SUPPORT AS 1524838 - Caterpillar

System Operation Description:Use this procedure to troubleshoot the system when there is an active 42-11 Injection Actuation Control Valve open/short.Note: Also use this procedure for an active 164-11 Injection Actuation Pressure system fault if you are directed by another test procedure.The injection actuation pressure control valve (IAPCV) regulates the high pressure oil to the injectors through a high pressure rail. The high pressure oil manifold is used to actuate the injectors and the high pressure oil manifold is used to control the fuel injection pressure. The IAPCV relieves excess high pressure oil back to the sump. The Electronic Control Module (ECM) controls the operation of the IAPCV by monitoring the engine speed and the injection actuation pressure sensor.
Illustration 1 g01130408
Schematic for the Injection Actuation Pressure Control Valve
The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere.
Test Step 1. Inspect Electrical Connectors And Wiring
Illustration 2 g01130179
Component locations (typical example) (1) Unit injector hydraulic pump (2) Injection actuation pressure sensor (3) Injection Actuation Pressure Control Valve (IAPCV) (4) High pressure supply line to cylinder head (5) Low pressure supply line to pump (6) ECM (7) J2/P2 ECM connector
Thoroughly inspect the J500/P500 IAPCV connector and the J2/P2 ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 3 g01130409
P2 terminations for the IAPCV (P2-61) Control (P2-62) Return
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the IAPCV.
Check the allen head screw on the ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and wiring for abrasion and pinch points from the IAPCV back to the ECM.Note: Ensure that the seal is installed on the harness connector for the injection actuation pressure control valve.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 the wiring appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with the connectors and/or the wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled. Verify that the repair eliminates the problem.STOPTest Step 2. Measure the Resistance of the Injection Actuation Pressure Control Valve's Solenoid
Turn the keyswitch to the OFF position.
Disconnect the J500/P500 IAPCV connector.Note: Ensure that the seal remains on the P500 connector when the connector is disconnected.
Use a multimeter to measure the resistance between J500-1 IAPCV and J500-2 IAPCV Common on the IAPCV. Record the value that was measured.Expected Result:The solenoid resistance of the IAPCV is between 4 Ohms and 16 Ohms.Results:
OK - The resistance is between 4 Ohms and 16 Ohms. There is not a problem with the solenoid for the IAPCV.