Injection Actuation Circuit

336D & 336D L Excavators PRF00001-UP (MACHINE) POWERED BY C9 Engine(SE...
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Product: EXCAVATOR
Model: 336D L EXCAVATOR PRF
Configuration: 336D & 336D L Excavators PRF00001-UP (MACHINE) POWERED BY C9 Engine
Troubleshooting
C9 Engines for Caterpillar Built Machines
Media Number -RENR5089-31 Publication Date -01/11/2014 Date Updated -06/11/2014
i02548622
Injection Actuation Pressure Control Valve Circuit - Test

SMCS - 1714-038
System Operation Description:
Use this procedure to troubleshoot any suspect problems with the Injection Actuation Pressure
Control Valve (IAPCV).
This procedure covers the following diagnostic codes:
• 42-05 Injector Actuation Valve open circuit
• 42-06 Injector Actuation Valve short to ground
The IAPCV is internal to the unit injector hydraulic pump. The IAPCV is a precision displacement
control actuator. This actuator changes the pump outlet flow that is based on the control current that is
supplied by the Electronic Control Module (ECM). The variable displacement unit injector hydraulic
pump pressurizes only the amount of high pressure oil that is needed.
The ECM software contains performance maps. The performance maps have a desired actuation
pressure for every engine operating condition. The ECM sends a control current to the IAPCV. This
signal creates an actual actuation pressure that matches the desired actuation pressure. If the actual
actuation pressure does not match the desired actuation pressure, the ECM will increase the control
current or the ECM will decrease the control current to the IAPCV in order to adjust pump outlet
flow.
The following problems can cause a 05 diagnostic code:
• An open circuit in the wiring
• An open circuit in the IAPCV
• A short to ground on the return wire
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336D & 336D L Excavators PRF00001-UP (MACHINE) POWERED BY C9 Engine(SE... Page 2 of 9
The following problems can cause a 06 diagnostic code:
• The control wire has a short to the +Battery.
• The return wire has a short to the +Battery.
• A short circuit in the IAPCV
• A short to ground on the control wire
Illustration 1 g01275408
Schematic for the injection actuation pressure control valve
Test Step 1. Inspect the Electrical Connectors and the Wiring
A. Remove the electrical power from the ECM.
Typical left side view
(1) J500/P500 connector
(2) J2/P2 connectors
B. Thoroughly inspect connectors (1) and (2). Refer to the diagnostic functional test
Troubleshooting, "Electrical Connectors - Inspect".
P2 terminations for the IAPCV
(P2-10) Return
(P2-20) Control
C. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the IAPCV.
D. Check the torque of the allen head screws for the ECM connectors. Refer to the diagnostic
functional test Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
E. Check the harness and wiring for abrasion and for pinch points from the IAPCV back to the
ECM.
Note: Ensure that the seal is installed on the harness connector for the injection actuation
pressure control valve.
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 the wiring are OK. Proceed to Test Step 2.
• Not OK - There is a problem with the connectors and/or the 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 Active Diagnostic Codes
A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to
Troubleshooting, "Electronic Service Tools".
B. Restore the electrical power to the ECM.
C. Start the engine.
D. Observe the "Active Diagnostic" screen on Cat ET. Wait at least 30 seconds so that any codes
may become active. Look for the code that is 05 or 06.
Expected Result:
One of the above codes is active.
Results:
• Active code - One of the above codes is active. Proceed to Test Step 3.
• No active codes - Neither of the above codes are active.
Repair: If one of the above codes is logged and the engine is not running properly, refer to
Troubleshooting, "Troubleshooting without a diagnostic code".
If the engine is running properly at this time, there may be an intermittent problem in a harness
that is causing the codes to be logged. Refer to the diagnostic functional test Troubleshooting,
"Electrical Connectors - Inspect".
STOP
Test Step 3. Measure the Resistance of the Injection Actuation Pressure Control Valve's
Solenoid
B. Disconnect the IAPCV connectors.
Note: Ensure that the seal on the P500 connector remains on the connector when the connector
is disconnected.
C. Measure the resistance between terminals 1 (Control) and 2 (Return) on the IAPCV. Record the
value of the resistance measurement.
Expected Result:
The resistance measurement is between 6.5 and 10.5 Ohms.
Results:
• OK - The resistance measurement is between 6.5 and 10.5 Ohms. Connect the J500/P500
connectors. Proceed to Test Step 4.
• Not OK - The resistance measurement is not between 6.5 and 10.5 Ohms. The solenoid's
resistance is not within the specification.
Repair: Replace the unit injector hydraulic pump. Verify that the problem is resolved.
STOP
Test Step 4. Check the Wiring for an Open Circuit
B. Disconnect the J2/P2 connectors.
C. Measure the resistance between terminals P2-20 (Control) and P2-10 (Return).
Expected Result:
The resistance measurement is within two Ohms of the value that was measured in the previous Test
Step.
Results:
• OK - The resistance measurement is within two Ohms of the value that was measured in the
previous Test Step. Proceed to Test Step 5.
• Not OK - The resistance measurement is not within two Ohms of the value that was measured
in the previous Test Step. There is a problem with the wiring harness. There may be a problem
with a connector.
Repair: Repair the wiring and/or the connector. Replace parts, if necessary. Verify that the
problem is resolved.
STOP
Test Step 5. Check the Wiring for a Short Circuit
A. Disconnect the IAPCV connectors.
Note: Ensure that the seal on the IAPCV connector remains on the connector when the
connector is disconnected.
B. Disconnect the P1 connector.
C. Measure the resistance between the points that are listed in Table 1. Be sure to wiggle the wires
in the harnesses as you make each resistance measurement.
Table 1
Resistance Measurements for the Wiring Harness
Connector and Terminal Terminal
All of the other terminals on the P2 connector
P2-20 (Control) All of the terminals on the P1 connector
Engine ground
All of the other terminals on the P2 connector
P2-10 (Return) All of the terminals on the P1 connector
Engine ground
Expected Result:
All of the resistance measurements indicate an open circuit.
Results:
• OK - All of the resistance measurements indicate an open circuit. Proceed to Test Step 6.
• Not OK - At least one resistance measurement does not indicate an open circuit. There is a
problem with a wiring harness. There may be a problem with a connector.
Repair: Repair the wiring and/or the connector. Replace parts, if necessary. Verify that the
problem is resolved.
STOP
Test Step 6. Check the ECM by Cranking the Engine
Note: This Test Step may activate additional diagnostic codes. Ignore the codes and monitor
the test lamp. Clear the codes at the end of the Test Step.
A. Verify that the IAPCV connectors are disconnected.
Note: Do not insert any wire that is larger than 18 AWG into the IAPCV harness connector. Do
not insert the probe for the voltage test lamp into the harness connector. These actions will
spread the sockets of the connector which will damage the connector. Damaged connectors
could cause intermittent connections.
B. Insert a Deutsch connector pin into each socket of the IAPCV harness connector.
C. Connect a voltage test lamp to the connector pins that are inserted in the IAPCV connector.
Crank the engine and observe the test lamp.
Expected Result:
The voltage test lamp illuminates when the engine is cranking.
Results:
• OK - The voltage test lamp illuminates when the engine is cranking. Remove the connector
pins from the IAPCV connector. Connect all of the electrical connectors. Clear any diagnostic
codes. Proceed to Test Step 7.
• Not OK - The voltage test lamp does not illuminate when the engine is cranking.
Repair: Replace the ECM. Refer to electronic troubleshooting Troubleshooting, "Replacing the
ECM".
STOP
Test Step 7. Perform the "Injection Actuation Pressure Test"
A. Disconnect the IAPCV connectors.
NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow
the starting motor to cool for two minutes before cranking the engine
again.
B. Crank the engine three times at 30 seconds intervals. This will purge the air from the system.
C. Connect the IAPCV connectors.
D. Start the engine.
E. Run the "Injection Actuation Pressure Test". The "Injection Actuation Pressure Test" is located
in the "Diagnostics" menu on Cat ET. Step through all of the pressure ranges.
Note: This is not the "Injection Act Press Driver Test".
F. After performing the "Injection Actuation Pressure Test", check for the following active
diagnostic codes:
◦ 05
◦ 06
Expected Result:
The test is successful. There are no diagnostic codes.
Results:
• OK - The problem appears to be resolved. The original problem was probably caused by a poor
electrical connection.
STOP
• Not OK - There is a problem with the IAPCV.
Repair: Replace the unit injector hydraulic pump. Verify that the problem is resolved.
STOP
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Injection Actuation Circuit

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336D & 336D L Excavators PRF00001-UP (MACHINE) POWERED BY C9 Engine(SE...

Injection Actuation Pressure Control Valve Circuit - Test

System Operation Description:

This procedure covers the following diagnostic codes:

• 42-05 Injector Actuation Valve open circuit

• 42-06 Injector Actuation Valve short to ground

The following problems can cause a 05 diagnostic code:

• An open circuit in the wiring

• An open circuit in the IAPCV

• A short to ground on the return wire

The following problems can cause a 06 diagnostic code:

• The control wire has a short to the +Battery.

• The return wire has a short to the +Battery.

• A short circuit in the IAPCV

• A short to ground on the control wire

Test Step 1. Inspect the Electrical Connectors and the Wiring

A. Remove the electrical power from the ECM.

• Not OK - There is a problem with the connectors and/or the wiring.

Verify that the repair eliminates the problem.

Test Step 2. Check for Active Diagnostic Codes

B. Restore the electrical power to the ECM.

C. Start the engine.

One of the above codes is active.

• No active codes - Neither of the above codes are active.

A. Remove the electrical power from the ECM.

B. Disconnect the IAPCV connectors.

The resistance measurement is between 6.5 and 10.5 Ohms.

Test Step 4. Check the Wiring for an Open Circuit

A. Remove the electrical power from the ECM.

B. Disconnect the J2/P2 connectors.

Test Step 5. Check the Wiring for a Short Circuit

A. Disconnect the IAPCV connectors.

B. Disconnect the P1 connector.

All of the resistance measurements indicate an open circuit.

Test Step 6. Check the ECM by Cranking the Engine

A. Verify that the IAPCV connectors are disconnected.

The voltage test lamp illuminates when the engine is cranking.

Test Step 7. Perform the "Injection Actuation Pressure Test"

A. Disconnect the IAPCV connectors.

C. Connect the IAPCV connectors.

D. Start the engine.

Note: This is not the "Injection Act Press Driver Test".

The test is successful. There are no diagnostic codes.

• Not OK - There is a problem with the IAPCV.

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