CONTROLLER 4878395 - Caterpillar

Table 1
Diagnostic Codes for Injector Data Incorrect
J1939 Code CDL Code Code Description
(code descriptions may vary) Comments
651-2 1-2 Engine Injector Cylinder #01 : Erratic, Intermittent or Incorrect The Electronic Control Module (ECM) detects an injector code that is incorrect for the engine.
The warning lamp will come on.
652-2 2-2 Engine Injector Cylinder #02 : Erratic, Intermittent or Incorrect
653-2 3-2 Engine Injector Cylinder #03 : Erratic, Intermittent or Incorrect
654-2 4-2 Engine Injector Cylinder #04 : Erratic, Intermittent or Incorrect
655-2 5-2 Engine Injector Cylinder #05 : Erratic, Intermittent or Incorrect (C6.6 engines only)
656-2 6-2 Engine Injector Cylinder #06 : Erratic, Intermittent or Incorrect (C6.6 engines only) The following background information is related to this procedure:Injector codes are 30 hexadecimal character codes that are supplied with each injector. The code is on a plate on the top of the injector and a card is also included in the packaging for the injector. The code is used by the ECM to balance the performance of the injectors.Refer to Troubleshooting, "Injector Code - Calibrate" for further information.
Illustration 1 g02131289
Typical code plate on an injector
Illustration 2 g02132293
Sequence for recording the injector code
Table 2
Troubleshooting Test Steps Values Results
1. Check for Active Diagnostic Codes
A. Connect the electronic service tool to the diagnostic connector.
B. Turn the keyswitch to the ON position.
C. Check for active diagnostic codes or recently logged diagnostic codes.
Diagnostic codes
Result: No diagnostic codes are present.
Return the unit to service.
Result: One or more of the preceding diagnostic codes are active.
Make a note of any cylinder numbers with the active diagnostic code. Proceed to Test Step 2.
2. Check the Injector Code on any Suspect Cylinders
A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools".
B. Turn the keyswitch to the ON position.
C. Select the following menu options on the electronic service tool to obtain the injector codes from the ECM:
"Service"
"Calibrations"
"Injector Trim Calibration"
D. Make a note of the injector codes for any suspect cylinders.
Diagnostic code
Result: The card that was supplied with the injector is available for the suspect cylinders.
Repair: Compare the injector code from the card with the injector code that was recorded from the electronic service tool for each suspect cylinder.
If the codes match, proceed to Test Step 3.
If the codes do not match, then use the electronic service tool to input the code from the card.
Result: The card with the injector code is not available.
Proceed to Test Step 3.
3. Manually Program the Injector Code
A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
B. Make a note of the injector code that is on the injector in any suspect cylinders.
Note: Refer to Illustration 2 for the correct sequence for recording the injector code.
C. Compare the injector code from the injector with the injector code from the electronic service tool for each suspect cylinder.
Injector codes
Result: The code on the injector is the same as the code in the ECM.
Repair: The injector is incorrect for the engine. Replace the injector with the correct injector for the engine. Refer to Disassembly