C13 Industrial Engine Caterpillar

Solenoid Valve - Test

Usage:

C13 JR9

Use this procedure to troubleshoot a problem with a solenoid valve. Also, use this procedure if one of the following diagnostic codes is active or easily repeated.

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Table 1
J1939 Code and Description	Comments
626–5 Ether Injection Control Solenoid : Current Below Normal	The code is latched. The code is logged. Ether injection is disabled.
626–6 Ether Injection Control Solenoid : Current Above Normal	The code is latched. The code is logged. Ether injection is disabled.
677-5 Engine Starter Motor Relay : Current Below Normal	This code indicates that there is a problem with the engine starter motor relay and/or the electrical circuit on the ECM.
677-6 Engine Starter Motor Relay : Current Above Normal	This code indicates that there is a problem with the engine starter motor relay and/or the electrical circuit on the ECM.
1074-5 Engine (Exhaust) Brake Output : Current Below Normal	This code indicates that there is a problem with the engine retarder solenoid and/or electrical circuit on the ECM.
1074-6 Engine (Exhaust) Brake Output : Current Above Normal	This code indicates that there is a problem with the engine retarder solenoid and/or electrical circuit on the ECM.
2791-5 EGR Valve Control : Current Below Normal	This code indicates that there is an electrical problem with the solenoid valve and/or circuit on the NRS valve actuator
2791-6 EGR Valve Control : Current Above Normal	This code indicates that there is an electrical problem with the solenoid valve and/or circuit on the NRS valve actuator.
2949-5 Engine Intake Valve Actuation System Oil Pressure Control Valve : Current Below Normal	This code indicates that there is a problem with the Engine Intake Valve Actuation System Oil Pressure Control Valve circuit or solenoid.
2949-6 Engine Intake Valve Actuation System Oil Pressure Control Valve : Current Above Normal	This code indicates that there is a problem with the Engine Intake Valve Actuation System Oil Pressure Control Valve circuit or solenoid.
3361-5 Aftertreatment #1 DEF Dosing Unit : Current Below Normal	This code indicates that there is a problem with the DEF injector and/or the electrical circuit for the DEF injector. Refer to Test Step 4.
3361-6 Aftertreatment #1 DEF Dosing Unit : Current Above Normal	This code indicates that there is a problem with the DEF injector and/or the electrical circuit for the DEF injector. Refer to Test Step 4.
3363-5 Aftertreatment #1 DEF Tank Heater : Current Below Normal	This code indicates that there is a problem with the coolant diverter valve and/or the electrical circuit for the coolant diverter valve.
3363-6 Aftertreatment #1 DEF Tank Heater : Current Above Normal	This code indicates that there is a problem with the coolant diverter valve and/or the electrical circuit for the coolant diverter valve.
3479-5 Aftertreatment #1 Fuel Pressure Control : Current Below Normal	This code indicates that there is a problem with the pilot fuel solenoid and/or electrical circuit on the CEM.
3479-6 Aftertreatment #1 Fuel Pressure Control : Current Above Normal	This code indicates that there is a problem with the pilot fuel solenoid and/or electrical circuit on the CEM.
4301-5 Aftertreatment #1 Fuel Injector #1 Heater Control : Current Below Normal	There is low current flow between the ECM and the relay for the heating element. The most likely cause of this code is an open circuit in the wiring between the ECM and the relay. There may be a problem with a connector.
4301-6 Aftertreatment #1 Fuel Injector #1 Heater Control : Current Above Normal	There is excessive current flow between the ECM and the relay for the heating element. If the high current continues for 10 seconds, the ECM disables the output for the heating element. The power to the ECM must be cycled to reset the fault detection circuit. The most likely cause of this code is a short circuit in the wiring between the ECM and the relay. There may be a problem with a connector.
5276-5 Engine Exhaust Manifold Bank #1 Flow Balance Valve Actuator Control : Current Below Normal	This code indicates that there is a problem with the exhaust balance valve solenoid and/or electrical circuit.
5276-6 Engine Exhaust Manifold Bank #1 Flow Balance Valve Actuator Control : Current Above Normal	This code indicates that there is a problem with the exhaust balance valve solenoid and/or electrical circuit.
5423-5 Aftertreatment #1 Fuel Pump Relay Control : Current Below Normal	This code indicates that there is problem with the relay and/or circuit for the ARD electric fuel pump.
5423-6 Aftertreatment #1 Fuel Pump Relay Control : Current Above Normal	This code indicates that there is problem with the relay and/or circuit for the ARD electric fuel pump.
5424-5 Aftertreatment #1 Fuel Flow Diverter Valve Control : Current Below Normal	This code indicates that there is a problem with the solenoid on the diverter valve and/or the electrical circuit on the ARD electric fuel pump.
5424-6 Aftertreatment #1 Fuel Flow Diverter Valve Control : Current Above Normal	This code indicates that there is a problem with the solenoid on the diverter valve and/or the electrical circuit on the ARD electric fuel pump.
5425-5 Aftertreatment #1 Fuel Pressure #2 Actuator Control : Current Below Normal	This code indicates that there is a problem with the main fuel solenoid and/or electrical circuit on the CEM.
5425-6 Aftertreatment #1 Fuel Pressure #2 Actuator Control : Current Above Normal	This code indicates that there is a problem with the main fuel solenoid and/or electrical circuit on the CEM.
5965-5 Aftertreatment #1 DEF Control Module Relay Control : Current Below Normal	This code indicates that there is a problem with the PETU main power relay circuit or the PETU main power relay.
5965-6 Aftertreatment #1 DEF Control Module Relay Control : Current Above Normal	This code indicates that there is a problem with the PETU main power relay circuit or the PETU main power relay.

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Table 2
Component	Controller	Electrical Checkout
Coolant Diverter Valve	Diesel Exhaust Fluid Controller (DCU)	DEF Coolant Diverter Valve Solenoid Override: Turn the keyswitch to the OFF position for 2 minutes. The keyswitch must be off for 2 minutes to allow the DEF pump to purge, to reset the code, and to reset the DCU. Turn the keyswitch to the ON position. Initiate the DEF Coolant Diverter Valve Solenoid Override through CAT ET to activate the coolant diverter valve circuit.
DEF Injector	Diesel Exhaust Fluid Controller (DCU)	DEF Dosing System Verification Test: Initiate the "DEF Dosing System Verification Test" through Cat ET to activate the injector circuit.
Engine Intake Valve Actuation System Oil Pressure Control Valve	A4:E4 Engine ECM	Start the engine. Use the "Intake Valve Actuation System Test" in diagnostic tests in Cat^® Electronic Technician (ET) to activate the "Engine Intake Valve Actuation System Oil Pressure Control Valve". Once the test is complete, review the active diagnostic codes to determine the code that is present.
Engine Retarder Solenoid	A4:E4 Engine ECM	Engine Retarder Solenoid Override: Initiate an "Engine Retarder Solenoid Override" through Cat ET to activate the engine retarder solenoid. Review active diagnostic codes to determine what code is present.
Engine Starter Motor Relay	A4:E4 Engine ECM	Attempt to start the engine. Once the ECM attempts to energize the relay, the code will become active. Refer to the machine-specific schematic for the "Engine Starter Motor Relay" wiring circuit.
Ether Solenoid	A4:E4 Engine ECM	Use the "Ether Injection Override" in the override parameters section in Cat ET to activate the ether starting aid solenoid. Review active diagnostic codes to determine what code is present.
Exhaust Balance Valve Solenoid	A4:E4 Engine ECM	Use the "Engine Exhaust Manifold Bank 1 Flow Balance Valve Solenoid Override" in the override parameters section in Cat ET to activate the exhaust balance valve solenoid. Review active diagnostic codes to determine what code is present.
Fuel Diverter Valve	A5:E2 Aftertreatment ECM	Use the "ARD Fuel Flow Diverter Actuator Override" in the override parameters section in Cat ET to activate the fuel diverter valve on the ARD fuel pump. Review active diagnostic codes to determine what code is present.
Main Control Solenoid	A5:E2 Aftertreatment ECM	ARD Ignition Test:Complete an ARD ignition test through Cat ET as a final verification of the repair. This circuit is continuously monitored in T4F software and does not require performing the electrical checkout during troubleshooting.
PETU Main Power Relay	A5:E2 Aftertreatment ECM	Turn the keyswitch to the OFF position for 2 minutes. The keyswitch must be off for 2 minutes to allow the DEF pump to purge, to reset the code, and to reset the DCU. Turn the keyswitch to the ON position. Check for an active code.
Pilot Control Solenoid	A5:E2 Aftertreatment ECM	ARD Ignition Test: Complete an ARD ignition test through Cat ET as a final verification of the repair. This circuit is continuously monitored in T4F software and does not require performing the electrical checkout during troubleshooting.
Relay for ARD Fuel Pump	A5:E2 Aftertreatment ECM	Use the "Aftertreatment Fuel Pump Relay Override" in the override parameters section in Cat ET to activate the ARD fuel pump. Review active diagnostic codes to determine what code is present.
Relay for ARD Heater	A5:E2 Aftertreatment ECM	ARD Nozzle Heater Circuit Test: Initiate the "ARD Nozzle Heater Circuit Test" through Cat ET to activate the ARD heater relay. Review active diagnostic codes to determine if a code is present.
Solenoid Valve for NRS Valve Actuator	A4:E4 Engine ECM	EGR System Test: Initiate the "EGR System Test" through Cat ET to activate the control solenoid for the NRS valve. If the fault becomes active, the test will abort. Review active diagnostic codes to determine what code is present.

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Table 3
Required Service Tools
Part Number	Description
372-5260	Test Lead Tool Group

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Illustration 1	g06114870

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Illustration 2	g06108266

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Table 4
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:There is an active or there is a logged 3361-5, 3821-5, 3361-6, or 3821-6 code. Proceed to Test Step 4. Result: There is an active or there is a logged -5 code other than a 3361-5 or 3821-5 code. Proceed to Test Step 2. Result: There is an active or there is a logged -6 code other than a 3361-6 or 3821-6 code. Proceed to Test Step 3.
2. Check the Wiring for an Open Circuit A. Verify that the harness connector is free of debris, free of corrosion and securely connected. B. Disconnect the solenoid from the harness. C. Connect a jumper wire between the terminals of the harness connector for the affected coil. The coil is replaced with a short circuit.	Create a Short	Result: A -5 code became active during the electrical checkout. The ECM did not detect the jumper wire. There is an open circuit in the wiring between the coil and the ECM connector. There may be a problem with a connector. Repair: Repair or replace the connectors or the wiring. Verify that the repair eliminated the problem. Result: A -6 code is activated during the electrical checkout. The ECM detected the jumper wire. There is a problem with the solenoid. Repair: Replace the solenoid. Verify that the repair eliminated the problem.
3. Check the Wiring for a Short Circuit A. Disconnect the solenoid from the harness.	Create an Open	Result: A -6 code became active during the electrical checkout. The ECM did not detect the open circuit. There is a short circuit in the wiring between the coil and the ECM connector. There may be a problem with a connector. Repair: Repair or replace the connectors or the wiring. Turn the keyswitch to the OFF position for 2 minutes. The keyswitch must be off for 2 minutes to allow the DEF pump to purge, the code to reset, and the DCU to reset. Verify that the repair eliminated the problem. Result: A -5 code is activated during the electrical checkout. The ECM detected the open circuit. There is a problem with the solenoid. Repair: Replace the solenoid. Turn the keyswitch to the OFF position for 2 minutes. The keyswitch must be off for 2 minutes to allow the DEF pump to purge, the code to reset, and the DCU to reset. Verify that the repair eliminated the problem.
4. Measure the Resistance of the Injector Note: A 372-5260 Test Lead Tool Group is required for completing this procedure. A. Turn the keyswitch to the OFF position. Allow 2 minutes to elapse before proceeding. B. Disconnect the DEF injector from the applicable harness. C. Inspect the connector for damage or debris. D. Connect two 398-4987 Probe to the DEF injector. The probes must be used to prevent damage to the DEF injector connector. E. Measure the resistance of the DEF injector.	Ohms	Result: The resistance of the injector measured between 10 Ohms to 20 Ohms. Proceed to Test Step 5. Result: The resistance of the injector did not measure between 10 Ohms to 20 Ohms. A failed DEF injector has been detected. Repair: Replace the injector. Refer to the Disassembly and Assembly manual for additional information. Perform a "DEF Dosing System Verification Test" using Cat ET to verify that the repair eliminated the problem.
5. Check the Wiring for a Short Circuit A. Disconnect the injector from the harness. B. Connect two 398-4985 Probe to the DEF injector harness connector. The probes must be used to prevent damage to the DEF injector connector. C. Measure the resistance between the following terminals: - The DEF injector positive wire and the DEF injector negative wire at the DEF injector connector - The DEF injector positive wire and a good ground - The DEF injector negative wire and a good ground. Note: The resistance between the DEF injector negative wire and a good ground should be greater than 1000 Ohms.	Create a Short	Result: The resistance of the DEF injector wiring harness measured greater than 1000 Ohms. Proceed to Test Step 6. Result: The resistance of the DEF injector wiring harness measured less than 1000 Ohms. There is a short circuit in the wiring harness between the DEF injector connector and the DCU or there is an external short to ground. Repair: Repair or replace the wiring harness. Perform a "DEF Dosing System Verification Test" using Cat ET to verify that the repair eliminated the problem.
6. Check the Wiring for an Open Circuit A. Disconnect the injector from the harness. B. Disconnect the PETU wiring harness from the DCU. C. Connect two 398-4985 Probe to the DEF injector harness connector. The probes must be used to prevent damage to the DEF injector connector. D. Connect one 398-5063 Probe to terminal 12 and one 398-5063 Probe to terminal 32 on the 86-pin DCU connector. The probes must be used to prevent damage to the DCU connectors. E. Measure the resistance between the following terminals: - Terminal 1 on the DEF injector connector and Terminal 32 on the 86-pin DCU connector - Terminal 2 on the DEF injector connector and Terminal 12 on the 86-pin DCU connector	Create an Open	Result: There are more than 10 Ohms of resistance on any one of the DEF injector circuit wires. There is an open in the harness. Repair: Repair or replace the wiring harness. Perform a "DEF Dosing System Verification Test" using Cat ET to 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).