G3500H Generator Set Engine Caterpillar

Detonation - Test

Usage:

Use this procedure to troubleshoot a detonation occurrence. Also, use this procedure if one of following diagnostic codes is active or easily repeated.

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Table 1
J1939 Code and Description	Comments
1352-3 Engine Cylinder #1 Knock Level : Voltage Above Normal	The Integrated Sensing Module (ISM) detects signal voltage that is not in the acceptable range. The code is logged.
1352-4 Engine Cylinder #1 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1352–19 Engine Cylinder #1 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1353-3 Engine Cylinder #2 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1353-4 Engine Cylinder #2 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1353–19 Engine Cylinder #2 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1354-3 Engine Cylinder #3 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1354-4 Engine Cylinder #3 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1354–19 Engine Cylinder #3 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1355-3 Engine Cylinder #4 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1355-4 Engine Cylinder #4 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1355–19 Engine Cylinder #4 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1356-3 Engne Cylinder #5 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1356-4 Engine Cylinder #5 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1356–19 Engine Cylinder #5 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1357-3 Engine Cylinder #6 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1357-4 Engine Cylinder #6 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1357–19 Engine Cylinder #6 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1358-3 Engine Cylinder #7 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1358-4 Engine Cylinder #7 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1358–19 Engine Cylinder #7 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1359-3 Engine Cylinder #8 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1359-4 Engine Cylinder #8 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1359–19 Engine Cylinder #8 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1360-3 Engine Cylinder #9 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1360-4 Engine Cylinder #9 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1360–19 Engine Cylinder #9 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1361-3 Engine Cylinder #10 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1361-4 Engine Cylinder #10 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1361–19 Engine Cylinder #10 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1362-3 Engine Cylinder #11 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1362-4 Engine Cylinder #11 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1362–19 Engine Cylinder #11 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1363-3 Engine Cylinder #12 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1363-4 Engine Cylinder #12 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1363–19 Engine Cylinder #12 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1364-3 Engine Cylinder #13 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1364-4 Engine Cylinder #13 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1364-19 Engine Cylinder #13 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1365-3 Engine Cylinder #14 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1365-4 Engine Cylinder #14 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1365-19 Engine Cylinder #15 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1366-3 Engine Cylinder #15 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1366-4 Engine Cylinder #15 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1366-19 Engine Cylinder #15 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1367-3 Engine Cylinder #16 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1367-4 Engine Cylinder #16 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1367-19 Engine Cylinder #16 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1368-3 Engine Cylinder #17 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1368-4 Engine Cylinder #17 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1368-19 Engine Cylinder #17 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1369-3 Engine Cylinder #18 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1369-4 Engine Cylinder #18 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1369-19 Engine Cylinder #18 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1370-3 Engine Cylinder #19 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1370-4 Engine Cylinder #19 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1370-19 Engine Cylinder #19 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1371-3 Engine Cylinder #20 Knock Level : Voltage Above Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1371-4 Engine Cylinder #20 Knock Level : Voltage Below Normal	The ISM detects signal voltage that is not in the acceptable range. The code is logged.
1371-19 Engine Cylinder #20 Knock Level : Data Error	The ISM detects signal voltage that is not in the acceptable range. The code is logged.

- 19 Code Information

The Engine ECM receives and processes detonation information via the CAN data link from the ISM.

A -19 knock level data error diagnostic is indicating that there is an unauthorized device on the CAN data link or an issue with the CAN data link that does not fall within the normal CAN data link test procedures.

The most likely cause is that another device on the CAN data link is sending a message to the engine ECM which is indicating a level of detonation detected which would fall into a range not considered to be normal under any operating scenarios.

If another device or system issue is sending a message that is received by the engine ECM which indicates this incorrect level of knock detection, engine detonation protection will be disabled.

Background Information

Detonation sensors are on the upper cylinder block between every two cylinders. Each sensor monitors two adjacent cylinders. Refer to Table2

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Table 2
J1939 Code and Description	Sensor for Cylinders
1352-3 Engine Cylinder #1 Knock Level : Voltage Above Normal	Sensor for cylinders 1 and 3
1352-4 Engine Cylinder #1 Knock Level : Voltage Below Normal	Sensor for cylinders 1 and 3
1353-3 Engine Cylinder #2 Knock Level : Voltage Above Normal	Sensor for cylinders 2 and 4
1353-4 Engine Cylinder #2 Knock Level : Voltage Below Normal	Sensor for cylinders 2 and 4
1356-3 Engine Cylinder #5 Knock Level : Voltage Above Normal	Sensor for cylinders 5 and 7
1356-4 Engine Cylinder #5 Knock Level : Voltage Below Normal	Sensor for cylinders 5 and 7
1357-3 Engine Cylinder #6 Knock Level : Voltage Above Normal	Sensor for cylinders 6 and 8
1357-4 Engine Cylinder #6 Knock Level : Voltage Below Normal	Sensor for cylinders 6 and 8
1360-3 Engine Cylinder #9 Knock Level : Voltage Above Normal	Sensor for cylinders 9 and 11
1360-4 Engine Cylinder #9 Knock Level : Voltage Below Normal	Sensor for cylinders 9 and 11
1361-3 Engine Cylinder #10 Knock Level : Voltage Above Normal	Sensor for cylinders 10 and 12
1361-4 Engine Cylinder #10 Knock Level : Voltage Below Normal	Sensor for cylinders 10 and 12
1364-3 Engine Cylinder #13 Knock Level : Voltage Above Normal	Sensor for cylinders 13 and 15
1364-4 Engine Cylinder #13 Knock Level : Voltage Below Normal	Sensor for cylinders 13 and 15
1365-3 Engine Cylinder #14 Knock Level : Voltage Above Normal	Sensor for cylinders 14 and 16
1365-4 Engine Cylinder #14 Knock Level : Voltage Below Normal	Sensor for cylinders 14 and 16
1368-3 Engine Cylinder #17 Knock Level : Voltage Above Normal	Sensor for cylinders 17 and 19
1368-4 Engine Cylinder #17 Knock Level : Voltage Below Normal	Sensor for cylinders 17 and 19
1369-3 Engine Cylinder #18 Knock Level : Voltage Above Normal	Sensor for cylinders 18 and 20
1369-4 Engine Cylinder #18 Knock Level : Voltage Below Normal	Sensor for cylinders 18 and 20

The Integrated Sensing Module (ISM) supplies 8 VDC to power the sensors. The detonation sensors provide electrical signals to the module that indicate mechanical engine vibrations. Each sensor outputs an electrical signal. The signal is amplified and the signal is filtered. The frequency of the signal corresponds to the mechanical frequency of the vibrations. The amplitude of the signal is proportional to the intensity of the vibrations.

The ISM monitors the signals to determine the presence and the severity of the detonation. The ISM can retard the timing of the cylinders to limit detonation levels. The timing may be retarded for a single cylinder or for more than one cylinder. The timing may be retarded for all the cylinders, if necessary. If retardation of the timing does not sufficiently limit the detonation, the ISM will shutdown the engine.

An ISM can retard timing by as few as three degrees for light detonation levels. The timing can be retarded up to six degrees for severe detonation. For most applications, the minimum allowable actual timing is ten degrees BTC (five degrees BTC for propane operation). A proportional strategy is used for advancing the timing after the timing has been retarded. The rate of advance is based on the level of detonation. The rate is faster for lighter detonation. The fastest rate of proportional timing advance is one degree per minute.

The ISM will diagnose the detonation sensors for a signal that is shorted to the −Battery side, to the +Battery side, or for an open circuit. To avoid detecting vibrations that are not related to detonation, the ISM only monitors a detonation sensor when one of the pistons that is monitored by that sensor is between top center and 40 degrees after top center on the power stroke. Therefore, the “Block Tap” method of testing the detonation sensors cannot be performed on this engine.

An input from a detonation sensor that is diagnosed by an ISM as "open/shorted to +battery" may measure 0 VDC on a voltmeter. This is caused by the lack of pull-up resistors in the detonation sensor circuit inside the ISM.

The ISM also supports related event codes when the levels of detonation warrant a reaction from the ISM. If the timing has been retarded by the maximum amount and the level of detonation remains high, the ISM will shutdown the engine. Detonation protection is disabled when the engine speed is less than 250 rpm.

Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Cat Electronic Technician (ET) to print the logged codes to a file.

The most likely causes of the diagnostic code are a poor connection or a problem in a wiring harness. The next likely cause is a problem with a sensor. The least likely cause is a problem with an ISM.

The troubleshooting procedure may generate more diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.

Note: The most likely cause of a code is a problem with an electrical connector or wiring. The least likely cause of a code is the ISM.

Note: The situation is unlikely to have a failed detonation sensor if a detonation event is only being detected at one cylinder. Detonation sensors are shared between two cylinders. A false detonation event due to a failed sensor would affect both cylinders being monitored by that sensor.

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Illustration 1	g06155107
For the complete circuit details, refer to the full schematic.

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Illustration 2	g06155115
For the complete circuit details, refer to the full schematic.

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Table 3
Troubleshooting Test Steps	Values	Results
1. Check for Codes A. Connect Cat^® Electronic Technician (ET) to the service tool connector. B. Determine if a code is active or logged.	Codes	Result: A -3 code is active. Proceed to Test Step 2. Result: A -4 code is active. Proceed to Test Step 3.
2. Create a Short at the Sensor Connector A. Turn the keyswitch to the OFF position. B. Disconnect the sensor with the active -3 code. C. Install the jumper wire between the following terminals at the sensor connector: - Terminal 3 (signal) and Terminal 2 (sensor return) D. Connect Cat ET. E. Use Cat ET to monitor the following: - -4 code F. Turn the keyswitch to the OFF position.	Create a Short	Result: A -4 code did not become active. Proceed to Test Step 4. Result: A -4 code became active. Repair: The wiring harness is OK. Replace the sensor. Verify that the repair eliminated the problem.
3. Create an Open at the Sensor Connector A. Turn the keyswitch to the OFF position. B. Disconnect the sensor with the active -4 code. C. Connect Cat ET. D. Use Cat ET to monitor the following: - -3 code E. Turn the keyswitch to the OFF position.	Create an Open	Result: A -3 code did not become active. Proceed to Test Step 4. Result: A -3 code became active. Repair: The wiring harness is OK. Replace the sensor. Verify that the repair eliminated the problem.
4. Check the 8 VDC Supply Voltage at the Sensor Connector A. Turn the keyswitch to the ON position. B. Measure the voltage at the sensor connector between the following pins: - Pin 1 and Pin 2 C. Reconnect the sensor.	8.0 ± 0.2 VDC	Result: The supply voltage is 8.0 ± 0.2 VDC. Proceed to Test Step 5. Result: The supply voltage is not 8.0 ± 0.2 VDC. Repair:Repair or replace the wiring harness. If the problem is not resolved, proceed to Test Step 5.
5. Perform the Wiggle Test Carefully following this procedure is the best way to identify the root cause of an intermittent problem. A. Connect Cat ET. B. Use CAT ET to perform the following test: - "Wiggle Test" C. Slowly wiggle the wiring and the connectors between the P2 connector and the sensor. Pay particular attention to the wiring near each connector. Be sure to wiggle all the wiring. As you wiggle the wiring look for these problems: - Loose connectors or damaged connectors - Moisture on the connectors or the wiring - Damaged that is caused by excessive heat - Damage that is caused by chafing - Improper routing of wiring - Damaged insulation	Test	Result: The wiring failed the Wiggle Test. Repair: There is a problem with the wiring harness. Repair or replace the wiring harness. Verify that the repair eliminated the problem. Result: The wiring passed the Wiggle Test. Repair: The problem may be intermittent. Inspect the wiring harness. Refer to Troubleshooting, "Electrical Connectors - Inspect" for additional information. If the wiring looks OK, perform the following procedure: 1. Turn the keyswitch to the OFF position. 2. Disconnect the connectors. Carefully inspect the terminals for proper installation. Make sure that each terminal is clean and dry. 3. Insert a pin into each socket. Verify that each socket grips the pin firmly. Repair any problems. 4. Connect all connectors. 5. Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).