C1.5 and C2.2 Industrial Engines Caterpillar

This procedure covers the following codes:

Illustration 1	g06343598
Schematic diagram for the ARD fuel injectors

Illustration 2	g03334765
View of the pin locations for the ARD fuel injectors on the P2 ECM connector. (20) ARD fuel injector no.1 ground (40) ARD fuel injector no. 1 power (60) ARD fuel injector no. 2 power (80) ARD fuel injector no. 2 ground

Illustration 3	g06343615
View of the pin locations for the ARD fuel injector power supplies on the P1 ECM connector. (18) Battery + (38) Battery + (58) Battery + (78) Battery +

Illustration 4	g03335583
Typical view of the ARD injectors (1) ARD injector 1 (2) ARD injector 2

Test Step 1. Inspect Electrical Connectors and Wiring

1. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.

2. Check the fuses for each ARD fuel injector.

3. Thoroughly inspect the connectors at the injectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

4. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the ARD injector solenoids.

5. Check the harness and wiring for abrasion and for pinch points from the injectors to the ECM.

6. Check the power supply wiring for the ARD fuel injectors for abrasion and for pinch points from the main relay to the ECM.

Results:

• All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion and of pinch points. - The harness is OK. 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 the seals are correctly in place and ensure that the connectors are correctly connected. Replace any blown fuses.

  Use the electronic service tool to clear all logged diagnostic codes and then verify that the repair eliminates the fault.

  STOP

Test Step 2. Check for Active Diagnostic Codes

1. Connect the electronic service tool to the diagnostic connector.

2. Turn the keyswitch to the ON position.

   Note: Wait at least 30 seconds for activation of the diagnostic codes.

3. Use the electronic service tool to verify if any of the diagnostic codes that are listed in Table 1 are active or recently logged.

Results:

• A 3556-6 or 6581-6 diagnostic code is active or recently logged. - Proceed to Test Step 3.

• There are no active diagnostic codes for the ARD injectors. - Proceed to Test Step 5 to check the ARD injector circuits for an open circuit. The ECM does not monitor this condition.

Test Step 3. Create an Open Circuit at the Injector Connector

1. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.

2. Disconnect the connector from the suspect injector.

3. Turn the keyswitch to the ON position. Wait at least 30 seconds for activation of the diagnostic codes.

4. Use the electronic service tool to check for active diagnostic codes.

5. Turn the keyswitch to the OFF position.

6. Remove the jumper wire.

Results:

• An XXXX-6 diagnostic code was active before disconnecting the injector. The diagnostic code is no longer active with the injector disconnected. -

  Repair: Perform the following repair:

  1. Thoroughly inspect the electrical connector on the suspect injector and the harness connector for the suspect injector. Ensure that the connectors are free from corrosion. Reconnect the connector for the suspect injector.

  2. Turn the keyswitch to the ON position.

  3. If the fault is still present, replace the faulty injector. Refer to Disassembly and Assembly for the correct procedure.

  4. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

  STOP

• The XXXX-6 diagnostic code is still present with the injector disconnected. - The injector is OK. Proceed to Test Step 4.

Test Step 4. Create an Open Circuit at the ECM Connector

1. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.

2. Disconnect the P2 connector from the ECM.

3. Turn the keyswitch to the ON position. Wait at least 30 seconds for activation of the diagnostic codes.

   Note: Diagnostic codes for all the engine sensors will be active with the P2 connector disconnected. Ignore all other codes and only look for the code relating to the suspect injector.

4. Use the electronic service tool to check for active diagnostic codes.

5. Turn the keyswitch to the OFF position.

Results:

• An XXXX-6 diagnostic code was active before the P2 connector was disconnected. The diagnostic code is no longer active with the P2 connector disconnected. - The fault is in the supply wire or the return wire between the injector and the P2 connector.

  Repair: Replace the faulty wiring.

  Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

  STOP

• The XXXX-6 diagnostic code is still active with the P2 connector disconnected -

  Repair: Perform the following repair:

  1. Make sure that the latest flash file for the application is installed in the ECM. Refer to Troubleshooting, "Flash Programming".

  2. Contact the Technical Communicator at a Caterpillar dealer.

     Note: This consultation can greatly reduce the repair time.

  3. If the Technical Communicator recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "Replacing the ECM".

  4. Start the engine. Wait for at least 30 seconds for activation of the diagnostic codes.

  5. If the fault is eliminated with the replacement ECM, reconnect the suspect ECM.

  6. If the fault returns with the suspect ECM, replace the ECM.

  7. Use the electronic service tool to clear all logged diagnostic codes and then verify that the repair eliminates the fault.

  STOP

Test Step 5. Create a Short at the Injector Connector

1. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.

2. Disconnect the suspect injector connector.

3. Fabricate a jumper wire 100 mm (4 inch) long.

4. Install the jumper wire between terminal 1 and terminal 2 on the harness connector for the suspect injector.

5. Turn the keyswitch to the ON position. Wait at least 30 seconds for activation of the diagnostic codes.

6. Use the electronic service tool to check for active diagnostic codes.

7. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.

8. Remove the jumper wire.

Results:

• An XXXX-6 diagnostic code is active for the suspect injector with the jumper installed. - The wiring and the ECM are OK. Reconnect the connector for the suspect injector. Proceed to Test Step 6.

• An XXXX-6 diagnostic code is not active for the suspect injector with the jumper installed - Proceed to Test Step 8.

Test Step 6. Override the Suspect Injector Solenoid

1. Connect the electronic service tool to the diagnostic connector.

2. Turn the keyswitch to the ON position.

3. Use the electronic service tool to override the suspect injector solenoid.

   Note: The injector solenoid will click for approximately 10 seconds when the override is used.

4. Turn the keyswitch to the OFF position.

Results:

• The injector solenoid clicks when the electronic service tool is used to override the injector - The injector circuit is OK.

  Repair: An intermittent fault may exist. Refer to Troubleshooting, "Electrical Connectors - Inspect" to identify intermittent faults.

  If directed to this test from another procedure, return and complete that procedure.

  STOP

• The injector solenoid does not click when the electronic service tool is used to override the injector or the engine is in a location where the click cannot be heard. - Proceed to Test Step 7.

Test Step 7. Check the Resistance of the Suspect Injector Solenoid

1. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.

2. Disconnect the harness connector for the suspect injector.

3. Use a suitable multimeter to measure the resistance between terminal 1 and terminal 2 on the suspect injector.

Results:

• The multimeter indicates a resistance across the two terminals - The injector is OK.

  Repair: An intermittent fault may exist.

  Refer to Troubleshooting, "Electrical Connectors - Inspect" to identify intermittent faults.

  If directed to this test from another procedure, return and complete that procedure.

  STOP

• The resistance measurement indicates an open circuit -

  Repair: Replace the suspect ARD injector.

  Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

  STOP

Test Step 8. Check the Wiring for an Open Circuit

1. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.

2. Disconnect the connector for the suspect injector. Disconnect connector P2 from the ECM.

3. Thoroughly inspect the P2 connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".

4. Use a suitable multimeter to measure the resistance between the following terminals:

   For number 1 ARD injector:

   • Terminal 1 on the harness connector for the injector and P2:20

   • Terminal 2 on the harness connector for the injector and P2:40

   For number 2 ARD injector:

   • Terminal 1 on the harness connector for the injector and P2:80

   • Terminal 2 on the harness connector for the injector and P2:60

Results:

• The measured resistance is greater than 2 Ohms - The fault is in the wiring between the injector connector and the P2 connector.

  Repair: Replace the faulty wiring.

  Use the electronic service tool to clear all logged diagnostic codes and then verify that the repair eliminates the fault.

  STOP

• The measured resistance is less than 2 Ohms -

  Repair: Perform the following repair:

  1. Make sure that the latest flash file for the application is installed in the ECM. Refer to Troubleshooting, "Flash Programming".

  2. Contact the Technical Communicator at a Caterpillar dealer.

     Note: This consultation can greatly reduce the repair time.

  3. If the Technical Communicator recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "Replacing the ECM".

  4. Remove the jumper wires and return all wires to the original configuration.

  5. Start the engine. Wait for at least 30 seconds for activation of the diagnostic codes.

  6. If the fault is eliminated with the replacement ECM, reconnect the suspect ECM.

  7. If the fault returns with the suspect ECM, replace the ECM.

  8. Use the electronic service tool to clear all logged diagnostic codes and then verify that the repair eliminates the fault.

  STOP