Battery 1 Voltage - Data Valid but Below Normal Operational Range - Moderately Se...

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FAULT CODE 441

Battery 1 Voltage - Data Valid but Below Normal
Operational Range - Moderately Severe Level
Overview

CODE REASON EFFECT

Fault Code: 441 Battery 1 Voltage - Data Valid but Below Normal Engine may stop
PID: S168 Operational Range - Moderately Severe Level. running or be
SPN: 168 ECM supply voltage is below the minimum difficult to start.
FMI: 1/18 system voltage level.
LAMP: Amber
SRT:

Unswitched Battery Supply

Circuit Description

The ECM receives constant voltage from the batteries through the unswitched battery wires
that are connected directly to the positive (+) battery post. There is one 30-amp fuse in the
unswitched battery wires to protect the OEM harness. In marine applications this is a 25
ampere fuse on 12V systems and a 15 ampere fuse on 24V systems. The ECM receives
switched battery input through the vehicle keyswitch wire when the vehicle keyswitch is
turned on. The battery return wires are connected directly to the negative (-) battery post.

Component Location

The ECM is located on the intake side of the engine. The ECM is connected to the battery
by the OEM harness. This direct link provides a constant power supply for the ECM. In
marine applications only circuits 1 and 3 are used for unswitched battery. The location of
the battery will vary with the OEM. Refer to the OEM manual for battery location.

Shop Talk

This fault code is logged when the ECM battery supply voltage drops below 6 volts.

z Verify that the ECM unswitched power is coming from the batteries and not the
starter or other device. Check for possible weak batteries.
z If the ECM unswitched battery supply is taken from the starter, check for low voltage

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during cranking. Low voltage during cranking can cause the ECM power supply to
drop below specifications and log Fault Code 441.

Cautions and Warnings

WARNING
Batteries can emit explosive gases. To reduce the possibility of
personal injury, always ventilate the compartment before servicing the
batteries. To reduce the possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-) battery cable last.

CAUTION
To reduce the possibility of pin and harness damage, use the following
test lead when taking a measurement:
Part Number 3822758 - male Deutsch/AMP/Metri-Pack test lead.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Check the battery.
STEP 1A. Check the battery Connections tight and corrosion-free?
connections.
STEP 1B. Check the battery Battery voltage acceptable in normal
voltage. and cranking conditions?
STEP 2. Check the fuse.
STEP 2A. Verify that the fuse is Fuse installed correctly?
installed correctly.
STEP 2B. Check for a blown fuse. Fuse blown?
STEP 3. Check the OEM power harness.
STEP 3A. Inspect the OEM power Dirty or damaged pins?
harness and ECM connector pins.
STEP 3B. Check for an open Less than 10 ohms?
circuit.
STEP 3C. Check for a short circuit Greater than 100k ohms?
in the power harness.
STEP 3D. Check for a short circuit Greater than 100k ohms?
to ground.
STEP 3E. Check for a short circuit Greater than 100k ohms?
from pin to pin.

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STEP 3F. Check the add-on or the Damaged wires?

accessory wiring at the positive
(+) terminal of the battery.
STEP 4. Clear the fault codes.
STEP 4A. Disable the fault code. Fault Code 441 inactive?
STEP 4B. Clear the inactive fault All fault codes cleared?
codes.

Guided Step 1 - Check the battery.

Guided Step 1A - Check the battery connections.

Conditions

z Turn keyswitch OFF.

Action

Check the battery voltage.

z Check the battery terminal

connections on both positive (+)
and negative (-) terminals.

Connections tight and corrosion-free? Connections tight and corrosion-free?

YES NO
No Repair Tighten the loose connections, and clean
the terminals.

Refer to the OEM troubleshooting and

repair manual.

Go to 1B Go to 4A

Guided Step 1B - Check the battery voltage.

Conditions

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z Turn
keyswitch
ON.

Action

Check the battery

voltage.

z Measure the
voltage from
the positive
(+) battery
terminal to
the negative
(-) battery
terminal
while trying
to start
engine.

Normal conditions:

z At least 12
VDC (12-
VDC
systems)
z At least 24
VDC (24-
VDC
systems).

Cranking
conditions:

z At least 6.2
VDC (12-
VDC
systems)
z At least 12
VDC (24-
VDC
systems).

Battery voltage Battery voltage acceptable in normal and cranking

acceptable in conditions?
normal and
cranking
conditions?
YES NO
No Repair Charge or replace the battery.

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Refer to the OEM troubleshooting and repair manual.

Go to 2A Go to 4A

Guided Step 2 - Check the fuse.

Guided Step 2A - Verify that the fuse is installed correctly.

Conditions

z Turn
keyswitch
OFF.

Action

Verify that the 30-

amp fuse is
installed correctly.

z Inspect the
30-amp fuse
for correct
installation.

Fuse installed Fuse installed correctly?

correctly?
YES NO
No Repair Install the fuse correctly.

Refer to Procedure 019-198.

Go to 2B Go to 4A

Guided Step 2B - Check for a blown fuse.

Conditions

z Turn keyswitch OFF.

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Action

Check for a blown fuse.

z Inspect the 30-amp fuse to see if it

is blown.

Fuse blown? Fuse blown?

YES NO
Replace the fuse. No Repair

Refer to Procedure 019-198.

Go to 4A Go to 3A

Guided Step 3 - Check the OEM power harness.

Guided Step 3A - Inspect the OEM power harness and ECM connector pins.

Conditions

z Turn keyswitch OFF.

z Disconnect the OEM power
harness connector from the ECM.

Action

Inspect the power harness and ECM

connector pins for the following:

z Corroded pins
z Bent or broken pins
z Pushed back or expanded pins
z Moisture in or on the connector
z Missing or damaged connector
seals
z Dirt or debris in or on the
connector pins
z Wire insulation damaged
z Connector shell broken.

For general inspection techniques, refer

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to Component Connector and Pin

Inspection, Procedure 019-361.

Dirty or damaged pins? Dirty or damaged pins?

YES NO
Clean the connector and pins. No Repair

Repair the damaged harness, connectors,

or pins if possible.

Refer to Procedure 019-071.

Go to 4A Go to 3B

Guided Step 3B - Check for an open circuit.

Conditions

z Turn
keyswitch
OFF.
z Disconnect
the OEM
power
harness
connector
from the
ECM.

Action

Check for an open

circuit.

z Measure the
resistance
from the
positive (+)
battery
terminal post
to all ECM
battery
SUPPLY (+)
pins, one at
a time, in the
OEM power
harness

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ECM
connector.
z Measure the
resistance
from the
negative (-)
battery
terminal post
to all ECM
battery
SUPPLY (-)
pins, one at
a time, in the
OEM power
harness
ECM
connector.

For general
resistance
measurement
techniques, refer
to the Resistance
Measurements
Using a Multimeter
and Wiring
Diagram,
Procedure 019-
360.

Less than 10 Less than 10 ohms?

ohms?
YES NO
No Repair Repair or replace the OEM power harness.

Refer to Procedure 019-071.

Go to 3C Go to 4A

Guided Step 3C - Check for a short circuit in the power harness.

Conditions

z Turn
keyswitch
OFF.
z Disconnect

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the OEM
power
harness
connector
from the
ECM.
z Disconnect
the battery.

Action

Check for a short

circuit in the power
harness.

z Measure the
resistance
from the
ECM battery
SUPPLY (+)
pins in the
OEM power
harness
ECM
connector to
the ECM
battery
SUPPLY (-)
pins.

For general
resistance
measurement
techniques, refer
to the Resistance
Measurements
Using a Multimeter
and Wiring
Diagram,
Procedure 019-
360.

Greater than 100k Greater than 100k ohms?

ohms?
YES NO
No Repair Repair or replace the OEM power harness.

Refer to Procedure 019-071.

Go to 3D Go to 4A

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Guided Step 3D - Check for a short circuit to ground.

Conditions

z Turn
keyswitch
OFF.
z Disconnect
the OEM
power
harness
connector
from the
ECM.

Action

Check for a short

circuit to ground.

z Measure the
resistance
from the
ECM battery
SUPPLY (+)
pins in the
OEM power
harness
ECM
connector to
engine block
ground.

For general
resistance
measurement
techniques, refer
to the Resistance
Measurements
Using a Multimeter
and Wiring
Diagram,
Procedure 019-
360.

Greater than 100k Greater than 100k ohms?

ohms?
YES NO
No Repair Repair or replace the OEM power harness.

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Refer to Procedure 019-071.

Go to 3E Go to 4A

Guided Step 3E - Check for a short circuit from pin to pin.

Conditions

z Turn
keyswitch
OFF.
z Disconnect
the OEM
power
harness
connector
from the
ECM.
z Disconnect
the OEM
harness
connector
from the
ECM.
z Disconnect
the battery.

Action

Check for a short

circuit from pin to
pin.

z Measure the
resistance
from one of
the ECM
battery
SUPPLY (+)
pins in the
OEM power
harness
ECM
connector to
all pins in the
OEM
harness
ECM
connector.

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z Measure the
resistance
from the
second ECM
battery
SUPPLY (+)
pin in the
OEM power
harness
ECM
connector to
all pins in the
OEM
harness
ECM
connector.

For general
resistance
measurement
techniques, refer
to the Resistance
Measurements
Using a Multimeter
and Wiring
Diagram,
Procedure 019-
360.

Greater than 100k Greater than 100k ohms?

ohms?
YES NO
No Repair Repair or replace the OEM power harness.

Refer to Procedure 019-071.

Go to 3F Go to 4A

Guided Step 3F - Check the add-on or accessory wiring at the positive (+)
terminal of the battery.

Conditions

z Turn keyswitch OFF.

Action

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Check the add-on or the accessory

wiring at the positive (+) terminal of the
battery.

z Starting at the positive (+) terminal,

follow any add-on or accessory
wiring, and examine wire(s) for
damaged insulation or an
installation error that can cause the
supply wire to be shorted to the
engine block.

Damaged wires? Damaged wires?

YES NO
Repair or replace the damaged wires. No Repair

Refer to the OEM troubleshooting and

repair manual.

Go to 4A Go to 4A

Guided Step 4 - Clear the fault codes.

Guided Step 4A - Disable the fault code.

Conditions

z Connect all components.

z Turn keyswitch ON.

Action

Disable the fault code.

z Start the engine and let it idle for

one minute.
z Use INSITE™ electronic service
tool to verify that the fault code is
inactive.

Fault Code 441 inactive? Fault Code 441 inactive?

YES NO

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No Repair No Repair
Go to 4B Go to 1A

Guided Step 4B - Clear the inactive fault codes.

Conditions

z Connect all components.

z Turn keyswitch ON.

Action

Clear the inactive fault codes.

z Use INSITE™ electronic service

tool to erase the inactive fault
codes.

All fault codes cleared? All fault codes cleared?

YES NO
No Repair No Repair
Repair complete Appropriate troubleshooting charts

Last Modified: 29-Mar-2005

Copyright© 2005
Cummins, Inc.
All rights reserved

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