Air Inlet Heater Test

329D & 329D L Excavators DJF00001-UP (MACHINE) POWERED BY C7 Engine(SE...
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Product: EXCAVATOR
Model: 329D L EXCAVATOR DJF
Configuration: 329D & 329D L Excavators DJF00001-UP (MACHINE) POWERED BY C7 Engine
Troubleshooting
C9 Engines for Caterpillar Built Machines
Media Number -RENR5089-31 Publication Date -01/11/2014 Date Updated -06/11/2014
i02907631
Air Inlet Heater Circuit - Test

SMCS - 1090-038
System Operation Description:
Use this procedure to troubleshoot any suspect problems with the air inlet heater circuit.
This procedure covers the following diagnostic codes:
• 617-05 Air Inlet Heater Relay open/current below normal
• 617-06 Air Inlet Heater Relay grounded/current above norm
The air inlet heater improves the engine's ability to start when the engine is cold. The air inlet heater also
reduces white smoke when the engine is cold.
The Electronic Control Module (ECM) controls the operation of the air inlet heater via the air inlet heater
relay.
The operation of the air inlet heater is determined by the following cycles:
Power Up Cycle - The air inlet heater is turned on for two seconds after the ECM is first powered up. This
will happen regardless of temperatures and engine speed.
Preheat Cycle - If the "SUM" of the coolant temperature and the inlet manifold air temperature is less than
25 °C (109 °F), then the heater will remain on up to 30 seconds. If the engine speed is zero after 30
seconds, the heater is turned off regardless of the temperature.
Crank Cycle - If the "SUM" of the coolant temperature and the inlet manifold air temperature is still less
than 25 °C (109 °F), the air inlet heater will remain on while the engine is being cranked.
Running Cycle - If the "SUM" of the coolant temperature and the inlet manifold air temperature is less
than 35 °C (127 °F), then the air inlet heater will remain on for seven minutes.
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Postheat Cycle - The air inlet heater is cycled on and off for an additional 13 minutes if the "SUM" of the
coolant temperature and the inlet manifold air temperature is still less than 35 °C (127 °F). The air inlet
heater will turn on for ten seconds and the air inlet heater will turn off for ten seconds.
Note: When you convert the "SUM" of two temperatures that are in degrees Celsius, the resulting
value in degrees Fahrenheit will be incorrect. The two temperatures must be converted prior to the
addition of the two values.
• Convert the reading for the coolant temperature from degrees Celsius to degrees Fahrenheit.
• Convert the reading for the inlet manifold air temperature from degrees Celsius to degrees
Fahrenheit.
• Add the two conversions together in order to arrive at the correct conversion for the sum in degrees
Fahrenheit. Refer to the example that is in Table 1.
Table 1
Example
Reading °C °F
Coolant Temperature 15 °C 59 °F
Inlet Manifold Air Temperature 10 °C 50 °F
"SUM"(1) 25 °C 109 °F
(1)
The sum cannot be directly converted. The direct conversion of 25 °C is 77 °F.
Illustration 1 g01234809
Schematic for the air inlet heater
Test Step 1. Inspect the Electrical Connectors and the Wiring
A. Remove the electrical power from the ECM.
Typical component locations for the air inlet heater
(1) Air inlet heater
(2) Air inlet heater relay
(3) Ground connector for the air inlet heater
(4) J2/P2 connectors
B. Thoroughly inspect the connector for the air inlet heater and connector (4). Inspect the connections
on air inlet heater relay (2) and air inlet heater (1). Refer to the diagnostic functional test
Troubleshooting, "Electrical Connectors - Inspect".
P2 terminals that are associated with the air inlet heater
(P2-5) Air inlet heater
(P2-79) Air inlet heater
C. Perform a 45 N (10 lb) pull test on each of the wires in the connectors that are associated with the
circuit.
D. Check the torque of the allen head screws for the ECM connectors. Refer to the diagnostic functional
test Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
E. Check the harness and wiring for abrasion and for pinch points from the air inlet heater back to the
ECM and from the air inlet heater back to the battery.
Expected Result:
All connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free
of corrosion, of abrasion and of pinch points.
Results:
• OK - The harness and the connectors appear to be OK. Proceed to Test Step 2.
• Not OK - There is a problem with the connectors and/or the wiring.
Repair: Repair the connectors and/or the wiring. Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the connectors are completely coupled. Verify that the
repair eliminates the problem.
STOP
Test Step 2. Check for Active Diagnostic Codes
A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to electronic
troubleshooting Troubleshooting, "Electronic Service Tools".
B. Restore the electrical power to the ECM.
C. Observe the "Active Diagnostic" screen on Cat ET. Wait at least 30 seconds so that any codes may
become active. Look for these codes:
◦ 617-05
◦ 617-06
Expected Result:
One of the above codes is active.
Results:
• Active 05 code - A 05 diagnostic code is active. Proceed to Test Step 3.
• Active 06 code - A 06 diagnostic code is active. Proceed to Test Step 5.
• No active codes - None of the above codes are active. There may be a problem with the high power
circuit. Proceed to Test Step 6.
Test Step 3. Check for an Open Circuit to the Relay
Small terminals for the typical air inlet heater relay
A. Disconnect the wires from the small terminals of the air inlet heater relay.
B. Install a test lamp across the wires.
C. Start the "Air Inlet Heater Override" on Cat ET and observe the test lamp.
Note: Do not leave the "Air Inlet Heater Override" ON. This prevents unnecessary cycling of the air
inlet heater and the battery from discharging. The "Air Inlet Heater Override" has a one minute timer
that disables the test when the time expires.
D. Stop the "Air Inlet Heater Override" and restore electrical power to the ECM.
Expected Result:
The test lamp turned on while the override was active.
Results:
• OK - The test lamp turned on while the override was active. The open circuit is in the relay.
Repair: Replace the air inlet heater relay. Clear any diagnostic codes. Verify that the problem is
resolved.
STOP
• Not OK - The test lamp did not turn on while the override was active. Proceed to Test Step 4.
Test Step 4. Check the Wiring Between the ECM and the Relay
A. Disconnect the J2/P2 connectors.
Note: Be sure to wiggle the harness during the following measurements in order to reveal an
intermittent condition.
B. Measure the resistance between terminal P2-5 and terminal 1 on the connector for the air inlet heater.
C. Measure the resistance between terminal P2-79 and terminal 2 on the connector for the air inlet
heater.
Expected Result:
Both of the resistance measurements are less than ten Ohms.
Results:
• OK - Both of the resistance measurements are less than ten Ohms.
Repair: Perform the following repair:
1. Temporarily connect a spare ECM.
2. Reconnect all connectors and wires.
3. Recheck the system for active diagnostic codes.
4. Repeat this test step.
5. If the problem is resolved with the spare ECM, reconnect the suspect ECM.
6. If the problem returns with the suspect ECM, replace the ECM.
7. Verify that the repair eliminates the problem.
STOP
• Not OK - At least one of the resistance measurements is more than ten Ohms. There is a problem
with the wiring between the ECM and the air inlet heater relay. There may be a problem with a
connector.
Repair: Repair the wire and/or the connector, when possible. Replace parts, if necessary. Verify that
the problem is resolved.
STOP
Test Step 5. Check for a Short Circuit in the Wiring to the Relay
Small terminals for the typical air inlet heater relay
A. Disconnect the wires from the small terminals for the air inlet heater relay.
C. Observe the "Active Diagnostic" screen on Cat ET. Wait at least 30 seconds so that any codes may
become active.
D. Remove the electrical power from the ECM.
Expected Result:
The short circuit diagnostic code (06) changed to an open circuit diagnostic code (05) when the wires to the
relay were disconnected.
Results:
• OK - The short circuit diagnostic code (06) changed to an open circuit diagnostic code (05) when the
wires to the relay were disconnected. The short circuit is in the relay.
Repair: Replace the relay. Clear the diagnostic codes.
Verify that the problem is resolved.
STOP
• Not OK - The short circuit diagnostic code (06) remained when the wires to the relay were
disconnected. There is a problem in the wiring between the ECM and the relay. There may be a
problem with a connector.
STOP
Test Step 6. Check for Battery Voltage at the Relay
A. Connect a test lamp between the +Battery side of the air inlet heater relay and the engine ground.
Expected Result:
The test lamp turns ON.
Results:
• OK - The test lamp turns ON. Battery voltage is reaching the relay. Proceed to Test Step 7.
• Not OK - The test lamp does not turn ON. Battery voltage is not reaching the relay.
Repair: There is an open circuit in the wiring between the battery and the relay. There may be a
problem with a connection.
Repair the wire and/or the connection, when possible. Replace parts, if necessary. Verify that the
problem is resolved.
STOP
Test Step 7. Check for Voltage Output at the Relay
A. Connect a test lamp between the output terminal of the air inlet heater relay and the engine ground.
Note: Observe the test lamp. The test lamp should be off, since the relay is not energized. If the test
lamp is on, ensure that the test lamp is connected to the output side of the relay.
C. Run the "Air Inlet Heater Override" on Cat ET and observe the test lamp.
Note: Do not leave the "Air Inlet Heater Override" ON. This prevents unnecessary cycling of the air
inlet heater and the battery from discharging. The "Air Inlet Heater Override" has a one minute timer
that disables the test when the time expires.
D. Stop the "Air Inlet Heater Override" and remove electrical power from the ECM.
Expected Result:
The test lamp turned on when the "Air Inlet Heater Override" was enabled.
Results:
• OK - The test lamp turned on when the "Air Inlet Heater Override" was enabled. The air inlet heater
relay and the +Battery connection to the air inlet heater relay are operating correctly. Proceed to Test
Step 8.
• Not OK - The test lamp did not turn on when the "Air Inlet Heater Override" was enabled.
Repair: Replace the relay.
329D & 329D L Excavators DJF00001-UP (MACHINE) POWERED BY C7 Engine(S... Page 10 of 12
STOP
Test Step 8. Check the Wiring Between the Relay and the Heater and Between the Heater and the
Engine Block
Typical left side view
(3) Ground connector
(5) Wire
A. Measure the resistance of wire (5) that connects the relay to the air inlet heater.
B. Measure the resistance of the ground strap that is connected between terminal (3) and the engine
block.
Expected Result:
Both of the resistance measurements are less than ten Ohms.
Results:
• OK - Both of the resistance measurements are less than ten Ohms. Proceed to Test Step 9.
• Not OK - At least one of the resistance measurements is more than ten Ohms. There is an open
circuit in the wiring. There may be a problem with a connector.
STOP
Test Step 9. Measure the Current through the Heater
Typical left side view
(3) Ground connector
(5) Wire
(6) Terminal
A. Connect a 155-5176 AC/DC Current Probe or an equivalent inductive pickup clamp around wire (5)
between the relay and the air inlet heater.
B. Connect the current probe to a multimeter.
C. Restore the electrical power to the ECM.
D. Run the "Air Inlet Heater Override" on Cat ET and observe the current reading on the multimeter.
Note: Do not leave the "Air Inlet Heater Override" On. Avoid unnecessary cycling of the air inlet
heater in order to prevent the battery from discharging. The "Air Inlet Heater Override" has a one
minute timer in order to disable the test when the time expires.
E. While the override is active, measure the voltage between terminals (6) and (3).
F. Stop the "Air Inlet Heater Override" and remove the electrical power from the ECM.
Expected Result:
The current reading is between 84 and 104 Amperes. The voltage reading is approximately 22 VDC.
Note: If the voltage reading does not match the specified value, you will need to adjust the current value
accordingly. For slightly lower voltages, the current value will be slightly lower. For slightly higher
voltages, the current value will be slightly higher.
Results:
• OK - The readings are within the specified ranges.
Repair: The readings are within the specified ranges. The air inlet heater circuit appears to be
operating correctly at this time. If an intermittent problem is suspected, refer to diagnostic functional
tests Troubleshooting, "Electrical Connectors - Inspect".
STOP
• Not OK - The voltage reading and/or the current reading is not within the specified ranges.
Repair: Replace the air inlet heater.
STOP
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Air Inlet Heater Test

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329D & 329D L Excavators DJF00001-UP (MACHINE) POWERED BY C7 Engine(SE...

Air Inlet Heater Circuit - Test

System Operation Description:

This procedure covers the following diagnostic codes:

• 617-05 Air Inlet Heater Relay open/current below normal

• 617-06 Air Inlet Heater Relay grounded/current above norm

Test Step 1. Inspect the Electrical Connectors and the Wiring

A. Remove the electrical power from the ECM.

• Not OK - There is a problem with the connectors and/or the wiring.

Test Step 2. Check for Active Diagnostic Codes

B. Restore the electrical power to the ECM.

One of the above codes is active.

• Active 05 code - A 05 diagnostic code is active. Proceed to Test Step 3.

• Active 06 code - A 06 diagnostic code is active. Proceed to Test Step 5.

Test Step 3. Check for an Open Circuit to the Relay

B. Install a test lamp across the wires.

The test lamp turned on while the override was active.

A. Disconnect the J2/P2 connectors.

Both of the resistance measurements are less than ten Ohms.

• OK - Both of the resistance measurements are less than ten Ohms.

Repair: Perform the following repair:

1. Temporarily connect a spare ECM.

2. Reconnect all connectors and wires.

3. Recheck the system for active diagnostic codes.

4. Repeat this test step.

7. Verify that the repair eliminates the problem.

B. Restore the electrical power to the ECM.

D. Remove the electrical power from the ECM.

Repair: Replace the relay. Clear the diagnostic codes.

Verify that the problem is resolved.

Test Step 6. Check for Battery Voltage at the Relay

The test lamp turns ON.

Test Step 7. Check for Voltage Output at the Relay

B. Restore the electrical power to the ECM.

Repair: Replace the relay.

Verify that the problem is resolved.

Both of the resistance measurements are less than ten Ohms.

Test Step 9. Measure the Current through the Heater

B. Connect the current probe to a multimeter.

C. Restore the electrical power to the ECM.

• OK - The readings are within the specified ranges.

Repair: Replace the air inlet heater.

Verify that the problem is resolved.

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