CATERPILLAR DENOX, SYSTEM Caterpillar


Testing & Adjusting

Usage:

Troubleshooting

Troubleshooting can be difficult. The Troubleshooting Index gives a list of possible problems. To make a repair to a problem, make reference to the cause and correction on the pages that follow.

This list of problems, causes, and corrections will only give an indication of where a possible problem can be, and what repairs are needed. Normally, more or other repair work is needed beyond the recommendations in the list.

Remember that a problem is not normally caused only by one part, but by the relation of one part with other parts. This list is only a guide and cannot give all possible problems and corrections. The serviceman must find the problem and its source, then make the necessary repairs.

NOTE: Proper troubleshooting of the problems listed requires the serviceman to follow the probable causes listed in a sequential order (probable cause; one, two, three, etc.). DO NOT eliminate any cause with out correcting the previous cause.

NOTE: Activation of electronic components with low side drivers require grounding a coil that has a constant voltage applied. Applying a voltage to the ground of an electronic component with low side drivers could result in concluding that the component is defective when it is not.

1. Blank Caterpillar Monitoring System Display ... 11
2. Caterpillar Monitoring System Failure Light Flashing ... 12
3. Caterpillar Monitoring System Check System Light Flashing ... 13

Troubleshooting Problems

Problem 1: Blank Caterpillar Monitoring System Display

Probable Causes:

A. Power Shutoff To The DeNOx Control Box
1. Emergency Push Button Is Activated

Deactive the emergency push button stop switch.

2. Engine STOP/START/AUTO/OFF Switch Is In The OFF Position

Turn the switch to the correct setting.

3. The ON/OFF Switch In The DeNOx Control Box Is OFF

Turn the switch to the ON position.

4. Circuit Breakers Are Tripped In The DeNOx Control Box And In The Engine Control Box

Reset The Circuit Breakers.

5. Faulty Wiring Or Component

Disconnect all connections to the DeNOx control box. Check resistance at the engine harness receptacle (on the DeNOx control box) between pin-1 and pin-5. The resistance should be greater than 200 000 ohms. If it is greater then restart the system. If it is less then disconnect components (primary filter pressure switch, low hydrocarbon fuel switch, empty hydrocarbon fuel switch, pump motor, etc.) one at a time. Measure the resistance at the engine harness receptacle between pin-1 and pin-5. Repeat until the resistance is at least 200 000 ohms. Repair or replace the faulty wiring or component that was just disconnected.

6. No Battery Voltage

Check battery voltage at the DeNOx control box engine harness receptacle between pin-1 and pin-5, and pin-2 and pin-5. If there is not any voltage then the problem is external to the DeNOx control box.

B. Open Wire
1. No Battery Voltage

Check for battery voltage at the Caterpillar Monitoring System (in the DeNOx control box) between pin-1 and pin-2. If no voltage then check for continuity between Caterpillar Monitoring System pin-1 and the DeNOx control box engine harness receptacle pin-1.

Defective Caterpillar Monitoring System

1. Replace The Caterpillar Monitoring System.

Problem 2: Caterpillar Monitoring System Failure Light Flashing

NOTE: The Caterpillar Monitoring System failure light will have one of the following alert indicators flashing. Refer to the alert indicator that is flashing for the troubleshooting procedure.

Probable Cause:

A. Hydrocarbon Fuel Empty Light Flashing
1. Empty Or Low Hydrocarbon Fuel

Check tank for hydrocarbon fuel. Fill if empty or low.

2. Empty Hydrocarbon Fuel Switch

Check for customer supplied "empty hydrocarbon fuel switch". If the switch is not supplied, then make sure there is a permanent jumper between customer connection pin-8 and pin-4 and that it is securely connected.

3. Empty Hydrocarbon Fuel Sensor

Check the "empty hydrocarbon fuel level sensor" for an open circuit or misadjustment. Repair or replace if necessary.

4. Open Circuit

Check for open circuit at the customer connection plug between pin-8 and pin-4. Repair or replace wiring.

B. System Leak Light Flashing
1. System Leak

Visually check for a system leak, including leaking injectors.

C. Change Filter Light Flashing
1. Filter

Replace the filter.

2. Filter Pressure Switch

Measure the resistance from the terminal to the ground with the wires to the filter pressure switch disconnected. If the resistance is less than 20 000 ohms then replace the filter pressure switch.

3. Reversed Wires

Check the wires to make certain they are not reversed. Correct the wires if necessary.

NOTE: Change filter light will continue to flash after the filter has been changed until the pump has run for five minutes after a filter change and system reset. This note only applies when the "System Failure" and "Change Filter" light are flashing because the system believes the filter has been plugged for 100 hours or more.

D. Catalyst Temperature Light Flashing
1. High Exhaust Temperature

Check the engine for a high exhaust temperature. Make sure the genset is not overloaded.

E. Pressure Fault Light Flashing
1. Hydrocarbon Fuel Pressure Sensor

Relieve the system of pressure. Measure the system's pressure. If the system's pressure range is outside of 100 ± 50 kPa (14 ± 7 psi) then check the hydrocarbon fuel pressure sensor according to "Hydrocarbon Fuel Pressure Sensor Test" in this publication. Repair or replace if necessary.

2. Leak In The System

Prime the system according to "System Priming" in this publication but with the injectors disconnected electrically. Measure the system's pressure after the pump is stopped with the injectors disconnected. If less than 440 kPa (64 psi) then check for a leak in the system. Repair any leaks.

3. Hydrocarbon Fuel Pump And Wiring

Prime the system according to "System Priming" in this publication. Measure the system's pressure. If less than 440 kPa (64 psi) then check the hydrocarbon fuel pump for operation. Check for battery voltage on the hydrocarbon fuel pump during "System Priming". If there is battery voltage, check the current to the hydrocarbon fuel pump motor. The current should be less than 4.75 amps. If the pressure is greater than 4.75 amps then replace the hydrocarbon fuel pump motor. If there is not battery voltage then check the wiring to the pump and check the pump relay. If voltage is greater than 15 VDC across pump relay terminal-30 and terminal-87, and terminal-30 and terminal-86 then replace the pump relay.

4. Hydrocarbon Fuel Pressure Regulator

Prime the system according to "System Priming" in this publication. Measure the system's pressure. If less than 440 kPa (64 psi) or greater than 570 kPa (83 psi) then replace the hydrocarbon fuel pressure regulator.

Problem 3: Caterpillar Monitoring System Check System Light Flashing

NOTE: The Caterpillar Monitoring System check system light will have one of the following alert indicators flashing. Refer to the alert indicator that is flashing for the troubleshooting procedure. If the Caterpillar Monitoring System check light is flashing without any alert indicator, then the injectors are plugged. Refer to "Checking For Plugged Hydrocarbon Injector" in this publication.

Probable Cause:

A. Hydrocarbon Fuel Low Light Flashing
1. Low Hydrocarbon Fuel

Check tank for hydrocarbon fuel. Fill if low.

2. Low Hydrocarbon Fuel Switch

Check for customer supplied "low hydrocarbon fuel switch". If the switch is not supplied, then make sure there is a permanent jumper between customer connection pin-10 and pin-4 and that it is securely connected.

3. Low Hydrocarbon Fuel Sensor

Check the "low hydrocarbon fuel level sensor" for an open circuit or misadjustment. Repair or replace if necessary.

4. Open Circuit

Check for open circuit between pin-10 and pin-4 of the customer connection plug. Repair or replace wiring.

B. Change Filter Light Flashing
1. Filter

Replace the filter.

2. Filter Pressure Switch

Measure the resistance from the terminal to the ground with the wires to the filter pressure switch disconnected. If the resistance is less than 20 000 ohms then replace the filter pressure switch.

3. Reversed Wires

Check the wires to make certain they are not reversed. Correct the wires if necessary.

C. Catalyst Temperature Light Flashing
1. High Exhaust Temperature

Check the engine for a high exhaust temperature. Make sure the genset is not overloaded.

x

DeNO System Test

This test is to determine if the deNOx system is operating correctly. After completing this test all components and associated wiring will have been checked.

1. Make sure the ON/OFF switch in the DeNOx control panel is in the OFF position.


(1) 7X1570 T-Harness Cable. (2) Personal Computer. (3) 7X1425 PC To communication Adapter Cable and 4C6805 Adapter. (4) 7X1700 Communication Adapter.

2. Connect the 7X1570 T-Harness Cable (1) to the service tool connection on the bottom of the DeNOx system control panel. Connect a computer with ET software as shown.

3. Disconnect the customer harness on the bottom of the DeNOx system control panel. Connect a jumper wire between pin-4 and pin-8, and between pin-4 and pin-10 on the customer connector on the bottom of the DeNOx system control panel. This will simulate the low and empty hydrocarbon fuel switches.

4. With the engine running place the ON/OFF switch in the DeNOx control panel in the ON position.

a. All alert indicators on the Caterpillar Monitoring System should flash for three seconds.

b. After approximately one second, the Caterpillar Monitoring System display should indicate 100 ± 50 kPa (15 ± 7 psi). This indicates the Caterpillar Monitoring System, hydrocarbon fuel regulated pressure sensor, and the associated wiring are working correctly.

c. Activate ET. Cat Data Link communications should be established. This indicates wiring to the service tool connector is good.

5. Hold the SERVICE/NORMAL switch in the NORMAL position. The Caterpillar Monitoring System display should scroll through hydrocarbon fuel delivery rate, pump hours, and hydrocarbon fuel pressure. This indicates the SERVICE/NORMAL switch and associated wiring are working correctly.

6. Hold the CLEAR/NORMAL/MODE in the MODE position until the Caterpillar Monitoring system display shows "-1-". This indicates the MODE function of the CLEAR/NORMAL/MODE switch and associated wiring are working correctly.

7. Disconnect the hydrocarbon fuel pressure sensor.

a. The Caterpillar Monitoring System display should continuously switch from 76 to 345F03 and the SERVE CODE message should be visible.

b. Reconnect the hydrocarbon fuel pressure sensor.

c. The Caterpillar Monitoring System display should continuously switch from 76 to 345F03 and the SERVE CODE message should no longer be visible.

d. Hold CLEAR/NORMAL/MODE in the clear position until the 345F03 display is cleared. This indicates that the clear function of the CLEAR/NORMAL/MODE switch and associated wiring ar working correctly.

8. Hold the CLEAR/NORMAL/MODE in the MODE position until the Caterpillar Monitoring System display shows "-3-".

9. Select DIAGNOSTICS/OVERIDE PARAMETERS/INJECTOR ON TIME PERCENT on the electronic service tool. Activate manual injection at 100 percent of rated.

a. The hydrocarbon fuel pump should start and the DeNOx system should prime. This indicates the hydrocarbon fuel pump, hydrocarbon fuel pump relay and associated wiring are working correctly.

b. The Caterpillar Monitoring System hydrocarbon fuel pressure display should increase to 480 ± 9 kPa (70 ± 1 psi). This indicates the hydrocarbon fuel pressure regulator, hydrocarbon fuel regulated pressure sensor and associated wiring are working correctly.

c. Put the Caterpillar Monitoring System back in default mode and select hydrocarbon usage.

d. Measure the flow from the hydrocarbon fuel injectors. Flow should agree with the Caterpillar Monitoring System display within .5 L/hr (.13 gal/hr).

10. Remove the jumper wire between pin-4 and pin-8 on the customer connector. The System Failure and Hydrocarbon Fuel Empty alert indicators should flash ten seconds after the jumper is removed.

11. Reinstall the jumper wire between pin-4 and pin-8 on the customer connector. The System Failure and Hydrocarbon Fuel Empty alert indicators should stop flashing ten seconds after the jumper is reinstalled. This indicates the wiring associated with the empty hydrocarbon fuel switch is good.

12. Remove the jumper wire between pin-4 and pin-10 on the customer connector. The Check System and Hydrocarbon Fuel Low alert indicators should flash ten seconds after the jumper is removed.

13. Reinstall the jumper wire between pin-4 and pin-10 on the customer connector. The Check System and Hydrocarbon Fuel Low alert indicators should stop flashing ten seconds after the jumper is reinstalled. This indicates the wiring associated with the low hydrocarbon fuel switch is good.

14. Place the ON/OFF switch in the OFF position. Remove the jumper wires from pin-4 to pin-8 and from pin-4 to pin-10 on the customer connector. Reconnect the customer harness to the customer connector on the bottom of the DeNOx control panel.

System Priming

When the system is first started up after initial installation, a filter change or other hydrocarbon fuel line maintenance, the system must be primed for proper operation. The purpose of priming the system is to remove air from the hydrocarbon fuel supply lines. Priming the system can be accomplished by two different methods. Priming the system with the injectors closed can be accomplished with the engine running or stopped. The operator must open the high pressure side of the hydrocarbon fuel system (crack a line) to the atmosphere to allow flow until the air is removed from the hydrocarbon fuel pump and hydrocarbon fuel supply lines. Priming the system with the injectors open requires that the engine is running, but the operator does not have to open a line.

NOTE: Do not run the hydrocarbon fuel pump longer than twenty seconds without hydrocarbon fuel.

Injectors Closed

1. Disconnect the hydrocarbon fuel supply line at the cooling block.

2. Hold the CLEAR/NORMAL/MODE switch in the MODE position.

3. Release the CLEAR/NORMAL/MODE switch when "-3-" appears on the Caterpillar Monitoring System display.

4. Hold the SERVICE/NORMAL switch in the SERVICE position to turn on the hydrocarbon fuel pump. While the switch is in this position the hydrocarbon fuel pressure will be displayed on the Caterpillar Monitoring System display.

5. Hold the switch in the "Service" position until the hydrocarbon fuel stream shows no sign of air.

6. Release the "Service/Normal" switch.

7. Connect the hydrocarbon fuel supply lines back at the cooling block.

Injectors Open

NOTE: This procedure must be performed with the engine running.

1. Place and hold the CLEAR/NORMAL/MODE switch in the MODE position until "-3-" appears in the Caterpillar Monitoring System display. When "-3-" appears in the Caterpillar Monitoring System display release the CLEAR/NORMAL/MODE switch.

2. Place and hold the CLEAR/NORMAL/MODE switch in the CLEAR position. The hydrocarbon fuel injection pump will run and the hydrocarbon fuel injectors will open (100 percent on time) whenever the CLEAR/NORMAL/MODE switch is held in the CLEAR position.

3. With the CLEAR/NORMAL/MODE switch held in the CLEAR position, the hydrocarbon fuel injection pressure will be displayed on the Caterpillar Monitoring System display. When system pressure reaches 480 ± 9 kPa (70 ± 1 psi), the system is primed.

Checking For Leaking Hydrocarbon Fuel Injectors

NOTE: This procedure requires two individuals to complete.

1. Remove the injector housing from the exhaust system. Leave the hydrocarbon fuel lines and the electrical lines connected.

2. Prime the system according to "System Priming" procedure in this publication.

3. One individual holds the "Service/Normal" switch in the "Service" position.

4. The other individual wipes any hydrocarbon fuel residue from the injector tips and inspects the injector tips for any fresh accumulation of hydrocarbon fuel.

5. Release the "Service/Normal" switch.

6. Replace any injector that leaks.

7. Replace the injector housing in the exhaust system.

Checking For Plugged Hydrocarbon Fuel Injector

NOTE: In order to obtain accurate results for this procedure, it should first be determined that there are no leaking hydrocarbon fuel injectors. Refer to "Checking For Leaking Hydrocarbon Fuel Injectors" to insure that none of the injectors are leaking.

1. Connect the electronic service tool to the service tool connector on the bottom of the DeNOx control panel.

2. Disconnect the electrical connectors for the injectors except the one that is being tested. Do not remove the injectors from the hydrocarbon fuel injector mounting block.

3. Connect the electrical connector of a spare injector to each of the electrical connectors that were disconnected. The spare injector will not be connected to the hydrocarbon fuel supply line. The purpose of connecting the spare injector is to provide the proper electrical load on the injector driver in the Hydrocarbon Injection Control (HIC) module.

3. Run the plugged injector test using the electronic service tool. This will indicate if the injector is plugged or okay.

4. Disconnect the electrical connector on the injector just tested. Remove one of the electrical connectors from one of the spare injectors. Connect the spare injector to the electrical connector of the injector that was just tested.

5. Connect the electrical connector to the next injector to be tested.

6. Run the plugged injector test using the electronic service tool. This will indicate if the injector is plugged or okay.

7. Follow this procedure for all of the injectors to be tested.

8. After testing all the injectors, replace the injectors that are plugged.

9. Reconnect all the electrical connectors to the hydrocarbon fuel injectors that are mounted in the hydrocarbon fuel injector mounting block.

Programming A Personality Module Using Flash Programming

NOTE: When you purchase either the FLASH program, LEXT3037, or the CAT ET program, JERD2124, a copy of the most current flash files are included. If you purchase the LEXT3037, you can also purchase the optional flash file subscription. The flash file subscription is NOT available with the purchase of CAT ET (JERD2124). However, the preferred method of obtaining flash files is to download them from the Caterpillar Mailbox. This method requires that you have a fast modem (9600 baud or faster) attached to a PC. The PC communications program Hyper ACCESS 5 (LERQ3133) is also required. Using this method, the latest flash files are available 24 hours a day.

NOTE: Operation of the engine following programming of the Personality Module is identical to operation following replacement of the Personality Module chip. The only difference is the software was already programmed in the chip for you when you replaced the chip, now you are actually performing the programming function. For example, if you are rerating an engine, you will still need Factory Passwords to change the Personality Module Code. The password used for flash programming is "MASTER" unless the operator has changed the original password.

1. Connect hardware as shown below.


(1) 7X1412 T-Harness Cable. (2) Personal Computer. (3) 7X1425 PC To Communication Adapter Cable and 4C6805 Adapter. (4) 7X1700 Communication Adapter.

NOTE: Use the 7X1412 T-Harness Cable for Flash Programming.

2. Start the LEXT3037 PC Program.

3. Select the Personality Module part number to be programmed into the ECM, and proceed with programming the Personality Module. The new ECM is shipped with a blank Personality Module.

4. PC Program Personality Module Messages and Their Meaning:

NOTE: A new ECM comes with a blank (previously unprogrammed) personality module. A blank personality module will prompt you for all three of the following messages. The information contained in the "ECM Status" will be scrambled and meaningless if the module has not been previously programmed (this is normal).

* Message - "The engine ID in the flash file does not match the engine ID in the ECM." The ECM has a personality module in it for a different engine. Stop the transfer and access information about "ECM Status" under the "Electronic Control Module" menu. Make sure the file you are about to transfer is for the same engine it will be installed in.
* Message - "The application ID in the flash file does not match the application ID in the ECM." The ECM has a personality module in it for a different application. Stop the transfer and access information about "ECM Status" under the "Electronic Control Module" menu. Make sure the file you are about to transfer is for the DeNOx application.

Message - "The ECM ID in the flash file does not match the ECM ID in the ECM." The ECM is not for use in the DeNOx application. Stop the transfer and access information about "ECM Status" under the "Electronic Control Module" menu. Make sure the ECM on the engine is for the DeNOx application.

NOTE: If you access the "ECM Status" under the "Electronic Control Module" menu of the PC Program, but do not follow this information access by programming the Personality Module, you must remove and reapply power to the ECM by cycling the HIC ON/OFF switch, cycling the AUTO/MANUAL/COOLDOWN/OFF switch through OFF, or by pressing and resetting the emergency stop push button before using an electronic service tool. If you do not cycle the power after reading the "ECM Status", the ECM will not communicate with your service tool, or start. Cycling the power is not necessary following successful programming of a personality module using the Flash Designer Program.

5. Start the engine and check for proper operation.

Program any parameters not previously in the old personality module if 253-02 Check Customer Or System Parameters (56) code is active. Read the code from the Active Diagnostic code screen of the electronic service tool to determine the parameter(s) requiring programming.

Remember, on initial power up of a new ECM, the Engine Serial Number parameter must be programmed to avoid a 253-02 Check Customer Or System Parameters (56) code.

Hydrocarbon Fuel Pressure Sensor Test

1. Check For Connector Damage

Check connector J2/P2 (HIC connector), the electrical connector for the pressure sensor and all associated wiring for damage or abrasion. Repair as required and proceed to Step 2.

2. Check For Shorts In Wiring Harness

a. Turn ON/OFF switch OFF.

b. Disconnect the pressure sensor connector and J2/P2 (HIC) connector.

c. Set Multimeter on the 20,000 Ohm scale and using the Signal Reading Probe, measure resistance between P2 pin-36 (+5V Analog Snsr Pwr, 997-OR) and P2 pin-30 (Analog Snsr Ret Gnd, 993-BR).

d. Using the Signal Reading Probe, measure Analog Sensor Supply voltage between P2 pin-36 (+5V Analog Snsr Pwr, 997-OR) and engine ground.

e. Using the Signal Reading Probe, measure Analog Sensor Supply voltage between P2 pin-30 (Analog Snsr Ret Gnd, 993-BR) and engine ground.

Resistance should be more than 20,000 ohms for each measurement.

If measurements are okay, proceed to Step 3.

If measurements are not okay, there is a short circuit in the harness or connectors. Repair the harness or connectors as required. Repeat Step 2 until all measurements check okay.

3. Analog Sensor Supply Test At HIC

a. Turn ON/OFF switch to OFF.

b. Reconnect J2/P2 (HIC connector) if not already done.

c. Disconnect the pressure sensor connector.

d. Turn ON/OFF switch to ON.

e. Using the Signal Reading Probe, measure the Analog Sensor Supply voltage between J2/P2 pin-36 (+5V Analog Snsr Pwr, 997-OR) and J2/P2 pin 30 (Analog Snsr Ret Gnd, 993-BR).

The voltage should measure 5.0 ± 0.2 VDC.

If the voltage is correct, proceed to Step 4.

If the voltage is not correct, there is a problem with the Analog Sensor Supply circuit. Verify that the HIC is receiving the correct voltage from the battery. If the HIC is receiving the correct voltage from the battery, then the HIC is not supplying the correct voltage to the sensor. Replace the HIC.

4. Analog Sensor Supply Voltage Test At Sensors

a. Turn ON/OFF switch OFF.

b. Reconnect J2/P2 (HIC) connector.

c. Disconnect the pressure sensor.

d. Using the Signal Reading Probe, measure the Analog Sensor Supply voltage between pin-A (+5V Analog Snsr Pwr, 997-OR) and pin-B (Analog Snsr Ret Gnd, 993-BR).

The voltage should measure 5.0 ± 0.2 VDC.

If the voltage is correct, proceed to Step 5.

If the voltage is not correct, there is a short circuit in the harness or connectors. Repair the harness or connectors as required. Repeat Step 4.

5. Check Analog Sensor For Shorts

a. Turn ON/OFF switch OFF.

b. Reconnect J2/P2 (HIC connector).

c. Disconnect the pressure sensor.

d. Turn ON/OFF switch OFF.

e. Using the Signal Reading Probe, measure the Analog Sensor Supply voltage between J2/P2 pin-36 (+5V Analog Snsr Pwr, 997-OR) and J2/P2 pin-30 (Analog Snsr Ret Gnd, 993-BR).

f. Connect the pressure sensor.

g. Using the Signal Reading Probe, measure the Analog Sensor Supply voltage between J2/P2 pin-36 (+5V Analog Snsr Pwr, 997-OR) and J2/P2 pin-30 (Analog Snsr Ret Gnd, 993-BR).

The voltage should measure 5.0 ± 0.2 VDC.

If the pressure sensor supply voltage is within limits, the sensor is not shorted.

If the pressure sensor supply voltage is within limits before connecting the sensor and is outside the limits after connecting the sensor, the sensor is faulty. Replace the Sensor.

System Schematic


DeNOx control panel

Caterpillar Information System:

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