3516B Generator Set Engines with Dynamic Gas Blending Caterpillar

Injector Solenoid - Test

Usage:

Use this procedure to troubleshoot a problem with the injectors. 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	CDL Code and Description	Comments
651-5 Engine Injector Cylinder #01 : Current Below Normal	1-5 Cylinder #1 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
651-6 Engine Injector Cylinder #01 : Current Above Normal	1-6 Cylinder #1 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
652-5 Engine Injector Cylinder #02 : Current Below Normal	2-5 Cylinder #2 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
652-6 Engine Injector Cylinder #02 : Current Above Normal	2-6 Cylinder #2 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
653-5 Engine Injector Cylinder #03 : Current Below Normal	3-5 Cylinder #3 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
653-6 Engine Injector Cylinder #03 : Current Above Normal	3-6 Cylinder #3 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
654-5 Engine Injector Cylinder #04 : Current Below Normal	4-5 Cylinder #4 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
654-6 Engine Injector Cylinder #04 : Current Above Normal	4-6 Cylinder #4 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
655-5 Engine Injector Cylinder #05 : Current Below Normal	5-5 Cylinder #5 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
655-6 Engine Injector Cylinder #05 : Current Above Normal	5-6 Cylinder #5 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
656-5 Engine Injector Cylinder #06 : Current Below Normal	6-5 Cylinder #6 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
656-6 Engine Injector Cylinder #06 : Current Above Normal	6-6 Cylinder #6 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
657-5 Engine Injector Cylinder #07 : Current Below Normal	7-5 Cylinder #7 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
657-6 Engine Injector Cylinder #07 : Current Above Normal	7-6 Cylinder #7 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
658-5 Engine Injector Cylinder #08 : Current Below Normal	8-5 Cylinder #8 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
658-6 Engine Injector Cylinder #08 : Current Above Normal	8-6 Cylinder #8 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
659-5 Engine Injector Cylinder #09 : Current Below Normal	9-5 Cylinder #9 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
659-6 Engine Injector Cylinder #09 : Current Above Normal	9-6 Cylinder #9 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
660-5 Engine Injector Cylinder #10 : Current Below Normal	10-5 Cylinder #10 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
660-6 Engine Injector Cylinder #10 : Current Above Normal	10-6 Cylinder #10 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
661-5 Engine Injector Cylinder #11 : Current Below Normal	11-5 Cylinder #11 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
661-6 Engine Injector Cylinder #11 : Current Above Normal	11-6 Cylinder #11 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
662-5 Engine Injector Cylinder #12 : Current Below Normal	12-5 Cylinder #12 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
662-6 Engine Injector Cylinder #12 : Current Above Normal	12-6 Cylinder #12 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
663-5 Engine Injector Cylinder #13 : Current Below Normal	13-5 Cylinder #13 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
663-6 Engine Injector Cylinder #13 : Current Above Normal	13-6 Cylinder #13 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
664-5 Engine Injector Cylinder #14 : Current Below Normal	14-5 Cylinder #14 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
664-6 Engine Injector Cylinder #14 : Current Above Normal	14-6 Cylinder #14 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
665-5 Engine Injector Cylinder #15 : Current Below Normal	15-5 Cylinder #15 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
665-6 Engine Injector Cylinder #15 : Current Above Normal	15-6 Cylinder #15 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
666-5 Engine Injector Cylinder #16 : Current Below Normal	16-5 Cylinder #16 Injector : Current Below Normal	The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.
666-6 Engine Injector Cylinder #16 : Current Above Normal	16-6 Cylinder #16 Injector : Current Above Normal	The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired. The code is logged.

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Illustration 1	g03848110

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Electrical Shock Hazard. The unit injector system uses 90 - 120 volts. The ECM sends this signal to the unit injectors. Do not come in contact with the unit injector harness connector while the engine is operating. Failure to follow this instruction could resulting in personal injury or death.

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Table 2
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.	Code	Result: A code is active or logged. Proceed to Test Step 3. Result: A code is not active or logged. Proceed to Test Step 2.
2. Perform the "Cylinder Cutout Test" A. Start the engine. B. Run the engine to run until normal operating temperature is reached. C. Connect Cat ET. D. Use Cat ET to perform the following fuel injector test: - "Cylinder Cutout Test" E. Look for a noticeable change in fuel usage.	Fuel Usage	Result: There is a noticeable change in fuel usage. The injectors are firing on all cylinders at this time. Proceed to Test Step 3. Result: There is not a noticeable change in fuel usage. Repair: Verify that the valve lash for the affected cylinder is OK. If the valve lash is OK, replace the injector. If the problem is not resolved, proceed to Test Step 3.
3. Check the Wiring Harness between the ECM and the Injector Connectors for an Open Circuit A. Turn the main disconnect switch to the OFF position. Note: A strong electrical shock hazard is present if the keyswitch is not turned off. B. Disconnect the connector for the affected cylinder at the cylinder head. C. Fabricate a jumper wire that is long enough to create a test circuit across the harness connector at the cylinder head. Crimp connector pins to each end of the jumper wire. D. Connect the jumper wire between the following terminal locations: Terminal 1 (supply) and Terminal 2 (return) This test will effectively create a short circuit for the cylinder. E. Connect Cat ET. F. Use Cat ET to perform the following fuel injector test: - "Injector Solenoid Test" Note: Perform the test at least two times.	Wiring Harness	Result: Cat ET displays "Short" for the cylinder with the jumper wire. The wiring harness is OK. Proceed to Test Step 4. Result: Cat ET displays "Open" for the cylinder with the jumper wire. The ECM did not detect the jumper wire. There is an open circuit in the wiring harness. Repair: Repair or replace the connectors or wiring. Ensure that all the seals are properly in place and ensure that the connectors are coupled. If the problem is not resolved, proceed to Test Step 4.
4. Check the Harness between the ECM and the Injector Connectors for a Short Circuit A. Turn the main disconnect switch to the OFF position. Note: A strong electrical shock hazard is present if the keyswitch is not turned off. B. Disconnect the harness connectors for the injector solenoid at the cylinder head. There will then be an open circuit at the harness connector. C. Connect Cat ET. D. Use Cat ET to perform the following fuel injector test: - "Injector Solenoid Test" Note: Perform the test at least two times.	Wiring Harness	Result: Cat ET displays "Open" for the cylinder. The wiring harness is OK. Proceed to Test Step 5. Result: Cat ET displays "Short" for the cylinder. There is a problem with the wiring harness. Repair: Repair or replace the connectors or wiring. Ensure that all the seals are properly in place and ensure that the connectors are coupled. If the problem is not resolved, proceed to Test Step 5.
5. Check the Harness between the ECM and the Rigid Harness for a Short Circuit A. Turn the main disconnect switch to the OFF position. Note: A strong electrical shock hazard is present if the keyswitch is not turned off. B. Disconnect the harness connectors for the injector solenoid at the cylinder head. There will then be an open circuit at the harness connector. C. Connect Cat ET. D. Use Cat ET to perform the following fuel injector test: - "Injector Solenoid Test" Note: Perform the test at least two times.	Wiring Harness	Result: Cat ET displays "Open" for the cylinder. The wiring harness is OK. Proceed to Test Step 6. Result: Cat ET displays "Short" for the cylinder. There is a problem with the wiring harness. Repair: Repair or replace the connectors or wiring. Ensure that all the seals are properly in place and ensure that the connectors are coupled. If the problem is not resolved, proceed to Test Step 6.
6. Check the Harness between the ECM and the Rigid Harness for an Open Circuit A. Turn the main disconnect switch to the OFF position. Note: A strong electrical shock hazard is present if the keyswitch is not turned off. B. Disconnect the harness connectors for the affected cylinder at the cylinder head. C. Fabricate a jumper wire that is long enough to create a test circuit across the harness connector at the cylinder head. Crimp connector pins to each end of the jumper wire. D. Connect the jumper wire between the following terminal locations: Terminal 1 (supply) and Terminal 2 (return) This test will effectively create a short circuit for the cylinder. E. Connect Cat ET. F. Use Cat ET to perform the following fuel injector test: - "Injector Solenoid Test" Note: Perform the test at least two times.	Wiring Harness	Result: Cat ET displays "Short" for the cylinder with the jumper wire. The wiring harness is OK. Proceed to Test Step 7. Result: Cat ET displays "Open" for the cylinder with the jumper wire. The ECM did not detect the jumper wire. There is an open circuit in the wiring harness. Repair: Repair or replace the connectors or wiring. Ensure that all the seals are properly in place and ensure that the connectors are coupled. If the problem is not resolved, proceed to Test Step 7.
7. Check the ECM for Proper Operation A. Turn the main disconnect switch to the OFF position. Note: A strong electrical shock hazard is present if the keyswitch is not turned off. B. Disconnect the P2 connector. When the P2 connector is disconnected, numerous diagnostic codes will be generated when the keyswitch is turned ON. The codes are normal. Ignore the codes. Reset all active codes and clear all logged codes after you complete this Test Step. C. Connect Cat ET. D. Use Cat ET to perform the following fuel injector test: - "Injector Solenoid Test" Note: Allow the test to continue until each solenoid is activated at least two times. E. Turn the main disconnect switch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned off. F. Use a jumper wire to create a short circuit on J2 between the following terminals: - Solenoids supply and Solenoids return G. Connect Cat ET. H. Use Cat ET to perform the following fuel injector test: - "Injector Solenoid Test" Note: Allow the test to continue until each solenoid is activated at least two times.	ECM	Result: Cat ET displays "Short" for the solenoid with the jumper wire. Cat ET will display "Open" when the P2 connector is not connected to the ECM. Repair: The problem is in the injector. Perform the following procedure: 1. Replace the injector. 2. Use Cat ET to perform the following fuel injector test: - "Injector Solenoid Test" Verify that the repair eliminated the problem. Result: Cat ET does not display "Short" for the solenoid with the jumper wire. Cat ET does not display "Open" when P2 is not connected to the ECM. Repair: Perform the following procedure: 1. Temporarily connect a test ECM. Refer to Troubleshooting, "Test ECM Mode" for additional information. 2. Activate the "Injector Solenoid Test". Allow the Injector Solenoid Test to continue until each solenoid is activated at least two times. If the test ECM fixes the problem, connect the suspect ECM. If the problem returns with the suspect ECM, replace the ECM. Note: Before you consider replacing the ECM, consult with the Dealer Solutions Network (DSN) for assistance. 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).