WASHER-HARD 8T5439 - 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 V 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 V 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.
Illustration 1 g00721120
3516 Primary ECM
Illustration 2 g00979375
3516 Secondary ECMTest Step 1. Check for Connector Damage.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET 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 ECM connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and for pinch points.Expected Result:All connectors, pins, and sockets are coupled and/or inserted, and the harness and wiring should be free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are okay. 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).
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.
Observe the diagnostic codes on the Cat ET.Expected Result:A CID-FMI from 1-05 to 16-05 or from 1-06 to 16-06 should not be 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 4.Test Step 3. Perform the Injector Solenoid Test.Note: This test will help the service technician verify that the ECM can fire the solenoids. DO NOT try to manually crank the engine during this test. The ECM will terminate the Injector Solenoid Test.
Perform this test on both the primary ECM and on the secondary ECM.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Ensure that the ECM connector J2/P2 is connected. Ensure that the injector connectors J4/P4 through J19/P19 are connected.
Connect