BALL 1838450 - Caterpillar

System Operation Description:Digital inputs provide digital signals (on/off) to the OCP control of the generator set. One example of a digital signal is the opening or closing of a switch. The inputs can be programmed for use with a variety of fluid levels, temperatures, pressures, and status conditions. Two of the digital inputs are programmed at the factory. The factory programmed inputs are used by the OCP to control emergency stop and remote initiate functions. The spare digital inputs must be programmed before use.For additional information on programming digital inputs, see System Operation, "Digital Input Programming"Conditions Which Generate This Code: This code is generated when the digital input is active. The code may indicate that a problem exists with the genset, or the code may indicate a status that does not need to be repaired.Test Step 1. PERFORM THE INITIAL CHECK.
Use the Caterpillar Electronic Technician (Cat ET) in order to check for active diagnostic codes on the Engine ECM. If any codes are present, correct the diagnostic codes first. Expected Result:No other diagnostic codes or indicators are active on the Engine ECM.Results:
OK - No other diagnostic codes or indicators are active. Proceed to Test Step 2
NOT OK - Another Engine ECM diagnostic code is active.Repair: Exit this procedure. Troubleshoot the active code or indicator. Refer to the engine Troubleshooting manual for your particular genset.STOPTest Step 2. CHECK THE SETPOINTS.
View the Digital Input setpoints. Make a note of the setpoints. See Testing and Adjusting, "Electronic Control Module (ECM) - Configure". Compare the setpoints against the default setpoints of the particular generator set. Expected Result:The setpoints are correct.Results:
OK - The setpoints are correct for your particular genset. Proceed to Test Step 3
NOT OK - The setpoints are NOT correct.Repair: Reprogram the setpoints. Reset the genset. Resume normal operation and verify that the problem has been corrected.STOPTest Step 3. CHECK THE DIGITAL INPUT WIRING
Check the wiring to the corresponding digital inputs for an unwanted short circuit. The short can be to the battery negative ("B-"). Carefully check ALL wires that are connected to the appropriate digital input for abrasion or worn spots in the insulation that could be causing the short. Check the wires in the generator control panel. Check the wires in the engine harness. Refer to the appropriate wiring diagrams for the circuit that is being checked. Expected Result:The wiring is correct.Results:
OK - No problems can be found with the digital input wiring. Proceed to test step 4
NOT OK - The digital input wiring is defective.Repair: Repair the wiring or replace the wiring.Proceed to test step 4Test Step 4. CHECK IF THE DIAGNOSTIC CODE REMAINS
Inspect the harness connectors and clean the contacts of the machine harness connectors.
Reconnect all harness connectors.
Reset the genset.
Operate the genset.
Check the status of the diagnostic code. Expected Result:The diagnostic code is not active. Results:
OK - The diagnostic code is not active. The diagnostic code does not exist at this time. The initial diagnostic code was probably caused by a poor connection or a short at