COUPLING-PERMANENT 1242111 - Caterpillar

System Operation Description:The engine has electronic fuel injectors that are mechanically actuated and electronically energized. The Electronic Control Module (ECM) sends a 105 volt pulse to each injector solenoid. The pulse is sent at the proper time and at the correct duration for a given engine load and speed. The solenoid is mounted on top of the fuel injector body. The 105 volt pulse can be individually cut out to aid in troubleshooting misfire problems.If an open is detected in the solenoid circuit, a diagnostic code is generated. The ECM continues to try to fire the injector. If a short is detected, a diagnostic code is generated. The ECM will disable the solenoid circuit. The ECM will then enable the solenoid. If the short circuit remains this sequence of events will be repeated until the problem is corrected.The injector codes must be programmed into the ECM. The injector code is a four digit number (last four digits of the serial number for the injector) that is found on each of the unit injectors. The ECM uses this number to compensate for manufacturing variations between individual injectors. If you replace any of the unit injectors, you must reprogram the code for the new injectors. Also, if you replace the ECM, you must reprogram all of the injector codes. The ECM will generate the following diagnostic code if the injector codes are not programmed:
1495-02 Injector Trim Codes Not Programmed
Illustration 1 g01017760
Typical example
Test Step 1. Check for Connector Damage.
Turn the Engine Control Switch (ECS) to the OFF/RESET position.
Turn the circuit breaker for the battery to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the allen head screw on each ECM connector for the proper torque. Refer to Troubleshooting, "Inspecting Electrical Connectors" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points. Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The connectors and wiring are OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring need repair.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Check for "LOGGED" Diagnostic Codes.
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.
Observe the diagnostic codes on Cat ET. Expected Result:A CID-FMI from 1-05 to 16-05 or from 1-06 to 16-06 is not logged.Results:
OK - A CID-FMI from 1-05 to 16-05 or from 1-06 to 16-06 is not logged. Proceed to Test Step 3.
Not OK - A CID-FMI from 1-05 to 16-05 or from 1-06 to 16-06 is logged. Proceed to Test Step 5.Test Step 3.