G3400 Engines (EIS) Caterpillar

The Electronic Ignition System (EIS control module) is a electronic control that provides the following:

• Precise spark timing

• Spark ignition to the ignition coils

• Detonation protection

• Diagnostics of performance of system components

• Ignition timing

• Engine performance

Cat Data Link - The Cat data link is used to communicate the programmed parameters from the Digital diagnostic Tool (DDT) or the Caterpillar Electronic Technician (ET) to the EIS control module. Communications between the EIS control module and the Caterpillar engine control module are conducted over the Cat data link.

Detonation Sensor Inputs - The connection of sensors to these inputs and outputs are used in order to determine the number of sensors that are connected on the engine.

Transformer Primary Driver and Returns - The combination of these inputs and outputs are used in order to determine the number of ignition coils that are connected to the EIS control module.

Control Diagnostics - The EIS control module will diagnose faults for an incorrect number of detonation sensors that are programmed. The EIS control module will also diagnose faults for an incorrect number of engine cylinders that are programmed. These diagnostics are based on a difference between the number of cylinders that are programmed through the DDT or the Cat ET and the actual number of cylinders or sensors electronically determined in order to be connected to the EIS control module. The EIS control module will diagnose a fault when the control module determines that the internal memory circuit, which stores the programmed parameters, has experienced a permanent memory problem. The EIS control module will diagnose a fault code when communications with the engine control module have been lost.

Test Step 1. Inspect the Electrical Connectors and Wiring

Illustration 1	g01043894
Schematic diagram of the detonation sensors

1. Set the engine control to the OFF/RESET mode. Remove the electrical power from the engine.

Note: For the following steps, refer to Troubleshooting, "Inspecting Electrical Connectors".

2. Thoroughly inspect each of the following connectors:
   • Connectors for the EIS control module

   • Connectors for each detonation sensor

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   Illustration 2	g01044156
   Harness side of the EISC connector (EISC-E) Signal from the right detonation sensor (EISC-H) Signal from the left detonation sensor (EISC-M) 13 VDC for the right detonation sensor (EISC-P) 13 VDC for the left detonation sensor (EISC-Y) Ground for the left detonation sensor (EISC-d) Ground for the right detonation sensor

   1. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the detonation sensors.
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   Illustration 3	g01044294
   Detonation sensor (1) Buffer module (2) Accelerometer (3) Wiring

   2. Check the wiring (3) between each accelerometer (1) and each buffer module (2) for corrosion, for abrasion, and for pinch points.

   3. Some engines have replaced the buffer module with a knock sensor. Check the wiring between the detonation sensor and the EISC connector. Refer to Illustration 1.

   4. Check the harnesses and the wiring for abrasion and for pinch points from each buffer module to the EIS control module.

Expected Result:

The connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.

Results:

• OK - The components are in good condition with proper connections. Proceed to Test Step 2.

• Not OK - The components are not in good condition and/or at least one connection is improper.

  Repair: Perform the necessary repairs and/or replace parts, if necessary.

  STOP

Test Step 2. Check the Programmable Parameters

1. Use the DDT or Cat ET to compare the number of detonation sensors on the engine with the number of sensors that are programmed in the EIS control module. Access Screen 31 on the DDT.

Expected Result:

The number of programmed detonation sensors matches the actual number of detonation sensors on the engine.

Results:

• OK - Proceed to Test Step 1.

• Not OK -

  Repair: Program the correct number of sensors into the control. Clear all of the diagnostic codes on powerup.

  STOP

Test Step 3. Check for an Open Circuit

1. Measure the resistance of the harness for the detonation sensor.

   1. For the left detonation sensor, measure the resistance between the points that are listed in Table 1. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
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      Table 1

      Resistance Measurements for the Harness for the Left Detonation Sensor
      Terminal on the EIS Connector	Terminal on the Connector for the Left Detonation Sensor
      EISC-P (13 VDC for the left detonation sensor)	A (13 VDC for the detonation sensor)
      EISC-Y (Ground for the left detonation sensor)	B (Ground for the detonation sensor)
      EISC-H (Left detonation sensor signal)	C (Left detonation sensor signal)

   2. For the right detonation sensor, measure the resistance between the points that are listed in Table 2. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
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      Table 2

      Resistance Measurements for the Harness for the Right Detonation Sensor
      Terminal on the EISConnector	Terminal on the Connector for the Right Detonation Sensor
      EISC-M (13 VDC for the right detonation sensor)	A (13 VDC for the detonation sensor)
      EISC-d (Ground for the left detonation sensor)	B (Ground for the detonation sensor)
      EISC-E (Left detonation sensor signal)	C (Left detonation sensor signal)

Expected Result:

Each check of the resistance is less than 2 Ohms.

Results:

• OK - Each check of the resistance is less than 2 Ohms. The wiring does not have an open circuit. Reconnect the detonation sensors. Proceed to Test Step 7.

• Not OK - At least one check of the resistance is greater than 2 Ohms. There is an open in the wiring for a detonation sensor.

  Repair: Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved.

  STOP

Test Step 4. Check for a Short Circuit

1. Remove the electrical power from the engine.

2. Disconnect the EIS connector.

3. Disconnect the connectors for the detonation sensors.

4. At the EIS connector, measure the resistance of the harness for the detonation sensor.

   1. For the left detonation sensor, measure the resistance between the points that are listed in Table 3. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
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      Table 3

      Resistance Measurements for the Harness for the Left Detonation Sensor
      Terminals on the EIS Connector
      EISC-H (Left Detonation Sensor Signal)	EISC-A (+Battery)
      	EISC-B (−Battery)
      	EISC-D (Output for the shutdown lamp)
      	EISC-E (Right detonation sensor signal)
      	EISC-L (Ignition shutdown)
      	EISC-M (13 VDC for the right detonation sensor)
      	EISC-P (13 VDC for the left detonation sensor)
      	EISC-Y (Ground for the left detonation sensor)
      	EISC-Z (Ground for the speed/timing sensor)
      	EISC-d (Ground for the right detonation sensor)

   2. For the right detonation sensor, measure the resistance between the points that are listed in Table 4. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
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      Table 4

      Resistance Measurements for the Harness for the Right Detonation Sensor
      Terminals on the EIS Connector
      EISC-E (Right Detonation Sensor Signal)	EISC-A (+Battery)
      	EISC-B (−Battery)
      	EISC-H (Left detonation sensor signal)
      	EISC-J (13 VDC for the speed/timing sensor)
      	EISC-M (13 VDC for the right detonation sensor)
      	EISC-Y (Ground for the left detonation sensor)
      	EISC-Z (Ground for the speed/timing sensor)
      	EISC-d (Ground for the right detonation sensor)

Expected Result:

Each check of the resistance is greater than 2 Ohms.

Results:

• OK - Each check of the resistance is greater than 2 Ohms. The signal wire does not have a short circuit. Reconnect the detonation sensors. Proceed to Test Step 15.

• Not OK - At least one check of the resistance is less than 2 Ohms. The signal wire has a short circuit.

  Repair: Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved.

  STOP

Test Step 5. Perform a Self Test of the EIS Control Module

1. Perform a self test of the EIS control module. Refer to Troubleshooting, "Control Module Self Test".

Expected Result:

The self test was successful.

Results:

• OK - The self test was successful.

  Repair: Replace the detonation sensor. Torque the sensor to 10 N·m (90 lb in).

  STOP

• Not OK - The self test was not successful.

  Repair: Perform the corrective action according to Troubleshooting, "Control Module Self Test". Verify that the original problem is resolved.

  STOP

Test Step 6. Check for a Short Circuit

1. Remove the electrical power from the engine.

2. Disconnect the EIS connector.

3. Disconnect the connectors for the detonation sensors.

4. At the EIS connector, measure the resistance of the harness for the detonation sensor.

   1. For the left detonation sensor, measure the resistance between the points that are listed in Table 5. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
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      Table 5

      Resistance Measurements for the Harness for the Left Detonation Sensor
      Terminals on the EISConnector
      EISC-H (Left Detonation Sensor Signal)	EISC-A (+Battery)
      	EISC-B (−Battery)
      	EISC-D (Output for the shutdown lamp)
      	EISC-E (Right detonation sensor signal)
      	EISC-J (13 VDC for the speed/timing sensor)
      	EISC-L (Ignition shutdown)
      	EISC-M (13 VDC for the right detonation sensor)
      	EISC-P (13 VDC for the left detonation sensor)
      	EISC-V (13 VDC for the inlet manifold pressure sensor)
      	EISC-Y (Ground for the left detonation sensor)
      	EISC-Z (Ground for the speed/timing sensor)
      	EISC-d (Ground for the right detonation sensor)

   2. For the right detonation sensor, measure the resistance between the points that are listed in Table 8. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
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      Table 6

      Measurements for the Resistance of the Harness for the Right Detonation Sensor
      Terminals on the EISConnector
      EISC-E (Right Detonation Sensor Signal)	EISC-A (+Battery)
      	EISC-B (−Battery)
      	EISC-D (Output for the shutdown lamp)
      	EISC-H (Left detonation sensor signal)
      	EISC-J (13 VDC for the speed/timing sensor)
      	EISC-L (Ignition shutdown)
      	EISC-M (13 VDC for the right detonation sensor)
      	EISC-P (13 VDC for the left detonation sensor)
      	EISC-V (13 VDC for the inlet manifold pressure sensor)
      	EISC-Y (Ground for the left detonation sensor)
      	EISC-Z (Ground for the speed/timing sensor)
      	EISC-d (Ground for the right detonation sensor)

Expected Result:

Each check of the resistance is greater than 2 Ohms.

Results:

• OK - Each check of the resistance is greater than 2 Ohms. The signal wire does not have a short circuit. Proceed to Test Step 3.

• Not OK - At least one check of the resistance is less than 2 Ohms. The signal wire has a short circuit.

  Repair: Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the original problem is resolved.

  STOP

Test Step 7. Perform a Self Test of the EIS Control Module

1. Perform a self test of the EIS control module. Refer to Troubleshooting, "Control Module Self Test".

Expected Result:

The self test was successful.

Results:

• OK - The self test was successful.

  Repair: Operate the engine under the conditions that caused the original problem. If the problem persists, refer to Troubleshooting, "Inspecting Electrical Connectors".

  STOP

• Not OK - The self test was not successful.

  Repair: Perform the corrective action that is appropriate for the fault. Refer to Troubleshooting, "Control Module Self Test". Verify that the original problem is resolved.

  STOP

Test Step 8. Check for the Number of Cylinders

1. Use the DDT or the Cat ET. By using the DDT, access screen 32 on the Engine Configuration screen.

Expected Result:

The programmed engine configuration matches the engines.

Results:

• OK - Proceed to Test Step 9.

• Not OK -

  Repair: Program the correct engine family into the control. Clear all of the diagnostic codes on powerup. Verify that the repairs have solved the problem.

  STOP

Test Step 9. Check the Transformers for Shorts to Ground

1. Set the engine control to the OFF/RESET mode. Remove the electrical power from the engine.

2. Disconnect the EIS control from the engine harness.

   Perform the following procedure for the 8 cylinder engine.

3. Measure the resistance between pins N, R,S, W, X, a, b,and f to pins A, B, F, K, T, g, m, c, the connector housing, and the engine block. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.

   Perform the following procedure for the 12 cylinder engine.

4. Measure the resistance between pins N, S, X, b, the connector housing, and the engine block. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.

Expected Result:

The resistance at all checks is less than 2 Ohms.

Results:

• OK - The resistance is less than 2 Ohms. No shorts to ground were found on the unused transformers in the 8 cylinder and/or in the 12 cylinder engines. Proceed to Test Step 10.

• Not OK -

  Repair: Repair the connector or wiring and/or replace the connector or the wiring. Clear all of the diagnostic codes on powerup. Verify that the repairs have solved the problem.

  STOP

Test Step 10. Check the Ignition Harness for Open Circuits

Illustration 4	g01167074

1. Measure the resistance between the points that are listed in Figure 4.

2. Measure the resistance from transformer pin 2 to engine bulkhead connector pin 2.

Expected Result:

Each check of the resistance is less than 2 Ohms.

Results:

• OK - Each check of the resistance is greater than 2 Ohms. The ignition harness is free of open circuits and/or the ignition harness had only one fault. Proceed to Test Step 11.

• Not OK - An open circuit has been found in the ignition harness. Two or more open or shorts are required to generate this fault.

  Repair: Repair the wiring for the ignition harness and/or the connectors. Replace parts, if necessary.

  STOP

Test Step 11. Check the Engine Harness for an Open Circuit

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Illustration 5	g01169463
Engine harness connector (EIS control connector) High side pins

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Illustration 6	g01169489
Engine harness connectors (EBC connectors) for the 8 cylinder and the 12 cylinder engines High side pins

1. Measure the resistance between the points that are listed in Figure 5 and Figure 6. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each connector.

2. Measure the resistance between the points that are listed in Figure 7 and Figure 8. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each connector.

Illustration 7	g01169508
Engine harness connector (low side pins)

Illustration 8	g01169510
Engine harness connector (EBC connectors) for the 8 cylinder and the 12 cylinder engines Low side pins

Expected Result:

All of the readings are less than 2 Ohms.

Results:

• OK - Each check of the resistance is greater than 2 Ohms. The engine harness is free of open circuits or the engine harness only has one fault. Proceed to Test Step 15.

• Not OK - The harness has an open circuit.

  Repair: Perform the necessary repairs and/or replace parts, if necessary.

  STOP

Test Step 12. Perform a Self Test of the EIS Control Module

1. Perform a self test of the EIS control module. Refer to Troubleshooting, "Control Module Self Test".

Expected Result:

The self test was successful.

Results:

• OK - The self test was successful.

  Repair: Replace the detonation sensor. Torque the sensor to 10 N·m (90 lb in).

  STOP

• Not OK - The self test was not successful.

  Repair: Perform the corrective action according to Troubleshooting, "Control Module Self Test". Verify that the original problem is resolved.

  STOP

Test Step 13. Check the Harness for an Open Circuit

1. Disconnect the EIS control module from the left and right detonation sensors and disconnect the engine harness.

2. Disconnect the air/fuel ratio control from the engine harness.

3. Measure the resistance between the following connections:
   • EISC pin G to ECM J1 pin 19.

   • EISC pin K to ECM J1 pin 4.

4. Measure the resistance in the harness from the Cat data link at Terminal 265 to the engine block.

Expected Result:

All of the readings are less than 2 Ohms.

Results:

• OK - No open circuits were found in the Cat data link. Proceed to 14.

• Not OK -

  Repair: Repair the wiring or replace the wiring. Verify that the original problem is resolved. Clear all diagnostic codes on powerup.

  STOP

Test Step 14. Check the Cat Data Link for Shorts

1. Measure the resistance between the points that are listed in Table 8.

2. Measure the resistance between the points that are listed in the Table 8.

Expected Result:

All of the readings are less than 2 Ohms.

Results:

• OK - All of the readings are less than 2 Ohms. The circuits for the Cat data link are not shorted to power or shorted to ground. The circuit is not shorted to the surrounding pins. Proceed to Test Step 15.

• Not OK - A short has developed in the harness.

  Repair: Repair the wiring or replace the wiring. Verify that the original problem is resolved. Clear all diagnostic codes on powerup.

  STOP

Test Step 15. Perform a Self Test of the EIS Control Module

1. Perform a self test of the EIS control module. Refer to Troubleshooting, "Control Module Self Test".

Expected Result:

The self test was successful.

Results:

• OK - The self test was successful.

  Repair: Replace the detonation sensor. Torque the sensor to 10 N·m (90 lb in).

  STOP

• Not OK - The self test was not successful.

  Repair: Perform the corrective action according to Troubleshooting, "Control Module Self Test". Verify that the original problem is resolved.

  STOP