Battery 1 Voltage - Data Valid but Above Normal Operational Range - Moderately Se...

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FAULT CODE 442

Battery 1 Voltage - Data Valid but Above Normal
Operational Range - Moderately Severe Level
Overview

CODE REASON EFFECT

Fault Code: 442 Battery 1 Voltage - Data Valid but Above Possible electrical
PID: P168 Normal Operational Range - Moderately damage to all
SPN: 168 Severe Level. ECM supply voltage is above electrical components.
FMI: 0/16 the maximum system voltage level.
LAMP: Amber
SRT:

Unswitched Battery Supply Circuit

Circuit Description

The electronic control module (ECM) receives constant voltage from the batteries through
the unswitched battery wires that are connected directly to the positive (+) battery post.
There is one 30-amp fuse in the unswitched battery wire to protect the OEM harness. In
marine applications this is a 25 ampere fuse on 12V systems an a 15 ampere fuse on 24V
systems. The ECM receives switched battery input through the vehicle keyswitch wire when
the vehicle keyswitch is turned on. The battery return wires are connected directly to the
negative (-) battery post.

Component Location

The ECM is located on the intake side of the engine. The ECM is connected to the battery
by the OEM harness. This direct link provides a constant power supply for the ECM. In
marine application only circuits 1 and 3 are use for unsiwtchd battery. The location of the
battery will vary with the original equipment manufacturer (OEM). Refer to the OEM manual
for battery location.

Shop Talk

This fault code is logged when the ECM battery supply voltage exceed 36 volts. Causes of
this fault code include:

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z Faulty alternator or regulator that is overcharging the system

z Batteries connected in series instead of parallel
z Incorrect jump-starting procedure.

Cautions and Warnings

CAUTION
To reduce the possibility of pin and harness damage, use the following
test lead when taking a measurement:
Part Number 3822758 - male Deutsch/AMP/Metri-Pack test lead.

Troubleshooting Steps

STEPS
STEP 1. Check the fault codes.
STEP 1A. Read the fault codes.
STEP 2. Check the equipment battery
system.
STEP 2A. Check the battery
voltage.
STEP 2B. Check the alternator.
STEP 3. Clear the fault codes.
STEP 3A. Disable the fault code.
STEP 3B. Clear the inactive fault
codes.
SPECIFICATIONS
Fault Code 442 inactive
Less than 20 VDC for 12-VDC system.
Less than 32 VDC for 24-VDC system
Alternator charging within OEM
specifications?
Fault Code 442 inactive
All fault codes cleared

Guided Step 1 - Check the fault codes.

Guided Step 1A - Read the fault codes.

Conditions

z Connect the INSITE™ electronic

service tool.
z Turn keyswitch ON.

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Action

Read the fault codes.

z Start the engine and idle for one

minute.
z Use INSITE™ electronic service
tool to read the fault codes.

Fault Code 442 active? Fault Code 442 active?

YES NO
No Repair No Repair
Go to 2A Go to 3B

Guided Step 2 - Check the equipment battery system.

Guided Step 2A - Check the battery voltage.

Conditions

z Turn
keyswitch
OFF.
z Disconnect
all
aftermarket
devices from
the battery
supply
circuit.
z Disconnect
the OEM
power
harness
connector
from the
ECM.

Action

Check the battery

voltage.

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z Measure the
battery
voltage from
one of the
ECM battery
SUPPLY (+)
pins in the
OEM power
harness
ECM
connector to
engine block
ground.
z Repeat
above step
for the
second ECM
battery
SUPPLY (+)
pin in the
OEM power
harness
ECM
connector.

Less than 20 VDC Less than 20 VDC for 12-VDC system and less than 32 VDC
for 12-VDC system for 24-VDC system?
and less than 32
VDC for 24-VDC
system?
YES NO
No Repair Install the battery system correctly. Refer to the equipment
manufacturer's troubleshooting and repair manual.

Go to 2B Go to 3A

Guided Step 2B - Check the alternator.

Conditions

z Turn
keyswitch
OFF.
z Use an OEM
ammeter or
install an
ammeter

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between the
alternator
and the
battery.

Action

Check the
alternator.

z Start the
engine and
check the
alternator
charging rate
(amps).

NOTE: Place a
load on the
batteries, if
necessary, to
measure the
alternator output
properly.

Alternator charging Alternator charging within OEM specifications?

within OEM
specifications?
YES NO
No Repair Repair or replace the alternator, regulator, and/or the OEM wiring
to the alternator.

Refer to the OEM troubleshooting and repair manual.

Go to 3A Go to 3A

Guided Step 3 - Clear the fault codes.

Guided Step 3A - Disable the fault code.

Conditions

z Connect all components.

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z Turn keyswitch ON.

Action

Disable the fault code.

z Start the engine and let it idle for

one minute.
z UseINSITE™ electronic service
tool to verify Fault Code 442 is
inactive.

Fault Code 442 inactive? Fault Code 442 inactive?

YES NO
No Repair No Repair
Go to 3B Go to 1A

Guided Step 3B - Clear the inactive fault codes.

Conditions

z Connect all components.

z Turn keyswitch ON.

Action

Clear the inactive fault codes.

z Use INSITE™ electronic service

tool erase the inactive fault code.

All fault codes cleared? All fault codes cleared?

YES NO
No Repair No Repair
Repair complete Appropriate troubleshooting charts

Last Modified: 29-Mar-2005

Copyright© 2005
Cummins, Inc.
All rights reserved

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