This procedure covers the following codes:
| Diagnostic Trouble Codes for the Solenoid Valves | ||
|---|---|---|
| CDL Code | Description | Notes |
| 18-5 | Fuel Control Valve : Current Below Normal | The Electronic Control Module (ECM) detects the following conditions: A low current condition for the suction control valve solenoid on the high-pressure fuel pump for 0.6 seconds. There are no active 168 diagnostic codes. The ECM has been powered for at least 0.25 seconds. If equipped, the warning lamp will come on. The ECM will log the diagnostic code. This diagnostic code detects a fault in the suction control valve solenoid circuit that is most likely to be an open circuit. |
| 18-6 | Fuel Control Valve : Current Above Normal | The ECM detects the following conditions: A high current condition for the suction control valve solenoid on the high-pressure fuel pump for 0.6 seconds. There are no active 168 diagnostic codes. The ECM has been powered for at least 0.25 seconds. If equipped, the warning lamp will come on. The ECM will log the diagnostic code. This diagnostic code will detect a fault in the circuit for the solenoid in the suction control valve. This problem is most likely to be caused by a high side short to ground or a low side short to power. |
| 526-5 | Turbo Wastegate Drive : Current Below Normal | The ECM detects the following conditions: A low current condition in the output from the ECM to the solenoid for the wastegate regulator. There are no active 168 diagnostic codes. The ECM has been powered for at least 2 seconds. If equipped, the warning lamp will come on once the diagnostic code has been active for 30 seconds. The diagnostic code will be logged. The engine will be derated while this diagnostic code is active. After the engine derate has been activated, the electronic service tool will indicate "Turbo Protection Derate Active". This diagnostic code will detect a fault in the circuit for the wastegate regulator solenoid that is most likely to be an open circuit. |
| 526-6 | Turbo Wastegate Drive : Current Above Normal | The ECM detects the following conditions: A high current condition in the output from the ECM to the solenoid in the wastegate regulator There are no active 168 diagnostic codes. The ECM has been powered for at least 2 seconds. If equipped, the warning lamp will come on once the diagnostic code has been active for 30 seconds. The diagnostic code will be logged. The engine will be derated while this diagnostic code is active. After the engine derate has been activated, the electronic service tool will indicate "Turbo Protection Derate Active". This diagnostic code will detect a fault in the circuit for the solenoid in the wastegate regulator. This problem is most likely to be caused by a high side short to ground or a low side short to power. |
| 2461-5 | ARD Fuel Pressure #1 Control : Current Below Normal | The ECM detects the following conditions: A low current condition in the output from the ECM to the solenoid for the pilot fuel control valve on the Aftertreatment Regeneration Device (ARD) There are no active 41 diagnostic codes. The ECM has been powered for at least one second. If equipped, the warning lamp will come on. The ECM will log the diagnostic code. |
| 2461-6 | ARD Fuel Pressure #1 Control : Current Above Normal | The ECM detects the following conditions: A high current condition in the output from the ECM to the solenoid for the ARD pilot fuel control valve There are no active 41 diagnostic codes. The ECM has been powered for at least one second. If equipped, the warning lamp will come on. The ECM will log the diagnostic code. The ECM will try to activate the control valve at 1 second intervals for 10 seconds. If the control valve does not activate, the ECM will disable the control valve until the keyswitch has been cycled. |
The following background information is related to this procedure:
Electronically controlled wastegate
The engine has a turbocharger with an electronically controlled wastegate. Typically, the wastegate is a mechanical valve that is used in the turbocharger in order to regulate the intake manifold pressure to a set value.
The control system for the electronically controlled wastegate precisely regulates the intake manifold pressure by using a wastegate regulator to control the wastegate.
The required intake manifold pressure is calculated by the software that is contained in the ECM. The ECM uses the wastegate regulator to control the wastegate in order to provide the precise value of intake manifold pressure. The solenoid in the wastegate regulator is controlled by a PWM signal from the ECM.
Suction control valve for the high-pressure fuel pump:
The high-pressure fuel pump is equipped with a suction control valve. The suction control valve precisely controls the amount of fuel that enters the high-pressure fuel pump.
The amount of fuel that is required is calculated by the software that is contained in the ECM. The solenoid in the suction control valve is controlled by a PWM signal from the ECM.
ARD pilot fuel control valve
The ARD pilot fuel control valve controls the amount of fuel that is injected into the ARD when a regeneration is taking place.
The amount of fuel that is required is calculated by the software that is contained in the ECM. The ARD pilot fuel control valve is controlled by a PWM signal from the ECM.
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| Illustration 1 | g03744016 |
Schematic for the solenoid valves | |
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| Illustration 2 | g01977637 |
View of the pin locations on the P2 connector for the solenoid valves (14) Wastegate regulator return (24) Wastegate regulator PWM signal (67) ARD pilot fuel control valve PWM signal (68) ARD pilot fuel control valve return (69) High pressure fuel pump suction control valve PWM signal (70) High pressure fuel pump suction control valve return | |
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| Illustration 3 | g01944633 |
(1) Wastegate regulator | |
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| Illustration 4 | g01971875 |
Connector for the wastegate regulator (1) Return (2) Signal | |
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| Illustration 5 | g01971813 |
High-pressure fuel pump (2) Suction Control Valve (SCV) | |
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| Illustration 6 | g02477083 |
View of the Clean Emissions Module (CEM) (3) Pilot fuel control valve | |
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| Illustration 7 | g01976190 |
Connector for the ARD pilot fuel control valve (1) ARD pilot fuel control valve PWM signal (2) ARD pilot fuel control valve return | |
Test Step 1. Inspect Electrical Connectors and Wiring
- Thoroughly inspect the P1/J1 ECM connectors and the P2/J2 ECM connectors and thoroughly inspect the connectors for the solenoid valves. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
- Thoroughly inspect the 31-pin connector and the 40-pin connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
- Perform a 45 N (10 lb) pull test on each of the wires that are associated with the solenoid valves.
- Check the screw for the ECM connector for the correct torque of 6 N·m (53 lb in).
Results:
- All connectors, pins, and sockets are correctly connected and the harness is free of corrosion, abrasion, and pinch points - Proceed to Test Step 2.
- There is a fault in the connectors and/or the harness. -
Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all of the seals are correctly in place and ensure that the connectors are correctly connected.Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
STOP
Test Step 2. Check for Diagnostic Codes
- Turn the keyswitch to the OFF position.
- Connect the electronic service tool to the diagnostic connector.
- Turn the keyswitch to the ON position.
- Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes.
Results:
- An XXXX-5 diagnostic code is active or recently logged - Proceed to Test Step 3.
- An XXXX-6 diagnostic code is active or recently logged - Proceed to Test Step 6.
- No Codes - The fault seems to be resolved.
Repair: For intermittent faults, refer to Troubleshooting, "Electrical Connectors - Inspect".
STOP
Test Step 3. Create a Short Circuit in the Harness at the Solenoid
- Turn the keyswitch to the OFF position.
- Disconnect the connector for the suspect solenoid.
- Fabricate a jumper wire that is 150 mm (6 inch) long.
- Install the wire between the two pins on the harness connector for the suspect solenoid in order to create a short circuit.
- Turn the keyswitch to the ON position. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool.
- Remove the jumper wire from the connector for the solenoid valve.
Results:
- An XXXX-5 diagnostic code was active before installing the jumper. An XXXX-6 diagnostic code is active when the jumper is installed - There is a fault in the solenoid.
Repair: Perform the following procedure:
- Temporarily connect a replacement for the suspect valve to the harness.
- Turn the keyswitch to the ON position. Use the electronic service tool in order to check for active diagnostic codes. Wait at least 30 seconds in order for the codes to be displayed.
- If the fault is eliminated, reconnect the suspect valve. If the fault returns, permanently install the replacement valve. Refer to Disassembly and Assembly for the correct procedure.
STOP
- A 2461-5 diagnostic code is still active with the jumper installed. - Reconnect the ARD pilot fuel control valve. Proceed to Test Step 4.
- An 18-5 or 526-5 diagnostic code is still active with the jumper installed. - Proceed to Test Step 9.
Test Step 4. Create a Short Circuit at the 40-Pin Connector
- Turn the keyswitch to the OFF position.
- Disconnect the 40-pin connector.
- Fabricate a jumper wire that is 150 mm (6 inch) long.
- Install the wire between pin 21 and pin 22 on the 40-pin connector on the harness between the engine and the CEM.
- Turn the keyswitch to the ON position. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool.
Note: While the 40-pin connector is disconnected, diagnostic codes for the other components that are connected to the 40-pin connector will be active. Disregard the diagnostic codes for all the other components. Only address the 2461 diagnostic codes.
- Remove the jumper wire.
Results:
- A 2461-5 diagnostic code was active before installing the jumper. A 2461-6 diagnostic code is active when the jumper is installed - The fault is in the CEM harness.
Repair: Repair the faulty wiring or replace the faulty wiring.Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
STOP
- A 2461-5 diagnostic code is still active with the jumper installed. - Reconnect the 40-pin connector. Proceed to Test Step 5.
Test Step 5. Create a Short Circuit at the 31-Pin Connector
- Turn the keyswitch to the OFF position.
- Disconnect the 31-pin connector.
- Fabricate a jumper wire that is 150 mm (6 inch) long.
- Install the wire between pin 21 and pin 22 on the 31-pin connector on the harness between the engine and the CEM.
- Turn the keyswitch to the ON position. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool.
Note: While the 31-pin connector is disconnected, diagnostic codes for the other components that are connected to the 31-pin connector will be active. Disregard the diagnostic codes for all the other components. Only address the 2461 diagnostic codes.
- Remove the jumper wire.
Results:
- A 2461-5 diagnostic code was active before installing the jumper. A 2461-6 diagnostic code is active when the jumper is installed - The fault is in the harness between the 31-pin connector and the 40-pin connector.
Repair: Repair the faulty wiring or replace the faulty wiring.Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
STOP
- A 2461-5 diagnostic code is still active with the jumper installed. - Proceed to Test Step 9.
Test Step 6. Create an Open Circuit at the Solenoid
- Turn the keyswitch to the OFF position.
- Disconnect the connector for the suspect solenoid valve.
- Turn the keyswitch to the ON position. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool.
Results:
- An XXXX-6 diagnostic code was active before disconnecting the valve. An XXXX-5 diagnostic code is active with the valve disconnected. -
Repair: Perform the following procedure:
- Temporarily connect a replacement for the suspect valve to the harness.
- Turn the keyswitch to the ON position. Use the electronic service tool in order to check for active diagnostic codes. Wait at least 30 seconds in order for the codes to be displayed.
- If the fault is eliminated, reconnect the suspect valve. If the fault returns, permanently install the replacement valve. Refer to Disassembly and Assembly for the correct procedure.
STOP
- A 2461-6 diagnostic code is still active with the valve disconnected. - Reconnect the ARD pilot fuel control valve. Proceed to Test Step 7.
- An 18-6 or a 526-5 diagnostic code is still active with the valve disconnected. - Proceed to Test Step 9.
Test Step 7. Create an Open Circuit at the 40-Pin Connector
- Turn the keyswitch to the OFF position.
- Disconnect the 40-pin connector.
- Turn the keyswitch to the ON position. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool.
Note: While the 40-pin connector is disconnected, diagnostic codes for the other components that are connected to the 40-pin connector will be active. Disregard the diagnostic codes for all the other components. Only address the 2461 diagnostic codes.
Results:
- A 2461-6 diagnostic code was active before disconnecting the 40-pin connector. A 2461-5 diagnostic code is active with the 40-pin connector disconnected. - The fault is in the CEM harness.
Repair: Repair the faulty wiring or replace the faulty wiring.Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
STOP
- A 2461-6 diagnostic code is still active with the 40-pin connector disconnected. - Reconnect the 40-pin connector. Proceed to Test Step 8.
Test Step 8. Create an Open Circuit at the 31-Pin Connector
- Turn the keyswitch to the OFF position.
- Disconnect the 31-pin connector.
- Turn the keyswitch to the ON position. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool.
Note: While the 31-pin connector is disconnected, diagnostic codes for the other components that are connected to the 31-pin connector will be active. Disregard the diagnostic codes for all the other components. Only address the 2461 diagnostic codes.
Results:
- A 2461-6 diagnostic code was active before disconnecting the 31-pin connector. A 2461-5 diagnostic code is active with the 31-pin connector disconnected. - The fault is in the harness between the 31-pin connector and the 40-pin connector.
Repair: Repair the faulty wiring or replace the faulty wiring.Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
STOP
- A 2461-6 diagnostic code is still active with the 31-pin connector disconnected. - Proceed to Test Step 9.
Test Step 9. Bypass the Engine Wiring Harness
- Turn the keyswitch to the OFF position.
- For an 18 or a 526 diagnostic code, perform the following steps:
- Disconnect the P2 connector and the connector for the suspect valve.
- Remove the signal wire and the return wire for the suspect valve from the P2 connector.
- Remove the signal wire and the return wire from the connector for the suspect valve.
- Fabricate two jumper wires that are long enough to reach from the ECM to the connector for the suspect valve.
- Insert one end of a jumper into the plug for the signal wire on the P2 connector. Insert the other end of the jumper into the plug for the signal wire on the connector for the suspect valve.
- Insert one end of the other jumper into the plug for the return wire on the P2 connector. Insert the other end of the jumper into the plug for the return wire on the connector for the suspect valve.
- Reconnect the P2 connector and the connector for the valve.
- For a 2461 diagnostic code, perform the following steps:
- Disconnect the P2 connector and the 31-pin connector.
- Remove the wires from P2:67 and P2:68.
- Remove the wires from pins 21 and 22 on the 31-pin connector.
- Fabricate two jumper wires that are long enough to reach from the ECM to the 31-pin connector.
- Insert one end of a jumper into P2:67. Insert the other end of the jumper into socket 21 on the 31-pin connector.
- Insert one end of the other jumper into P2:68. Insert the other end of the jumper into socket 22 on the 31-pin connector.
- Reconnect the P2 connector and the 31-pin connector.
- Turn the keyswitch to the ON position. Wait for 10 seconds.
- Use the electronic service tool in order to monitor the "Active Diagnostic Code" screen. Check for either the open circuit diagnostic code for the suspect valve or the short circuit diagnostic code for the suspect valve.
- Remove the jumpers and reconnect the wires that were previously removed.
- Reconnect the connectors.
Results:
- The diagnostic code disappears when the jumper is installed - There is a fault in the engine wiring harness.
Repair: Perform the following repair:
- Repair the faulty harness or replace the faulty harness.
- Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
STOP
- The diagnostic code is still present with the jumper installed -
Repair: Perform the following repair:
- Make sure that the latest flash file for the application is installed in the ECM. Refer to Troubleshooting, "Flash Programming".
- Contact the Technical Communicator at a Cat dealer.
Note: This consultation can greatly reduce the repair time.
- If the Technical Communicator recommends the use of a test ECM, install a test ECM. Refer to Troubleshooting, "Replacing the ECM".
- Use the electronic service tool to recheck the system for active diagnostic codes.
- If the fault is resolved with the test ECM, reconnect the suspect ECM.
- If the fault returns with the suspect ECM, replace the ECM.
- Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
STOP