The override parameters screen has multiple overrides. The parameters control various functions on the engine and CEM. These functions and features allow the technician to troubleshoot different engine systems.
- Connect to Cat ET.
- Select the appropriate Electronic Control Module (ECM).
- Select the "Diagnostics" tab.
- Select the "Diagnostic Tests" tab.
- Select the "Override Parameter" tab.
Override Parameters Listed in the Engine ECM Menu
This override is used to activate the ether injection solenoid circuit to ensure that the circuit is working properly. The ether canister must be removed during testing of the ether solenoid circuit.
Override Parameters Listed in the Selective Catalyst Reduction System Menu
DEF Dosing Control Module Key Switch Line Test
This override resets all the Diesel Exhaust Fluid Control Units (DCU's) without having to cycle key power to the other ECM's. The reset ensures that each diesel exhaust fluid controller completes a purge cycle, resets any active codes, and shuts down correctly.
This test turns off the keyswitch power from the A5:E2 Selective Catalyst Reduction Controller to each DCU for approximately 2 minutes. Once each DCU has successfully powered down and reset, the keyswitch power supply will be turned back on. Each DCU will then be operational.
Aftertreatment #1 Line Heater #5 State Override
This override activates the output for DEF Line Heater #5 which is the DEF ground level fill circuit. This circuit consists of 3 separate heaters, and this override activates all the line heaters associated with the ground level fill.
Override Parameters Listed in each of the Diesel Exhaust Fluid Controller Menu's
Aftertreatment DEF Backflow Valve Override
This override allows the user to test the electrical circuit for the backflow valve. This override commands the DEF backflow valve to a known position. This test can be used to make sure that the DEF backflow valve is working properly.
DEF Coolant Diverter Valve Solenoid Override
The override is used to check the solenoid and diverter valve harness electrically. This override will open the coolant diverter valve which allows coolant to flow through the PETU assembly. This test can be used to verify that the coolant diverter valve is working properly.
This override allows the user to test the electrical circuit for the DEF injector. The override commands the DEF injector to open. This override only operates when there is no engine speed.
System Troubleshooting Settings
The "System Troubleshooting Settings" screen will allow overrides to be enabled.
- Connect to Cat ET and select the appropriate ECM.
- Select the "Diagnostics" tab.
- Select the "Diagnostic Tests" tab.
- Select "System Troubleshooting Settings".
System Troubleshooting Settings Listed in the Engine ECM Menu
Engine Emissions Operator Inducement Service Mode Override
The override is used by service technicians to stop the inducement counter and disable engine restrictions due to inducement to perform troubleshooting. Once the override is activated, navigation of other Cat ET functions is possible.
This override allows the service technician to disable the inducement to troubleshoot problems. Factory passwords are required to perform this override as the engine will be operating outside of the emissions window.
The purpose of this screen is to show all the active diagnostic codes.
- Connect to Cat ET.
- Select the appropriate Electronic Control Module (ECM).
- Select the "Diagnostics" tab.
- Select the "Active Diagnostic Codes" tab.
Tab Functions At Bottom of Screen
This tab will clear specific codes when highlighted.
This tab will reset all the active codes.
This tab is not available for Tier 4 engines. Refer to the Troubleshooting guide.
This tab is not available for Tier 4 engines. Refer to the Troubleshooting guide.
The purpose of this screen is to show all the logged diagnostic codes.
- Connect to Cat ET.
- Select the appropriate Electronic Control Module (ECM).
- Select the "Diagnostics" tab.
- Select the "Logged Diagnostic Codes" tab.
Tab Functions At Bottom of Screen
This tab will clear specific codes when highlighted.
This tab will clear all logged diagnostic codes.
This tab is not available for Tier 4 engines. Refer to the Troubleshooting guide.
This tab is not available for Tier 4 engines. Refer to the Troubleshooting guide.
The purpose of this screen is to show all the active event codes.
- Connect to Cat ET.
- Select the appropriate Electronic Control Module (ECM).
- Select the "Diagnostics" tab.
- Select the "Events" tab.
- Select the "Active Events" tab.
Tab Function At Bottom of Screen
This tab will clear specific codes when highlighted.
This tab will reset all the active codes. Some of the event codes will "latch" to active status. Repairing the system will not "unlatch" the event codes and the event codes must be reset with Cat ET.
The purpose of this screen is to show all the logged event codes.
- Connect to Cat ET.
- Select the appropriate Electronic Control Module (ECM).
- Select the "Diagnostics" tab.
- Select the "Events" tab.
- Select the "Logged Events" tab.
Tab Functions At Bottom of Screen
This tab will clear specific codes when highlighted.
This tab will clear all logged diagnostic codes.
This tab is not available for Tier 4 engines. Refer to the Troubleshooting guide.
This tab is not available for Tier 4 engines. Refer to the Troubleshooting guide.
Cat ET diagnostic tests are listed below.
- Connect to Cat ET and select the appropriate ECM.
- Select the "Diagnostics" tab.
- Select the "Diagnostic Tests" tab.
Diagnostic Tests Listed in the Engine ECM Menu
The purpose of the injector solenoid test is to diagnose injector wiring and injector solenoid functionality.
This test identifies an open circuit or a short circuit in the circuit for the injector solenoids. The test activates the injector solenoids one at a time while the engine is not running. A good solenoid will create an audible click when the solenoid is activated. Cat ET indicates the status of the solenoid as "OK", "Open", or "Short".
The cylinder cutout test allows one cylinder or multiple cylinders to be cut out. The cylinder cutout test is useful when troubleshooting poor engine performance or a suspected injector failure
The cylinder cutout test disables the injector by not providing the injector pulse to the solenoid. The cylinder cutout test can be performed on one injector or multiple injectors at once.
Note: When the fuel system functional test is started, the engine speed and operating conditions will change and there will be more noise associated with test.
The fuel system functional test performs several checks on the high-pressure fuel system. The test raises the engine speed, then begins checking for high-pressure fuel leakage in the system. The test will then check for fuel leaks before and after the accumulator/quill tubes and flow limiters by cutting out fuel injection on each individual cylinder and checking the fuel rail for excessive pressure loss. It then performs checks on the high-pressure fuel pump by checking to make sure that the output of the pump is within the desired range.
Note: Following repairs made to the high-pressure fuel system, remove the accumulator leak detection plugs at the repair location. Run a Fuel System Functional Test and then reinstall the accumulator leak detection plugs afterwards.
The purpose of the Wiggle Test is to detect intermittent electrical faults in electronic control systems. The Wiggle Test function allows the user to determine if there is an intermittent wiring problem. The test will indicate (by changing the value reading) which parameter moved beyond a predetermined range while wiggling the wiring harness, sensor, or connector.
This test requires that the engine is OFF and the key switch is in the ON position (or ECM energized and 0 engine speed). If the engine is started with the wiggle test active, the wiggle test will abort.
The Wiggle Test will reduce all ECM requirements to trip fault codes, making the diagnostics sensitive. Under normal operation some fault codes need multiple occurrences before the code will log. But during this test the fault codes will trip the first time.
The mechanic wiggles and shakes the wiring to see if codes go active. An audible alarm is also activated if the ECM sees any parameter change state electrically. Once the test has ended, the ECM returns to normal diagnostic state.
Diagnostic Tests Listed in the Selective Catalyst Reduction System Menu
Aftertreatment System Functional Test
The test will dose DEF into the exhaust stream while the engine is running to test the SCR dosing system operation.
The DEF dosing system will purge and the diesel exhaust fluid control units (DCU's) will power down completely. The DCU's will then power back on and prime the DEF dosing system. Once the system is completely primed, each DEF system will begin to inject DEF into the exhaust system. Currently the entire SCR system is being tested. The test will take approximately 45 minutes to complete.
This test checks the operation of the dosing system when the engine is not running.
The DEF dosing system will purge, and the DCU will power down completely. Once the system is completely primed, each DEF injector will open to allow a small amount of DEF into the exhaust stream in order to test the complete dosing system functionality.
This test can only be performed 3 times before the engine and aftertreatment must be ran at operating temperature (exhaust temperature of greater than 200 C) or until an "Aftertreatment System Functional Test" is performed.
Diagnostic Tests Listed in the Diesel Exhaust Fluid Controller Menu
Aftertreatment #X DEF Dosing System #X Prime Test
This test primes the #1 dosing system. The test is used to ensure that the #1 DEF pump is able to build adequate pressure.
This test turns on the #1 DEF pump for 5 minutes. During this time, the #1 DEF pump will pressurize the entire #1 DEF dosing system to operating pressure. The #2 and #3 DEF injectors will open momentarily to purge air out of the line. Then the DEF injectors will close again to maintain a constant pressure within the dosing system. The #1 DEF pump will purge the system at the end of the test.
This test verifies that the DEF purging process is working correctly by purging the DEF pumps and lines.
This service test is used to purge the DEF system. This test turns on all the DEF pump and opens the reverting valves. The opening of the reverting valves will cause the DEF to be pumped from the injectors back into the tank. This draining allows the user to de-pressurize the system prior to working on the system.
Aftertreatment #X DEF Dosing Injector #X Accuracy Test
This test is used with the 441-0451 DEF Test Kit to measure the amount of DEF that the SCR dosing system is spraying into the exhaust system. The test can also be used to verify visually that there is an acceptable spray pattern from each DEF Injector.
Note: The DEF injectors must be removed from the exhaust system during this test and placed in an appropriate container. Failure to do so could result in issues with the SCR system operation. Refer to Testing and Adjusting, "Aftertreatment SCR System Dosing Test"
This test turns on the DEF pump and opens the DEF injector. The DEF injector atomizes the DEF and the spray pattern must be uniform in order for the SCR system to work properly. Once the test is completed, the DEF pump will purge the system. The user must check to see if the amount of DEF in the container meets the specification.
This test checks the electrical circuit integrity by activating the line heaters. The test is used to validate a repair made to any of the heated line circuits.
This test turns on all the line heaters. The test will cycle the line heaters on and off for 5 minutes. After 5 minutes, the test will turn off. This test is used to check the line heater circuit for faults.
Cat ET calibrations are listed below.
- Connect to Cat ET .
- Select the appropriate Electronic Control Module (ECM).
- Select the "Service" tab.
- Select the "Calibrations" tab.
Calibrations Listed in the Engine ECM Menu
Injector trim files calibrate each injector. The injectors are calibrated so the injectors will deliver a precise amount of fuel at the exact time needed.
Caterpillar tests each injector to verify the accuracy of the injector duration and timing. If the injectors do not pass, the injectors are not used. If the injectors do pass, trim files are created and the injectors are installed. The trim file adjusts the duration and timing of each injector, so the injectors all function the same. When new injectors are installed, the technician records the serial numbers of each injector and searches for the injectors in SIS web. The trim files can be downloaded and stored on a pc. The technician loads the trim file for each injector into the ECM.
In Illustration 1 you can see each injector that falls in the box is a good injector that passed the tests.
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| Illustration 1 | g02157706 |
In Illustration 2 you can see that the trim files have been applied. The trim files correct the injectors back to nominal so the injectors all inject the same amount at the same time.
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| Illustration 2 | g02157717 |
Note: If the injectors fall outside of the main window, the injectors are scrapped.
Air Inlet Temperature Sensor Installation Calibration
- Select "Air Inlet Temperature Sensor Installation Calibration" and click "Start".
- Click "Next" and then click "Accept".
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Illustration 3 g03147678 - Click "Yes" and the engine should be placed under a relatively high load and high engine speed operating condition. This load does not necessarily have to be the highest possible load the installation could see. If loading the engine is not possible, increase the engine speed to 1800 RPM.
- Enter the ambient temperature from thermocouple or hand held thermometer, then click "OK". The ambient temperature must be below the Air Inlet Temperature displayed in the window. Measure the ambient temperature in the shade away from hot air flow generated from the fan. Make sure to use Celsius if Cat ET is set up in Celsius.
- The engine should be placed under a relatively high load and high engine speed for 2 minutes then click "Next". If loading the engine is not possible, increase the engine speed to 1800 RPM for 2 minutes then click "Next".
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Illustration 4 g03147742 - Click "Yes" and decrease the engine speed to low idle (600 - 700 RPM) and remove any load from the engine.
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Illustration 5 g03147748 - Enter the ambient temperature from thermocouple or hand held thermometer, then click "OK". The ambient temperature must be below the Air Inlet Temperature displayed in the window. Measure the ambient temperature in the shade away from hot air flow generated from the fan. Make sure to use Celsius if Cat ET is set up in Celsius.
- Run the engine at low idle (600 - 700 RPM) and remove any load from the engine for 2 minutes and then click "Next".
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Illustration 6 g03327553 - The calibration value has been calibrated. Write down the calibration so you can enter the calibration value in the configuration parameters. Next, click "Accept".
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Illustration 7 g03147698 - Calibration Successful, ignore "Conditions Not Met" displayed in above window for Engine Intake Manifold Mass Flow Rate. Go to Configuration, select System Settings, and enter the calibrated value into the Air Inlet Temperature Sensor Calibration. You will need Factory Passwords to program this value.
- Connect to Cat ET .
- Select the appropriate Electronic Control Module (ECM).
- Select the "Service" tab.
- Select the "Dyno Mode" tab.
Dyno Mode is used to run an engine on a dyno without derates or diagnostic trouble codes tripping from missing machine components. Normally, while in chassis an ECM is looking for inputs from various machine components, like the transmission ECM or body ECM. Dyno Mode does not require the CEM to be installed. If the ECM does not see the inputs, the ECM assumes that something is wrong and sets a diagnostic trouble code.
- Select the "Dyno Mode" tab.
- Select "Enable" to enable dyno mode.
- Return to the "Service" tab.
- Select the "Service Procedures" tab.
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Illustration 8 g03147687 - Select the "Powertrain Protection Reset" ( Available on select models).
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Illustration 9 g03137155 - Select "Reset Protection".
The engine is installed on the dyno and the technician selects Dyno mode. Dyno mode tells the engine ECM that the engine is on a dyno and the ECM ignores all the normal inputs from the machine. Once in dyno mode, if the engine has multiple power ratings the highest rating should be selected.
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| Illustration 10 | g03137154 |
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| Illustration 11 | g03137153 |
Aftertreatment SCR Catalyst Replacement
The Aftertreatment SCR Catalyst Replacement procedure must be performed when the SCR Catalyst has been replaced. This is necessary to ensure that the engine meets emissions requirements. Follow the procedure below to reset the SCR Catalyst model in the aftertreatment software.
- Connect to Cat® ET.
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Illustration 12 g03740190 - Connect to "Selective Catalyst Reduction System".
- Select "Service" from the top menu and select "Service Procedures".
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Illustration 13 g03740205 - Select "Aftertreatment #1 SCR Catalyst Replacement" and select "Start".
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Illustration 14 g03740210 - Select "Reset".
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Illustration 15 g03740216 - Read the warning and select "Accept" to continue.
- Enter the factory passwords to continue.
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Illustration 16 g03740230 - Once the reset is completed, a log of the reset is captured and visible as a new row of information in the "Aftertreatment #1 SCR Catalyst Replacement" screen.
- Connect to Cat ET.
- Select the "Selective Catalyst Reduction System".
- Select the "Information" tab.
Aftertreatment Abnormal Shutdown History
This feature allows the user to see when the engine was shutdown improperly. This screen shows hot shutdown events, and cold shutdown events.
A hot shutdown can damage the aftertreatment or SCR system.
A cold shutdown can damage the SCR dosing system.
Snapshots allow viewing of data in Cat ET approximately 9.5 seconds before and 3.5 seconds after the diagnostic trouble code was recorded.
- Select the "Information" tab. Select the "Snapshot" tab, then select the "Viewer" tab.
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Illustration 17 g03137100 - Select the diagnostic trouble code to be viewed. Select "View Data".
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Illustration 18 g03137099 - Select a group or select "Temporary Group"
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Illustration 19 g03137098 - Select the channels to view and add the channels to the group. Select "OK".
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Illustration 20 g03137096 - The sliding time bar indicates when the diagnostic trouble code was recorded. Data can be viewed 9.5 seconds before and 3.5 after the time the code was recorded .
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Illustration 21 g03137095 - Select the "View Graph" tab for graphic illustrations. Select the channels you want to view, and select "OK".
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| Illustration 22 | g03137092 |
Tab Functions At Bottom of Screen
This tab pulls up the histogram menu.
This tab is not available for Tier 4 engines.
This tab will clear the current histogram data for this key cycle.
This labels all bars in the graph.
This labels each bar in the graph as the mouse pointer is moved over the bar.
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| Illustration 23 | g03137091 |
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The total number of occurrences. | |
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| Illustration 24 | g03137090 |
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The amount of engine hours operated at indicated inlet temperature. | |
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| Illustration 25 | g03137088 |
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The amount of engine hours operated at indicated coolant temperature. | |
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| Illustration 26 | g03137087 |
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The amount of engine hours operated at indicated engine speed. | |
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| Illustration 27 | g03137086 |
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The amount of engine hours operated at indicated intake manifold air temperature. | |
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| Illustration 28 | g03137084 |
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The amount of engine hours operated at indicated intake manifold pressure. | |
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| Illustration 29 | g03137083 |
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This screen is used to help understand the operator use of the disable switch and at what soot load the regenerations take place. Manual disable status 0 = regenerations allowed due to switch position. Manual disable status 1= regenerations not allowed due to switch position. | |
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| Illustration 30 | g03137081 |
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This screen is used to illustrate load percentage at the current engine speed. This screen can be helpful in understanding how the engine is being used. The screen can also be used for comparison between similar machines and/or operators. | |
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| Illustration 31 | g03137080 |
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This histogram is populated when the engine system has calculated a condition in which high exhaust temperatures are present. A fault code will not be logged when the system calculates a high exhaust temperature condition. But the high exhaust temperature will derate the engine to protect the engine system. This action is normal under most circumstances and no additional troubleshooting is necessary. Refer to Troubleshooting, "Exhaust Temperature is High" for additional information. | |
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| Illustration 32 | g03137079 |
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There are certain engine conditions that put the engine in danger of turbocharger overspeed. The engines are calibrated and certified up to a certain altitude and ambient temperature limit. If the engine is operated outside this limit, the engine is more likely to experience turbocharger overspeed. In other words, the turbocharger has to work harder to maintain the desired boost pressure. This action is normal under most circumstances and no additional troubleshooting is necessary. | |