTOR
Model: D7R II TRACK-TYPE TRACTOR BRP
Configuration: D7R SERIES II TRACK-TYPE TRACTOR /FINGER TIP
CONTROL/ BRP00001-UP (MACHINE) POWERED BY 3176C ENGINE

Troubleshooting
3176C and 3406E Engines for the 572R Series II Pipelayer and for D7R Series II and D8R
Series II Track-Type Tractors
Media Number -SENR5003-07 Publication Date -01/06/2009 Date Updated -09/06/2009

i02148852
Injector Solenoid Circuit - Test

SMCS - 1290-038
System Operation Description:
Use this procedure to troubleshoot any suspect problems with the fuel injectors.
This procedure covers the following diagnostic codes:
 1-05
 2-05
 3-05
 4-05
 5-05
 6-05
 1-06
 2-06
 3-06
 4-06
 5-06
 6-06
 You have been directed to this procedure from Troubleshooting, "Troubleshooting without a
Diagnostic Code".
Perform this procedure under conditions that are identical to the conditions that exist when the problem
occurs. Typically, problems with the injector solenoid occur when the engine is warmed up and/or when the
engine is under vibration (heavy loads).
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 9/12/2011
D7R SERIES II TRACK-TYPE TRACTOR /FINGER TIP CONTROL/ BRP00001-U... Page 2 of 15
The engine has electronic unit injectors that are mechanically actuated and electronically energized. The
Electronic Control Module (ECM) sends a 105 volt pulse to each injector solenoid. The pulse is sent at the
proper time and at the correct duration for a given engine load and speed. The solenoid is mounted on top of
the fuel injector body. The 105 volt pulse can be individually cut out to aid in troubleshooting misfire
problems.
If an open is detected in the solenoid circuit, a diagnostic code is generated. The ECM continues to try to fire
the injector. If a short is detected, a diagnostic code is generated. The ECM will disable the solenoid circuit.
The ECM will then enable the solenoid. If the short circuit remains this sequence of events will be repeated
until the problem is corrected.
The injector codes must be programmed into the ECM. The injector code is a four digit number (last four
digits of the serial number for the injector) that is found on each of the unit injectors. The ECM uses this
number to compensate for manufacturing variations between individual injectors. If you replace any of the
unit injectors, you must reprogram the code for the new injectors. Also, if you replace the ECM, you must
reprogram all of the injector codes. The ECM will generate the following diagnostic code if the injector
codes are not programmed:
 268-02 Check Programable Parameters
For more information, refer to the calibration procedure Troubleshooting, "Injector Code - Calibrate".

Illustration 1 g01090095
Schematic


ECM connector P2 (ECM side)
(5) Injector 1 & 2 Solenoid Return
(6) Solenoid 1 Power
Test Step 1. Inspect Electrical Connectors and Wiring
Electrical shock hazard. The electronic unit injector system uses 90-120
volts.
A. Turn the keyswitch to the OFF/RESET position. A strong electrical shock hazard is present if the
keyswitch is not turned to the OFF/RESET position.
B. Thoroughly inspect the J2/P2 ECM connector and the J91/P91 injector connector. Refer to the
diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and in the J91/P91 injector
connector that are associated with injector solenoids.
Refer to Illustration 2.
D. Check the ECM connector (allen head screw) for the proper torque of 6.0 N·m (55 lb in).
E. Check the J91/P91 injector connector in order to ensure the proper mating of the connector.
F. Check the harness and wiring for abrasions and for pinch points from the injectors to the ECM.
Expected Result:
All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of
corrosion, of abrasion, and of pinch points.
Results:
 OK - The connectors and wiring are OK. Proceed to Test Step 2.
 Not OK - There is a problem with the connectors and/or wiring.
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.
Stop.
Test Step 2. Check for Logged Diagnostic Codes
A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
B. Turn the keyswitch to the ON position.
C. Monitor the "Logged Diagnostic Codes" screen on Cat ET.
Expected Result:
One or more of the following diagnostic codes has been logged:
 1-05
 2-05
 3-05
 4-05
 5-05
 6-05
 1-06
 2-06
 3-06
 4-06
 5-06
 6-06
Results:
 OK - There are logged diagnostic codes for the injectors. Proceed to Test Step 4.
 Not OK - There are no logged diagnostic codes for the injectors. Proceed to Test Step 3.
Test Step 3. Check the Variation of the Injectors Between Each of the Cylinders
A. Start the engine.
B. Allow the engine to warm up to normal operating temperature (approximately 77 °C (171 °F)).
C. After the engine is warmed to operating temperature, access the "Cylinder Cutout Test" on Cat ET by
accessing the following display screens in order:
 "Diagnostics"
 "Diagnostic Tests"
 "Cylinder Cutout Test"
D. Enable the cooling fan, if the fan is not controlled by the ECM. If the ECM controls the cooling fan,
the cooling fan will start automatically when the test begins.
E. Shut off all parasitic loads such as the air conditioning and the air compressors which could affect the
results of the test.
F. Set the engine speed to 1200 ± 20 rpm.
G. Select the start button at the bottom of the screen for the "Cylinder Cutout Test".
H. Select the "4 Cylinder Cutout Test" which is the default test.
I. Follow the instructions that are provided in the "Cylinder Cutout test". The cylinder cutout tests are
interactive so the procedure is guided to the finish.
Note: The "Manual Cylinder Cutout Test" is also available. Access the manual test by selecting the
"Change" button on the screen for the "Cylinder Cutout Test". The "4 Cylinder Cutout Test" is the
recommended starting procedure. The automated tests run twice collecting data. The two sets of data
are analyzed and an "OK" or "NOT OK" result is displayed.
Expected Result:
All cylinders indicate "OK".
Results:
 OK - All cylinders indicate "OK".
Repair: If the engine is misfiring or if the engine has low power, refer to the diagnostic procedure
Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable" and the diagnostic procedure
Troubleshooting, "Low Power/Poor or No Response to Throttle".
If a diagnostic code results from running the "Cylinder Cutout Test", proceed to Test Step 4.
 Not OK - A problem was found with one of the cylinders. Proceed to Test Step 4.
Test Step 4. Use the Injector Solenoid Test to Test the Injector Solenoids
A. Start the engine.
B. Allow the engine to warm up to normal operating temperature (approximately 77 °C (171 °F)).
C. Turn the keyswitch to the OFF/RESET position.
D. Turn the keyswitch to the ON position.
E. Access the "Injector Solenoid Test" on Cat ET by accessing the following display screens in order:
 "Diagnostics"
 "Diagnostic Tests"
 "Injector Solenoid Test"
F. Activate the test.
Note: The test is in the "Interactive Diagnostic Tests". Do not confuse the "Injector Solenoid Test"
with the "Cylinder Cutout Test". The "Cylinder Cutout Test" is used to shut off fuel to a specific
cylinder while the engine is running. The injector solenoid test is used in order to actuate the injector
solenoids. This allows the click of the injector solenoids to be heard when the engine is not running in
order to determine that the circuit is functioning properly.
G. As each solenoid is energized by the ECM an audible click can be heard at the valve cover. Listen for
a click at each valve cover. A black square will appear over the cylinder number when the cylinder is
being fired.
H. Perform the injector solenoid test at least two times.
Expected Result:
All cylinders indicate "OK".
Results:
 OK - There is not an electronic problem with the injectors at this time.
Repair: If the "Cylinder Cutout Test" returned a "NOT OK" for any injector, refer to the diagnostic
procedure Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable".
Stop.
 Not OK - Note the cylinders that indicate "OPEN" and/or "SHORT". Proceed to Test Step 5.
Test Step 5. Use the Injector Solenoid Test to Check for Shorts in the Engine Wiring Harness
volts.
B. Disconnect the J91/P91 injector connector at the valve cover base.
C. Turn the keyswitch to the ON position.
D. Perform the injector solenoid test at least two times.
Expected Result:
All cylinders indicate "OPEN".
Results:
 OK - All cylinders indicate "OPEN". Proceed to Test Step 6.
 Not OK - Note the cylinders that indicate a short circuit. Proceed to Test Step 7.
Test Step 6. Use the Injector Solenoid Test to Check for Opens in the Engine Wiring Harness

Engine harness connector for the injectors
volts.
B. Disconnect the J91/P91 injector connector at the valve cover base.
C. Fabricate a jumper wire 100 mm (4 inch) long. Crimp a Deutsch pin to both ends of the wire.
D. Insert one end of the jumper wire into the common socket of the problem injector. Insert the other end
of the jumper wire into the appropriate socket for the suspect injector in the P91 injector connector.
For example, if injector 5 is the problem injector, insert the jumper in terminal 5 and in terminal 8 of
the P300 injector connector.
E. Turn the keyswitch to the ON position.
F. Perform the injector solenoid test at least two times.
G. Turn the keyswitch to the OFF/RESET position.
H. Repeat this test for each suspect Injector. Ensure that the injector solenoid test is disabled before
handling the jumper wires.
Expected Result:
Cat ET displays "SHORT" for the cylinder with the jumper wire.
Results:
 OK 1 - Test Step 4 indicated that only one injector had an "OPEN" or "SHORT", or that one injector
had an "OPEN" but the other injector on the injector common line had a "SHORT". Proceed to Test
Step 9.
 OK 2 - Test Step 4 indicated that two injectors that share an injector common line are open. Proceed
to Test Step 10.
 OK 3 - Test Step 4 indicated that two injectors that share an injector common line are shorted.
Proceed to Test Step 11.
 Not OK - Proceed to Test Step 8.
Test Step 7. Use the Injector Solenoid Test to Check the ECM for Short Circuits
volts.
B. Disconnect the J2/P2 ECM connector from the ECM and check for evidence of moisture.
Expected Result:
All cylinders indicate "OPEN" when the P2 ECM connector is disconnected from the ECM.
Note: When the engine harness is disconnected all of the diagnostic codes for supply voltage to the sensors
will be active. This is normal. Clear all of these diagnostic codes after completing this test step.
Results:
 OK - The short circuit is in the engine harness.
Repair: Repair the engine harness or replace the engine harness, as required. Clear all diagnostic
codes after completing this test step.Verify that the repair eliminates the problem.
Stop.
 Not OK -
Repair: Perform the following repair:
1. Temporarily connect a test ECM.
2. Remove all jumpers and replace all connectors.
3. Recheck the system for active diagnostic codes.
4. Repeat the test step.
5. If the problem is resolved with the test ECM, reconnect the suspect ECM.
6. If the problem returns with the suspect ECM, replace the ECM.
7. Verify that the repair eliminates the problem.
Stop.
Test Step 8. Check the ECM For an Open Circuit
volts.
B. Disconnect the engine harness from the J2 ECM connector. Connect a 140-2266 Cable (Breakout T)
to the ECM. Do not connect the engine harness to the Breakout T.
C. Use a jumper wire to short between the socket of the injector and the common socket of the suspect
injector.
E. Perform the injector solenoid test at least two times.
Note: When the engine harness is disconnected all of the diagnostic codes for supply voltage to the
sensors will be active. This is normal. Clear all of these diagnostic codes after completing this test
D7R SERIES II TRACK-TYPE TRACTOR /FINGER TIP CONTROL/ BRP00001... Page 10 of 15
step.
Expected Result:
Cat ET displays "SHORT" for the cylinder with the jumper wire.
Results:
 OK - The ECM is OK. There is a open in the harness between the injector connector P91 and ECM
connector P2.
Repair: Replace the engine harness or repair the engine harness, as required.Verify that the repair
Stop.
 Not OK -
1. Temporarily connect a test ECM.
2. Remove all jumpers and replace all connectors.
3. Recheck the system for active diagnostic codes.
4. Repeat the test step.
5. If the problem is resolved with the test ECM, reconnect the suspect ECM.
6. If the problem returns with the suspect ECM, replace the ECM.
Stop.
Test Step 9. Check The Injector Harness Under the Valve Cover
volts.
B. Remove the valve cover.
C. Disconnect the harness from the problem injector. Disconnect the harness from the other injector that
has the same injector common line.
D. Thoroughly clean the terminals of both injectors and of the harness.
E. Exchange the harness between the two injectors that share the common line.
F. Turn the keyswitch to the ON position.
G. Perform the injector solenoid test at least two times.
Expected Result:
Exchanging the harness between the two injectors caused the problem to move to the other injector on Cat
ET.
Results:
 OK - Cat ET indicates that the problem has moved.
Repair: Replace the faulty injector. Restore the wiring to the proper injectors.Verify that the repair
Stop.
 Not OK - Cat ET still indicates that the problem is with the original injector.
Repair: Replace the injector harness under the valve cover.Verify that the repair eliminates the
problem.
Stop.
Test Step 10. Check the Engine Harness Under the Valve Cover for an Open Circuit in the Common
Line

Harness terminals of electronic unit injector
volts.
C. Disconnect each of the injectors that indicate an "OPEN" from the wiring harness. Ensure that each of
the connectors from the disconnected injector harness does not touch other components and short to
ground.
D. Attach a jumper wire to both terminals of the injector harness for the two injectors that share an
injector common line.
E. Turn the keyswitch to the ON position.
F. Perform the injector solenoid test at least two times.
Expected Result:
The cylinders with the short in place indicate an "OPEN".
Results:
 OK - The problem appears to be in the engine harness under the valve cover.
1. Replace the engine harness under the valve cover.
2. Run the injector solenoid test in order to check the installation of the new harness before
installing the valve covers.
Stop.
 Not OK - Both injectors indicate "SHORT".
Repair: Replace both injectors.Verify that the repair eliminates the problem.
Stop.
Test Step 11. Check the Engine Harness Under the Valve Cover for Short Circuits in the Injector
Wires
volts.
C. Disconnect each of the injectors that indicate a "SHORT" from the wiring harness. Ensure that each of
the connectors from the disconnected injector harness does not touch other components and short to
ground.
E. Perform the injector solenoid test at least two times.
Expected Result:
Both cylinders indicate an "OPEN".
Results:
 OK - Neither of the injector wires are shorted to the engine.
Repair: Leave the injector wires disconnected.
 Not OK - There is a short in the injector harness under the valve cover.
problem.
Stop.
Test Step 12. Check For a Short Circuit in the Injector Common Line to the Engine
volts.
B. Disconnect the J2/P2 ECM connector.
C. Locate the common line for the problem injector in the P2 connector. Measure the resistance from the
terminal to the engine ground stud connection.
Expected Result:
The multimeter indicates that the resistance is greater than five Ohms.
Results:
 OK - The harness is not shorted to ground.
Repair: Reconnect the engine harness to the ECM.
 Not OK - The harness is shorted to ground.
problem.
Stop.
Test Step 13. Check For a Short Circuit in the Injector
volts.
B. Reconnect one of the two disconnected injectors.
Expected Result:
The reconnected injector indicates a "SHORT".
Results:
 OK - The injector has an internal short.
Repair: Replace the Injector.Verify that the repair eliminates the problem.
Stop.
 Not OK - The injector is OK. There may be a problem with the other injector. Proceed to Test Step
14.
Test Step 14. Check For a Short Circuit in the Other Injector
volts.
B. Reconnect the other disconnected injector.
Expected Result:
The reconnected injector indicates a "SHORT".
Results:
 OK - The injector has an internal short.
Repair: Replace the faulty injector. Restore the wiring to the proper injectors.Verify that the repair
Stop.
 Not OK - This injector is OK.
Repair: There may be an intermittent problem. If the problem is intermittent, refer to the diagnostic
functional test Troubleshooting, "Electrical Connectors - Inspect".
Stop.

Copyright 1993 - 2011 Caterpillar Inc. Mon Sep 12 08:18:20 UTC+0700 2011
All Rights Reserved.
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Injector Solenoid Circuit - Test

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Injector Solenoid Circuit - Test

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D7R SERIES II TRACK-TYPE TRACTOR /FINGER TIP CONTROL/ BRP00001-U...

Injector Solenoid Circuit - Test

System Operation Description:

Test Step 1. Inspect Electrical Connectors and Wiring

Test Step 2. Check for Logged Diagnostic Codes

Test Step 8. Check the ECM For an Open Circuit

Test Step 13. Check For a Short Circuit in the Injector

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