C1.5 and C2.2 Industrial Engines Caterpillar

Use this procedure to troubleshoot the following diagnostic code:

Illustration 1	g03340445
Schematic diagram for the ECM switched battery supply (1) Fuse for the ECM switched battery circuit

Illustration 2	g03340482
View of the pin locations on the P1 connector (5) Start relay (19) Switched battery + (24) Engine glow plug relay (53) Fuel lift pump relay (54) ARD air pump relay (74) ARD glow plug relay

Test Step 1. Check for Active or Recently Logged Diagnostic Codes

1. Connect the electronic service tool to the diagnostic connector.

2. Turn the keyswitch to the ON position. Do not start the engine.

3. Check for active or recently logged diagnostic codes.

Results:

• A 4016-6 diagnostic code is active or recently logged. - Proceed to Test Step 2.

• A 4016-6 diagnostic code is not active or recently logged - The fault may be intermittent

  Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults.

  STOP

Test Step 2. Inspect Electrical Connectors and Wiring

1. Turn the keyswitch to the OFF position

2. Check the fuses.

3. Check the harness for abrasion and pinch points from the relays back to the ECM and from the ECM back to the battery.

4. Thoroughly inspect the ECM ground strap.

5. Thoroughly inspect the relays and the connector for the relays.

6. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are shown in Illustration 1.

Results:

• All connectors, pins, and sockets are correctly coupled and/or inserted. The harness and connectors are free of corrosion, abrasion, and pinch points. The fuses are OK. - Proceed to Test Step 1.

• There is a fault with the harness and connectors -

  Repair: Perform the following repair:

  Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all of the seals are correctly in place and ensure that the connectors are correctly connected. Replace any blown fuses.

  If fuse (1) is replaced and the fault reoccurs, continue with this procedure.

  STOP

Test Step 3. Check the Ground Wiring Between the Battery and the ECM

1. Turn the keyswitch to the OFF position.

2. Disconnect the wire from the battery negative terminal. Disconnect the wire from the battery positive terminal.

3. Disconnect the P1 connector from the ECM.

4. Use a suitable multimeter to measure the resistance between the wire that was removed from the battery negative terminal and the following terminals:

   • P1:20

   • P1:39

   • P1:40

   • P1:59

   • P1:60

   • P1:79

   • P1:80

Results:

• At least one of the resistance measurements is greater than two Ohms. - The fault is in the wiring between the battery negative terminal and the P1 connector.

  Repair: Replace the faulty wiring.

  Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

  STOP

• All of the resistance measurements are less than two Ohms - The wiring is OK Proceed to Test Step 4.

Test Step 4. Check the Application Wiring for a Short Circuit

1. Use the electronic service tool to clear all logged diagnostic codes.

2. Turn the keyswitch to the OFF position.

3. Disconnect all of the relays that are shown in Illustration 1.

   Note: Do not disconnect any other relays other than the relays that are shown in Illustration 1.

4. If fuse (1) has blown, then replace the fuse.

5. Turn the keyswitch to the ON position.

6. Use the electronic service tool to check for an active or recently logged 4016-6 diagnostic code.

7. Turn the keyswitch to the OFF position.

8. Check fuse (1).

Results:

• The fuse is blown and/or a 4016-6 diagnostic code was active or recently logged. - There is a fault in the application wiring

  Repair: Replace the application wiring. Reconnect the relays.

  Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

  STOP

• The fuse is OK. A 4016-6 is not active or recently logged. - Leave the relays disconnected. Proceed to Test Step 5

Test Step 5. Check the Relays

1. Turn the keyswitch to the OFF position.

2. Reconnect one of the relays that was disconnected in the previous Test Step.

3. Turn the keyswitch to the ON position.

4. Use the correct override in the electronic service tool to activate the relay that was reconnected.

   ARD Glow Plug Relay - "ARD #1 Glow Plug Relay"

   Engine Glow Plug Relay - "Glowplug Switch Output Override"

   ARD Air Pump Relay - "ARD Air System Relay Override"

   Fuel Lift Pump Relay - "Engine Fuel Supply Lift Pump Relay Override"

   Start Relay - "Starter"

5. Use the electronic service tool to check for an active or recently logged 4016-6 diagnostic code.

6. Turn the keyswitch to the OFF position.

7. Check fuse (1).

Results:

• Either a 4016-6 diagnostic code became active or the fuse was blown - The fault is in the relay that was reconnected.

  Repair: Install a replacement relay.

  Reconnect all relays. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

  STOP

• A 4016-6 diagnostic code is not active. The fuse is not blown. -

  Repair: Repeat this Test Step for each relay. Replace any relay that indicates a fault.

  Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

  STOP

• All relays are connected. A 4016-6 diagnostic code is not active. The fuse is not blown. - There may be an intermittent fault.

  Repair: Refer to Troubleshooting, " Electrical Connectors - Inspect" in order to identify intermittent faults.

  STOP