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• Accessing injector Access to Cat ET Injector Tests is reached only through the Diagnostics
tests pull down menu as follows:
Diagnostics / Diagnostic Tests
• Two injector tests There are two basic injector tests which can be accessed from this menu
available depending on the application selected:
Injector Solenoid Test
Cylinder Cutout Test
There are a variety of methods of testing injectors within the two
categories listed above, these will be covered later.
The Injector Solenoid Test is accessed through the Diagnostics pull down
menu using the following menu sequence:
NOTE: The injection actuation test, override parameters, and the wiggle
test can also be accessed from the diagnostic tests menu and will be
covered later in the presentation.
Cat Electronic Technician Course 3-1-3 Module Three
01/04 Lesson One
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• Injector solenoid tests There are several methods of testing injectors (and cylinders) for
mechanical and electrical faults using Cat ET. The first category to be
described is the Injector Solenoid Test.
This test can be performed when troubleshooting injector open/short
diagnostic messages. The Solenoid Test is usually performed first
because it is done with the engine off.
The Injector Solenoid Test verifies that the circuits from the ECM to the
injector are currently functioning. The ECM injector power supply and
drivers, the external/internal wiring harnesses, and the injector solenoids
are tested.
If no active fault is found, the logged fault screen should be checked. It is
possible that a loose connection could cause an intermittent fault which
may not be evident at the time of testing.
There are two ways to test the solenoids. The first method, shown here, is
automatic, and tests each solenoid in sequence. Select the Test All button,
• Automatic solenoid or the A key. A defective solenoid circuit will appear on the screen as
test
shown above. In this case, the screen shows cylinder 7 is open.
• Faulty cylinders There are differences between the automatic test on highway truck and
identified machine engines, trucks will test the solenoids continuously in sequence
and machines will test once through the injectors and then stop.
NOTE: Striking the letter underlined on the button performs the same
function as clicking the button.
Cat Electronic Technician Course 3-1-4 Module Three
01/04 Lesson One
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• Manual (individual) The other method of testing injector solenoids is to individually test each
injector solenoid test cylinder. This method is useful when an intermittent injector fault is
indicated on the Logged Fault screen. However, this method does not
work with on highway on truck engines.
With the suspect cylinder highlighted, select the Test button or the E key
on the keyboard. The solenoid can be repeatedly fired while the affected
wiring harness and connectors are manipulated. When the fault is found,
the Cat ET screen will show an open or short circuit as seen above.
In this case, the test has identified an open circuit on cylinder number 7.
This test is commonly called the "clack test" from the noise
accompanying injector solenoid actuation.
• Interpretation of The sound, or lack of sound from the test, is not in itself, a conclusive
solenoid test sounds symptom of a faulty injector.
When testing a HEUI injector however, a dead cylinder with no sound at
all, but accompanied by a normal electrical test indication, could mean
that the poppet valve is stuck.
This condition could be caused by improper injector removal or
installation, resulting in misalignment of the poppet valve bore, and
thereby leading to a stuck poppet valve. The use of a pry bar to remove a
3408/12E HEUI injector usually causes distortion of some close tolerance
machined parts such as the poppet valve and valve body.
Cat Electronic Technician Course 3-1-5 Module Three
01/04 Lesson One
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• Cylinder cutout tests The Cylinder Cutout Test is the second category of injector tests. This
test can be used when no diagnostic message is present and the problem is
mechanical.
The test is accessed through the Diagnostics pull down menu using the
following menu sequence:
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• Automatic and manual There are two basic Cylinder Cutout test routines, automatic and manual.
cylinder cutout tests
The automatic test, shown above, will test all cylinders and make a
comparison between them. The numbers are not a finite measurement but
are purely comparative. This test is performed with the engine running.
There are four buttons below the main box, at the bottom of the screen:
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• Manual cutout test In the case of engines with 12 cylinders or more, it is difficult to tell if a
cylinder is misfiring. It is easier to find the defective cylinder by cutting
out one bank completely and then checking the other bank.
• Torque stall test Another method is to perform a torque stall and watch the rpm drop as
each cylinder is cutout. Typically the rpm will drop about 100 rpm as the
cylinder is cutout. A dead cylinder will show no change.
In the illustration above, the odd numbered cylinders have been cutout
and the even numbered cylinders are being tested. Cylinder No. 7 is being
manually cutout. The engine noise will change if it is a good cylinder and
will not if it is a dead cylinder.
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• Locating a loose To locate this type of fault, return to the Injector Solenoid Test Screen and
connection highlight the cylinder in question. Press the Test key to perform the
"clack" test as the wiring is manipulated in various ways. Eventually, the
fault will be located as the wiring is disturbed.
The circuit should be retested and logged faults cleared. Note that an
active injector wiring fault cannot be observed on Cat ET unless the
engine is running. Conversely, a solenoid test is performed with the
engine stopped.
Cat Electronic Technician Course 3-1-9 Module Three
01/04 Lesson One
• Automatic injector If an out of normal range current flow is detected by the ECM, then the
disconnect injector will be deactivated for about 10 cycles. Thereafter, the ECM will
periodically retry the injector and disconnect if the problem is still
present. This explains why a suspect injector may be automatically
activated and deactivated at regular intervals on the cylinder cutout
screen.
• Cold cylinder cutout Some 3500 engines employ a Cold Cylinder Cutout Strategy. This
strategy process provides a means of reducing white smoke after a cold start. Also
some damage could be sustained by raw fuel washing down the cylinder
bore leading to a piston seizure.
During cold running conditions, the ECM determines if a cylinder is not
firing by turning off the cylinder and measuring the "rack." If there is no
change, then that cylinder is disconnected and the process moves on to the
next cylinder. The process continues until the complete engine is checked
for misfiring cylinders. The cycle repeats until the engine has warmed up.
• Cold cylinder cutout The Cold Cylinder Cutout process is independent of cold mode. This
disabled when: process is a function of coolant temperature, throttle position, parking
- Throttle opened brake position, and some transparent parameters within the ECM. All of
- Gear selected the conditions have to be met in order for the strategy to be enabled.
- Engine up to temp If the throttle is opened, a gear is selected or the engine comes up to
- Parking brake off
temperature, the process is disabled. This process should not be confused
with a misfire caused by an electrical fault or other mechanical
malfunction.
NOTE: The term "rack" does not imply that a physical rack is present in
an EUI engine. The term is synonymous with that used with mechanical
fuel systems.
Cat Electronic Technician Course 3 - 1 - 10 Module Three
01/04 Lesson One
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Speed/Timing Sensors
Pressure Sensors
Injectors
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Once the timing calibration sensor is installed, the engine is running, and
the calibration screen is initiated, press the Continue button at the lower
left hand portion of the calibration screen.
• Speed/timing sensor It is not always necessary to set the engine rpm for this procedure. This
calibration engine step is usually performed automatically by Cat ET when the timing
speed setting calibration sequence is initiated in the ECM. Engine speed is set to 800
rpm. If an error of 10º or more is detected, for example, timing
calibration is aborted. (These numbers may vary from application to
application.)
• Sensor calibration Calibration is required after an engine timing adjustment. If the ECM is
required after: replaced and the ECM Replacement Function is performed, the calibration
- ECM replacement data is copied with the other parameters to the new ECM. If not,
- Timing adjustment calibration is necessary. Most engine Service Manuals do not call for a
calibration after a Speed/Timing Sensor replacement. However, in this
case, good judgement may be the deciding factor.
Cat Electronic Technician Course 3 - 1 - 12 Module Three
01/04 Lesson One
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• Two methods to There have been two methods to perform pressure sensor calibration; the
calibrate pressure key switch, and the Cat ET methods. The ET method has been deleted
sensors with some engines.
Using the same pull down menu used with Speed/Timing sensor
calibration, select:
• Cat ET pressure Unlike Speed/Timing Sensor Calibration, the engine cannot be running
sensor calibration during Pressure Sensor Calibration. The Pressure Sensor Calibration
feature is only present in the pull down menu if the feature applies to the
engine selected.
The atmospheric pressure sensor is used as the baseline to adjust the other
pressure sensor outputs. Other sensors with readings which do not agree
with the atmospheric sensor's output readings will be adjusted (within
limits) to agree with the atmospheric sensor.
As long as the error is within the calibration range, the error will be
corrected by this process. If not, a repair is necessary.
There is a diagnostic routine built into the program which will identify a
calibration problem. It could be that a sensor is out of the normal output
range for calibration. For example, the reason for calibration may be that
oil pressure reads +4 psi (28 kPa) with the engine stopped. This means
that the oil pressure sensor absolute pressure reading is 19 psia (129 kPa).
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When using the status screen to troubleshoot a problem, the oil pressure
sensor reading should agree with the atmospheric sensor reading with the
engine stopped. Most engine pressure sensors are the absolute type.
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• Injector calibration The purpose of Injector Calibration is to enable a more precise fuel flow
balances fuel flow and timing balance between cylinders. The injectors are flow checked
and timing between
and calibrated at the factory. Any minute fuel flow deviations are
cylinders
represented by a code stamped on the top of the injector. These codes are
programmed into the ECM with the injector calibration function.
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The numbers seen on the right hand side are the default values which will
be used if no values are pre-programmed.
As the values from the injectors are read, they are transferred to the ECM
using this screen. This process provides a more even flow to each
cylinder, and therefore more even, smooth power balance throughout the
engine.
• ECM replacement All the calibrations previously mentioned are copied over to a new ECM
if the Copy Configuration / ECM Replacement function is performed
when the ECM is replaced. The only parts that must be manually
performed are the loading of the flash file and rating selection.
Cat Electronic Technician Course 3 - 1 - 17 Module Three
01/04 Lesson One
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Software maps were previously in the ECM. The ECM would select the
correct map using the trim code from the face of the injector. This code
was typically 4 or 6 digits.
• Trim files used for In order to accommodate this volume of data, it is loaded into a trim file
calibration which is uploaded to the Engine ECM.
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• Trim file sources: The files are stored and can be retrieved using SIS (Service Information
- SIS Windows System). The files are also provided with the replacement injectors on
- SIS Web CD.
- SIS Network
- CD ROM with
injector
At the time of writing there are two Trim File CDs supplied with SIS
Windows, by the end of the year, the files will be on 1 DVD. Also trim
files are available on a separate CD for TEPS dealers.
The injector serial number must be obtained first in order to download the
file to the PC.
Cat Electronic Technician Course 3 - 1 - 20 Module Three
01/04 Lesson One
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Locate the injector serial number obtained from the injector as shown
above (arrow).
• Injector confirmation Also locate the "Injector Confirmation Code" to the right of the Serial
codes Number, in this case 4382. The serial number and four digit random
- Cross checks number is printed onto the injector using a laser
injector serial
number
The four digit random number is included in the trim file. This feature is
a security measure to make sure the mechanic actually has the injector in
hand. Cat ET (Electronic Technician) cross checks the injector serial
number and code in the trim file with what is typed in. If there is not a
match, a dialog box will appear (shown later).
Cat Electronic Technician Course 3 - 1 - 21 Module Three
01/04 Lesson One
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• SIS Start the SIS (Service Information System) program. On the SIS main
- Source of trim files menu, locate "Injector Trim Files" (arrow).
NOTE: If this item is not on the main menu, then the Dealer SIS
Coordinator should be contacted to have the SIS Web profile changed to
turn on the "Injector Trim Files."
Cat Electronic Technician Course 3 - 1 - 22 Module Three
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• File downloads Follow the instructions on screen (left arrow) which says:
This box is used to input the serial number (right arrow) for the injector.
This serial number is the same as the file name for the trim file.
Cat Electronic Technician Course 3 - 1 - 23 Module Three
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• Entering injector Enter the injector serial number in the box (arrow) to identify the trim file
serial number for downloading.
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• Search for trim file Click on the Search button, this action will download the file. The file
will appear on the left hand side (arrow).
Click on this file name (arrow), this will bring up the “File Download"
dialog box.
The file version number can be ignored when performing the calibration.
There is no need to perform an upgrade if the injector file is an earlier
version than the file in SIS. This information is used by the factory and
does not affect replacement or calibration of injectors.
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• Trim file download After the Search button is selected, the File Download dialog box will
appear.
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Once all the files are all downloaded to the PC, they can be uploaded to
the the ECM for calibration.
NOTE: A folder called Injector Trim Files, can be created to contain the
downloaded trim files. Cat ET preferences can then be set to
automatically look to this folder for the trim files.
Cat Electronic Technician Course 3 - 1 - 27 Module Three
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• Select injector for Select the injector to program and click the Change button at the bottom
calibration of the screen. In this case injector number one is selected.
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• Select file Select (highlight) the file for calibration. This file will be copied to the
ECM.
NOTE: The Cat ET preferences menu allows the Injector Trim Files
folder to be automatically located in the same way as the Flash File folder
is located.
Cat Electronic Technician Course 3 - 1 - 30 Module Three
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• Enter confirmation Enter the Confirmation Code, this code was recorded from the injector
code with the serial number. This code ensures that the correct and compatible
file is selected – a confirmation.
Cat ET determines if the Confirmation Code and the file are a valid pair.
If not, Cat ET will display an error message as shown on this slide.
Cat Electronic Technician Course 3 - 1 - 31 Module Three
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• Double check injector Upon successful completion, the Injector Serial Number field will have a
code new value. At this point, it is prudent to double check that the serial
number appearing against the injector represents the injector that was
installed.
NOTE: It the Serial Number field has not been programmed, an Active
Fault will be displayed. The engine will run but with a warning light.
Cat Electronic Technician Course 3 - 1 - 33 Module Three
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• Injector trim file First, highlight the first injector to be exchanged as shown above, in this
exchange procedure case number one.
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Using the lower "With Injector" box, select the number of the new
position. In this case it is number four.
Click OK.
Cat Electronic Technician Course 3 - 1 - 35 Module Three
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Upon successful completion, both Injector Serial Number fields will have
new values.
NOTE: The Trim Files functions described in this section are only
possible using STW/Cat ET Version 2003B or higher. If a previous
version is used, none of these functions can be accessed.
Cat Electronic Technician Course 3 - 1 - 36 Module Three
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The HEUI Injection Actuation Pressure Test allows the user to override
the automatic ECM pressure control and manually change hydraulic
pressure from minimum to maximum.
• Accessing the test The test is accessed through the pull down menu as follows:
The pressure can be lowered using the Step Down button to the minimum
permitted by the compensator valve adjustment, and has a value of about
20% pump control valve (injection actuation) current.
The maximum pressure is produced using the Step Up button with about
50% pump control valve current. These values are variable depending on
parasitic load and oil viscosity.
The Step Up function will stop when pressure reaches the maximum limit.
Also the Step Down function will not cause the pressure to pull below the
value set by the spring in the compensator valve.
Cat Electronic Technician Course 3 - 1 - 37 Module Three
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• Accessing the The screen can be accessed through the pull down menu as follows:
Override parameters
Diagnostics / Diagnostic Tests / Override Parameters
function
In this case the Check Engine Lamp has been turned off for a functional
check of the ECM. The Low Oil Pressure Lamp has been grounded.
In the case of an open or a short in one of these circuits, the system can be
turned on and off to aid in tracing the fault.
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Wiggle Test
The Wiggle Test function allows the user to determine if there is an
intermittent wiring problem by indicating which parameter on the screen
has moved beyond a predetermined range while "wiggling" the wiring
harness, sensors, connectors etc.
• Accessing the Wiggle The Wiggle Test can be accessed using the following pull down menu:
Test
Diagnostics / Diagnostic Tests / Wiggle Test
Once you have selected the wiggle test through the pull down menu, a
warning box will appear. If all the conditions are met, then press the OK
button. If all the conditions are not met either complete them before
continuing with the test or press the Cancel button.
Cat Electronic Technician Course 3 - 1 - 39 Module Three
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• Screen Layout The Wiggle Test screen has the following areas:
The Wiggle Test display area is in a grid format and it displays the
description, value, and unit of predefined ECM parameters. The
Description column gives the name of the parameter. The Value column
displays the status of the selected parameter. The Unit column displays
the type of unit that the value is measured by.
If there are more parameters to view than what are shown in the display
area, a vertical scroll bar displays at the right side of the screen to view
the remaining parameters.
NOTE: If the service tool is unable to read the data, "Unavailable," "Not
Installed," or "Not Available" will display.
Cat Electronic Technician Course 3 - 1 - 40 Module Three
01/04 Lesson One
Groups …
Zoom In/Zoom Out
Active Codes
Start/Stop
The following exercises will reinforce the material introduced in this lesson and will allow questions to
be asked:
Notes
Cat Electronic Technician Course 3 - 1 - 43 Module Three
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4. Diagnose a HEUI hydraulic pressure problem using the Injection Actuation Pressure Test.
c. Access the Trim File from SIS, save the file to a directory in the PC