Usage:
The tests in this section are designed to establish whether a component and related parts are operating properly, and if not, to pinpoint the faulty component.
The tests may be used for basic health checks, to determine if problems exist, or as a guide to check for intermittent problems.
NOTE: Whenever troubleshooting any problem, be sure to check the service history records of the engine in order to prevent unnecessary parts replacement.
Circuit Tests
P-500: Inspecting Electrical Connectors
P-501: Electrical Power Supply
P-502: Throttle (PWM) Module
P-504: PTO Mode
P-505: Alarm Lamp Circuit Tests
Engine Circuit Tests
P-520: ECM/Personality Module
P-521: Sensor Supply Voltage
P-522: Engine Speed (RPM) Sensors
P-523: Engine Shutdown Switch
P-524: Fuel Shutoff Solenoid
P-525: Coolant Level Sensor
P-526: Coolant Temperature Sensor
P-527: Inlet Manifold (Boost) Pressure Sensor
P-528: Engine Oil Pressure Sensor
P-529: Atmospheric Pressure Sensor
P-534: Air Shutoff Solenoid
Rack Control Tests
P-530: Dynamic Rack Controls
P-531: Rack Position Sensor/Calibration
P-532: Rack Solenoid (BTM)
P-500: INSPECTING ELECTRICAL CONNECTORS
Many of the Operational Procedures and Diagnostic Code Procedures will direct you to inspect/check a specific wire harness electrical connector. Use the following steps to determine if the connector is the cause of the problem. If a problem is found in the electrical connector, repair the connector and continue the test procedure.
1. Check Connector Lock Ring Or Allen Screw. Ensure that the connector is properly locked and that the lock ring or allen screw is properly locking the connector together.
2. Perform 45 N (10 lb) Pull Test On Each Pin/Wire. Each pin, socket and wire should easily withstand 45 N (10 lb) of pull, and remain in the connector body. This test checks whether the wire was properly crimped in the pin or socket, and whether the pin or socket was properly inserted into the connector. Repair as needed.
NOTE: Pins should ALWAYS be crimped onto the wires, NEVER soldered.
3. Visually Inspect Connectors. Verify that pins and sockets are not corroded or damaged. Verify proper alignment and location of pins or sockets in the connector.
4. Visually Inspect Wiring. Look for worn insulation or abrasion to wires. Check for pinched or damaged harnesses.
5. Check Individual Pins And Sockets. This is especially important for intermittent problems. Use a new pin and insert the pin into each socket one at a time to check for a good grip on the pin by the socket. Repeat for each pin on the mating side of the connector, using a new socket for the test.
P-501: ELECTRICAL POWER SUPPLY
System Operation
Schematic
Diagnostic Codes
Functional Test
P-502: THROTTLE (PWM) MODULE
System Operation
Schematic
Diagnostic Codes
Functional Test
Calibration/Adjustment
P-504: PTO Mode
System Operation
Schematic
Functional Test
P-505: Alarm Lamp Circuit Tests
System Operation
Schematic
Functional Test
P-520: ECM/Personality Module
System Operation
NOTE: Install the Personality Module into the ECM making sure it seats properly into the Personality Module socket. Do not use excessive force to push the Personality Module into the socket. The socket is engine control switch (ECS) to accept the Personality Module in one position only. A "click" can be felt when the Personality Module is pushed in correctly. Install the Personality Module access cover back onto the ECM. Ensure the O-ring seal is seated properly. Improper O-ring placement could result in moisture damage from improper sealing.
Diagnostic Codes
Functional Test
P-521: Sensor Supply Voltage
System Operation
Schematic
Diagnostic Codes
Functional Test
P-522: Engine Speed (RPM) Sensors
System Operation
Schematic
Diagnostic Codes
Functional Test
Adjustment
1. Adjust clearance (1) between the flywheel and the sensor tip with the engine stopped as follows.
a. Align the centerline of the flywheel ring gear tooth with the centerline of the sensor access hole.
b. Install the sensor until the sensor face contacts the flywheel ring gear tooth.
c. Back out sensor 195 ± 15 degrees.
2. Tighten locknut (2) to a torque of 13.5 ± 1.0 N·m (120 ± 9 lb in). The clearance between the ring gear tooth and the sensor tip must be 0.76 ± 0.15 mm (.030 ± .006 in).
P-523: Engine Shutdown Switch
System Operation
Schematic
Functional Test
P-524: Fuel Shutoff Solenoid
System Operation
Schematic
Diagnostic Codes
P-525: Coolant Level Sensor
System Operation
Schematic
Diagnostic Codes
Functional Test
P-526: Coolant Temperature Sensor
System Operation
Schematic
Diagnostic Codes
Functional Test
P-527: Inlet Manifold (Boost) Pressure Sensor
System Operation
Schematic
Diagnostic Codes
Functional Test
P-528: Engine Oil Pressure Sensor
System Operation
Schematic
Diagnostic Codes
Functional Test
P-529: Atmospheric Pressure Sensor
System Operation
Schematic
Diagnostic Codes
Functional Test
P-530: Dynamic Rack Controls
System Operation
Schematic
Functional Test
P-531: Rack Position Sensor/Calibration
System Operation
Schematic
Diagnostic Codes
Functional Test
Calibration
1. Turn Engine Control Switch (ECS) to the OFF position, engine OFF.
2. Connect the ECAP to the Service Tool Connector J13.
3. Turn Engine Control Switch (ECS) to the ON position, engine OFF.
4. Select Calibrate/Monitor from the ECAP main menu and then select Rack Position Sensor Calibration to monitor Rack Position.
(1) Rack Solenoid (BTM). (2) Cover.
5. Remove (BTM) rack solenoid (1) and cover (2).
(3) Shutoff Lever.
6. Remove shutoff lever (3).
(4) Plugs.
7. Remove plugs (4) from the governor housing.
(5) 4C9581 Rack Zero Pins.
8. Install the 4C9581 rack zero pins (5) in the top of the fuel injection pump housing. Move rack control bar to engage both pins behind the racks.
9. Move rack control bar approximately 25 mm (1 in) toward the front of the engine and block in this position.
10. With the rack held back against the zero pins, read the Rack Position on the ECAP display.
A. If the Rack Position reading on the ECAP is 9.50 ± 0.05 mm (0.37 ± 0.002 in), the Rack Position Sensor is calibrated correctly. STOP.
B. If the Rack Position reading on the ECAP is not 9.50 ± 0.05 mm (0.37 ± 0.002 in), the rack position sensor needs further adjustment. Proceed to the next Step.
(6) Rack Position Sensor Locknut.
11. Use the 4C9580 Slotted Socket and a 1/2 inch drive ratchet to loosen the locknut (6) on the Rack Position Sensor.
12. Ensure the sensor wiring is connected to the engine harness connector wiring.
13. Ensure the Engine Control Switch (ECS) is in the ON position, engine OFF. Select the ECAP Calibrate/Monitor display for Rack Position Sensor Calibration from the main menu.
A. Turn the collar on the Rack Position Sensor in or out (as indicated by the ECAP display) until the ECAP displays Calibrated. Proceed to the next Step.
B. If the Rack Position Sensor is unable to calibrate, return to Functional Test Step 3.
14. Tighten the locknut to 55 ± 7 N·m (41 ± 5 lb ft).
15. Check the rack position calibration reading on the ECAP to verify that the rack position sensor is still in calibration after tightening the locknut.
16. Turn Engine Control Switch (ECS) to the OFF position, engine OFF.
17. Install rack solenoid (BTM).
18. Install shutoff lever and cover on governor housing. Ensure not to pinch a wire between the cover and housing.
19. Remove the 4C9581 rack zero pins and install the plugs in the top of the fuel injection pump housing.
20. Disconnect the ECAP. STOP.
P-532: Rack Solenoid (BTM)
System Operation
Schematic
Diagnostic Codes
Functional Test
P-534: Air Shutoff Solenoid
System Operation
Schematic
Functional Test
