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Crank Without Inject Circuit - Test

SMCS - 1901-038

System Operation Description:

Use this procedure to troubleshoot any suspect problems with the crank without injection inputs.
This procedure covers the following diagnostic code:

l 266-02 Incorrect Crank-without-injection inputs

The crank without injection is a feature that disables fuel injection during engine cranking. The
connector for the crank without injection input is located inside the engine compartment.

One of the two plugs (HHH or JJJ) must be installed at all times in the connector for the crank
without injection. For normal operation, plug HHH (engine run) must be installed in the connector.
In order for The Electronic Control Module (ECM) to enable the crank without injection, connector
JJJ (crank w/o injection input) must be installed.

The status of the "Crank w/o Injection" can be monitored using Caterpillar Electronic Technician
(ET) in order to determine the state of the crank without injection inputs.

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Illustration 1 g01249899
Schematic for the crank without injection

Test Step 1. Inspect the Electrical Connectors and the Wiring

A. Turn the keyswitch to the OFF position.

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Illustration 2 g01249923
Locations of the circuit components for the crank without injection

(1) Crank without injection plugs

(2) J1/P1 ECM connectors

B. Thoroughly inspect the connector for the crank without injection plugs (1). Also, thoroughly
inspect connectors (2). Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

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Illustration 3 g01249918
Terminal locations at the P1 ECM connector for the crank without injection

(P1-35) Crank without injection input (NC)

(P1-44) Crank without injection input (NO)

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Illustration 4 g01250093
Terminal locations at the connectors for the crank without injection

(Terminal A) Return (chassis ground)

(Terminal B) Crank without injection input (NC)

(Terminal C) Crank without injection input (NO)

C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated
with the circuit.

D. Check the allen head screw for each of the ECM connectors for the proper torque. Refer to
Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.

E. Check that all connectors, pins, and sockets are completely inserted and coupled. The harness
and wiring must be free of corrosion, of abrasion, and of pinch points. All connections and
grounds must be tight and free of corrosion.

Expected Result:

All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are
free of corrosion, of abrasion, and of pinch points. All connections and grounds are tight and free of
corrosion.

Results:

l OK - The harness and wiring appear to be OK. Proceed to Test Step 2.

l Not OK - There is a problem in the connectors and/or wiring.

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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 the Status on Cat ET

A. Check the connector for the crank without injection in order to ensure that the plug for HHH
(engine run) is installed.

B. Connect Cat ET to the service tool connector.

C. Turn the keyswitch to the ON position.

D. Observe the status for "Crank w/o Injection" on Cat ET.

E. Turn the keyswitch to the OFF position.

F. Remove plug HHH (engine run) and install plug JJJ (crank w/o injection input).

G. Turn the keyswitch to the ON position.

H. Observe the status for "Crank w/o Injection" on Cat ET.

Turn the keyswitch to the OFF position.

Expected Result:

The status reads "Off" when plug HHH (engine run) is installed. The status reads "On" when plug JJJ
(crank w/o injection input) is installed.

Results:

l OK - The status of the "Crank w/o Injection" on Cat ET agrees with the results that are stated
above.

Repair: The feature is working properly. There may be an intermittent problem in a connector
or in the wiring harness. If an intermittent problem is suspected, refer to Troubleshooting,
"Electrical Connectors - Inspect" for the correct troubleshooting procedures.

STOP

l Not OK - The status of the "Crank w/o Injection" on Cat ET does not agree with the results
that are stated above. The ECM is not detecting the inputs correctly. Proceed to Test Step 3.

Test Step 3. Check the Continuity at the Terminals of the Crank Without Injection Plugs

A. Disconnect the crank without injection plug from the connector.

B. Remove the crank without injection plugs from the connector.

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C. Check that plug HHH is in good repair:

a. Check for continuity between terminals A and B.

Continuity will exist between these terminals for a plug that is in good repair.

b. Check for continuity between terminals A and C. Also check for continuity between
terminals B and C.

An open circuit will exist between these terminals for a plug that is in good repair.

D. Check that plug JJJ is in good repair:

a. Check for continuity between terminals A and C.

Continuity will exist between these terminals for a plug that is in good repair.

b. Check for continuity between terminals A and B. Also check for continuity between
terminals B and C.

An open circuit will exist between these terminals for a plug that is in good repair.

Expected Result:

All of the measurements indicate that the plugs are OK.

Results:

l OK - Both of the plugs are OK. The crank without injection plugs are not the cause of the
problem. There is a problem in the wiring harness between the connector and the ECM. There
may be a problem with the ECM. Proceed to Test Step 4.

l Not OK - At least one of the measurements does not agree with the results that are given
above.

Repair: There is either a short circuit or an open circuit in one of the plugs. Replace the crank
without injection plug that failed the test. Verify that the repair eliminates the problem.

STOP

Test Step 4. Check for the Correct Operation of the ECM

A. Disconnect the J1/P1 ECM connectors.

B. Fabricate two jumper wires that are long enough to create a short between the ECM connector
and the engine ground stud. Crimp a connector socket to one end of each of the jumper wires.

C. Remove the wires from terminal locations P1-35 and P1-44 at the ECM connector. Install one
of the jumper wires into each of these terminal locations.

D. Reconnect the J1/P1 ECM connector.

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E. Connect the loose end of the jumper wire that is in terminal P1-35 to the engine ground stud.

F. Hold the loose end of the other jumper wire away from any ground source in order to create an
open circuit condition for this ECM input.

G. Turn the keyswitch to the ON position.

H. Observe the status for "Crank w/o Injection" on Cat ET.

The correct status for "Crank w/o Injection" in this configuration is "Off".

I. Turn the keyswitch to the OFF position.

J. Remove the loose end of the jumper wire that is in terminal P1-35 from the engine ground
stud. Hold the loose end of this jumper wire away from any ground source in order to create an
open circuit condition for this ECM input.

K. Connect the loose end of the jumper wire that is in terminal P1-44 to the engine ground stud.

L. Turn the keyswitch to the ON position.

M. Observe the status for "Crank w/o Injection" on Cat ET.

The correct status for "Crank w/o Injection" in this configuration is "On".

N. Turn the keyswitch to the OFF position.

Restore all wiring to the original configuration.

Expected Result:

The correct status for "Crank w/o Injection" was indicated during both of the tests.

Results:

l OK - The correct status for "Crank w/o Injection" was indicated during the tests.

Repair: The ECM is functioning properly. The problem is in the wiring harness between the
ECM connector and the connector for the crank without injection plug. Also, verify the ground
circuit that is at terminal A of the connector for the crank without injection plug. Verify that
the repair eliminates the problem.

STOP

l Not OK - The status for "Crank w/o Injection" was not correct during the tests.

Repair: The ECM is not responding correctly. There is a problem with the ECM. Replace the
ECM. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM.

STOP

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