HARNESS AS-PLATFORM 4947494 - Caterpillar

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to Systems Operation, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Complete the procedure in the order in which the steps are listed.
Table 2
Troubleshooting Test Steps Values Results
1. Determine the Diagnostic Code
A. Establish communication between Cat ET and the engine ECM. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
C. Determine the diagnostic trouble code that relates to an injector.
Diagnostic Code
Result: A logged -5 code or a logged -6 code is present.
Proceed to Test Step 3.
Result: An active -5 code is present.
Proceed to Test Step 4.
Result: An active -6 code is present.
Proceed to Test Step 5.
Result: A -2 code or a -7 code is present.
Proceed to Test Step 2.
2. Perform the "Fuel System Verification Test"
Note: Do not clear the diagnostic trouble code.
A. Perform the Fuel System Verification Test. Cat ET will clear the code when the test begins.
If the injector passes the test, the injector is okay. STOP.
If the injector fails the test, the injector is not okay.
Fuel System Verification Test
Result: The injector passes the test.
Result: The injector does not pass the test.
Perform the following steps:
1. Replace the injector.
2. Flash program the injector trim file into the ECM. Refer to Troubleshooting, "Injector Trim File - Install", if necessary.
3. Perform the "Fuel System Verification Test". This test will clear the active diagnostic code for the new injector.
4. If the problem has been corrected, return the unit to service.
5. Troubleshoot any active codes.
If a -5 injector code is present, proceed to Test Step 4.
If a -6 injector code is present, proceed to Test Step 5
3. Check the Integrity of the External Engine Harness
A. Inspect the injector wiring harness between the ECM and the valve cover. Look for these problems:
Improper routing of the wire harness
Missing clamps or other hardware
Loose connectors or damaged connectors
Damage that is caused by excessive heat
Damage that is caused by chafing
B. Slowly wiggle the external wiring harness and the connectors. Pay particular attention to the wiring near each connector. Look for a logged code to become active as you wiggle the wiring.
Fuel System Verification Test
Result: The external engine harness is OK. A logged code does not become active.
Proceed to Test Step 6.
Result: A problem with the external engine harness has been identified.
Repair: Stop the engine. Repair the wiring problem. Replace parts, if necessary. Start the engine. Verify that the problem is resolved.
4. Check the External