336L Injectors

6/7/23, 10:33 AM SIS 2.
2014/12/19 Injector Solenoid - Test (KENR6848-28)
SMCS - 1290 i06027066

System Operation Description:
This procedure covers the following diagnostic trouble codes.
PC
Note: Refer to Troubleshooting, "Cat ET Service Features" for information about service features.
P-0
202 00
Table 1
3
Diagnostic Trouble Codes
CDL J1939
15: 3 / 0 9 7
Code Code
Code Description
2 6 /
Comments
0 D E
1-2 651-2
KE 8
Cylinder #1 Injector : Erratic,
:08- 7 The code is logged.
The engine Electronic Control Module (ECM) receives a signal from the injector
solenoid that is invalid. Or, the ECM receives a signal from the injector solenoid
N
Intermittent, or Incorrect
0
that cannot be accurately interpreted.
R 5
The ECM continues to energize the injector solenoid.
©2 684 :00 The code is logged.
023
Cylinder #1 Injector : Current The ECM detects an open circuit.
8
1-5 651-5
Below Normal The ECM continues the attempt to energize the solenoid circuit until the circuit is
repaired.
Cat The code is logged.

The ECM detects a short circuit. The ECM will disable the solenoid circuit in order
erp
Cylinder #1 Injector : Current
1-6 651-6 to prevent damage to the circuit.
Above Normal
The ECM disables this solenoid circuit. The ECM will periodically attempt to
illa energize the solenoid circuit until the circuit is repaired.
r In
The code is logged.
Cylinder #1 Injector : Not The ECM has determined that the mechanical wear for the injector is out of
1-7 651-7
c.
Responding Properly specifications.
https://sis2.cat.com/#/print-preview/service/%257B%2522title%2522%253A%2522Injector%2520Solenoid%2520-%2520Test%2520(KENR6848-28)%2522%252C%2522formattedPublicationDate%25… 1/15
6/7/23, 10:33 AM SIS 2.0
The code is logged.

The engine ECM receives a signal from the injector solenoid that is invalid. Or, the
2-2 652-2 ECM receives a signal from the injector solenoid that cannot be accurately
interpreted.
The code is logged.
2-5 652-5
repaired.
The code is logged.
Above Normal
energize the solenoid circuit until the circuit is repaired.
The code is logged.
2-7 652-7
The code is logged.
interpreted.
The code is logged.
3-5 653-5
repaired.
The code is logged.
Above Normal
The code is logged.
3-7 653-7
6/7/23, 10:33 AM SIS 2.0
The code is logged.

interpreted.
The code is logged.
4-5 654-5
repaired.
The code is logged.
Above Normal
The code is logged.
4-7 654-7
The code is logged.
interpreted.
The code is logged.
5-5 655-5
repaired.
The code is logged.
Above Normal
The code is logged.
5-7 655-7
6/7/23, 10:33 AM SIS 2.0
The code is logged.

c.
interpreted.
The code is logged.
6-5 656-5
repaired.
The code is logged.
Above Normal
The code is logged.
6-7 656-7
Background Information
Perform this procedure when the engine is at normal operating temperature. Pay careful attention to the condition of the wiring and the
connectors as you perform this procedure. The wiring and/or the connectors may have problems that only occur during vibration.
Each injector for the common rail fuel system contains a solenoid. The ECM sends 105 V pulses to each injector solenoid. The pulses are
sent at the proper time and at the correct duration for a given engine load and speed.
Cooling of the Injector Solenoids
Each injector solenoid is cooled by a stream of fuel.
Trim Files
When an injector is replaced, program the new injector code into the ECM. Refer to Troubleshooting, "Injector Trim File - Install" for
information that is related to trim files. If the ECM is replaced, all of the injector codes must be programmed into the new ECM. Refer to
6/7/23, 10:33 AM SIS 2.0
Troubleshooting, "ECM - Configure" for information that is related to the configuration of a new ECM.
Diagnostic Tests on the Caterpillar Electronic Technician (ET)
Cat ET includes the following test that aids in troubleshooting injector solenoids:
Injector Solenoid Test - This test identifies an open circuit or a short circuit in the circuits for the injector solenoids. The test is performed
while the engine is not running. The "Injector Solenoid Test" briefly activates each solenoid. A good solenoid will create an audible click
when the solenoid is activated. Cat ET indicates the status of the solenoid as "OK", "Open", or "Short".
Fuel System Verification Test - This test evaluates the health of each injector. This test will determine if an injector needs to be replaced.
When the test is performed, Cat ET indicates the status of each injector as "Success" or "Failed". Perform the test immediately after
replacing an injector. Also, perform this test if a -2 code or a -7 code is active.
Note: The "Fuel System Verification Test" must be performed when the engine is running and the coolant temperature is above 65° C
(149° F).
Note: Refer to the following schematic. Two injector solenoids share a common supply wire. For this reason, an open circuit or a short
circuit in a supply wire could cause diagnostic codes for two cylinders.
Inc
.
6/7/23, 10:33 AM SIS 2.0
Illustration 1 g01951596
Schematic for the injector solenoids on C9.3 engines
6/7/23, 10:33 AM SIS 2.0
r In
c.
6/7/23, 10:33 AM SIS 2.0
6/7/23, 10:33 AM SIS 2.0
Illustration 2 g02077734
Terminal locations at the P2 ECM connector
(P2-99) Injector 5 & 6 supply
(P2-105) Injector 6 return
Table 2
Troubleshooting Test Steps Values Results
Result: A logged -5 code or a logged -6 code is present.

1. Determine the Diagnostic Code
Proceed to Test Step 3.
A. Establish communication between Cat® ET and the
Result: An active -5 code is present.
engine ECM. Refer to Troubleshooting, "Electronic
Service Tools", if necessary.
Diagnostic
B. Download the "Warranty Report" from the engine
Code Result: An active -6 code is present.
ECM before performing any troubleshooting or
clearing diagnostic trouble codes.
C. Determine the diagnostic trouble code that relates
Result: A -2 code or a -7 code is present.
to an injector.
2. Perform the "Fuel System Verification Test" Fuel System Result: The injector passes the test.
Note: Do not clear the diagnostic trouble code. Verification
Test STOP
A. Perform the Fuel System Verification Test. Cat ET
will clear the code when the test begins. Result: The injector does not pass the test.
If the injector passes the test, the injector is OK.
ar I
nc.
6/7/23, 10:33 AM SIS 2.0
If the injector fails the test, the injector is NOT OK. Repair: Perform the following steps:
1. Replace the injector.
2. Flash program the injector trim file into the ECM. Refer to
Troubleshooting, "Injector Trim File - Install", if necessary.
3. Perform the "Fuel System Verification Test". This test will

clear the active diagnostic code for the new injector.
4. If the problem has been corrected, return the unit to service.
5. Troubleshoot any active codes.
If a -5 injector code is present, proceed to Test Step 4.
If a -6 injector code is present, proceed to Test Step 5
3. Check the Integrity of the External Engine

Harness
Result: The external engine harness is OK. A logged code
A. Inspect the injector wiring harness between the does not become active.
ECM and the valve cover. Look for these problems:
· Improper routing of the wire harness Proceed to Test Step 6.
· Missing clamps or other hardware
Fuel System
· Loose connectors or damaged connectors Result: A problem with the external engine harness has been
Verification
· Damage that is caused by excessive heat identified.
Test
· Damage that is caused by chafing
Repair: Stop the engine. Repair the wiring problem. Replace
B. Slowly wiggle the external wiring harness and the parts, if necessary. Start the engine. Verify that the problem is
connectors. Pay particular attention to the wiring near resolved.
each connector. Look for a logged code to become
active as you wiggle the wiring.
4. Check the External Engine Harness for an Open Fuel System Result: "Short" is displayed for the cylinder with the jumper
Circuit Verification wire.
Test
A. Turn the keyswitch to the OFF position. A strong The external engine harness is OK. Remove the jumper wire.
6/7/23, 10:33 AM SIS 2.0
electrical shock hazard is present if the keyswitch is Connect the harness connectors. Proceed to Test Step 6.
not turned off.
Result: "Open" is displayed for the cylinder with the jumper
B. Disconnect the harness connectors for the affected wire. The ECM did not detect the jumper wire. There is an
cylinder at the cylinder head. open circuit in the external engine harness.
C. Fabricate a jumper wire to short circuit the different Repair: Repair the problem with the harness. Replace parts, if
terminal locations at the connector for the injector necessary. Start the engine. Verify that the problem is
harness at the valve cover. Crimp connector pins on resolved.
both ends of the jumper wire.
D. Connect the jumper wire between terminal locations

1 (supply) and 2 (return). This connection will
effectively create a short circuit for the cylinder.
E. Turn the keyswitch to the ON position.
F. Perform the "Injector Solenoid Test" at least two

times.
G. Monitor the screens on Cat ET.
H. Repeat this test for each suspect circuit. Stop the

"Injector Solenoid Test" before handling the jumper
wire. Restore the wiring to the original configuration.
5. Check the External Engine Harness for a Short Short Circuit Result: All cylinders indicate "Open". The external engine
Circuit harness does not have a short circuit.
A. Turn the keyswitch to the OFF position. A strong Proceed to Test Step 6.
electrical shock hazard is present if the keyswitch is
not turned off. Result: One or more cylinders indicate "Short". Note the
cylinders that indicate "Short".
B. Disconnect the connector at the valve cover.
Repair: Repair the problem with the harness. Replace parts, if
C. Turn the keyswitch to the ON position. necessary. Start the engine. Verify that the problem is
resolved.
D. Perform the "Injector Solenoid Test" at least two
times.
pill
6/7/23, 10:33 AM SIS 2.0
ar I
E. Turn the keyswitch to the ON position.
F. Perform the "Injector Solenoid Test" at least two

times.
n c.
G. Monitor the screens on Cat ET.
6. Check the Injector Harness Under the Valve Open or Short Result: "Short" is displayed for the cylinder with the jumper
Cover for an Open Circuit or for a Short Circuit Circuit wire and "Open" when the jumper wire is removed. The
harness wiring is OK.
A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch is Repair: Perform the following procedure:
not turned off. 1. Replace the suspect injector.
B. Remove the valve cover in order to gain access to 2. Program the injector trim file into the ECM. Refer to
the suspect injector. Troubleshooting, "Injector Trim File - Install", if necessary.
3. Perform the "Fuel System Verification Test". This test will
C. Disconnect the harness connector from the suspect clear the active diagnostic code for the new injector.
injector. 4. Return the unit to service.
D. Thoroughly clean the terminals on the injector Result: O"Short" is not displayed for the cylinder with the
solenoid and on the harness connector. jumper wire and "Open" is not displayed when the jumper wire
is removed. There is a problem with the injector harness under
E. Use a jumper wire to short circuit the connector the valve cover. There may be a problem with a connector.
terminals for the suspect injector. This connection will
effectively replace the injector solenoid with a short Repair: Repair the problem with the harness. Replace parts, if
circuit. necessary. Start the engine. Verify that the problem is
resolved.
F. Turn the keyswitch to the ON position.
G. Perform the "Injector Solenoid Test" at least two

times.
Note: The injector solenoid that shares the supply wire

of the injector that is short circuited may indicate a
false test result. Disregard this test result.
Turn the keyswitch to the OFF position.

6/7/23, 10:33 AM SIS 2.0
Remove the jumper wire from the injector connector.

Removing the jumper will effectively replace the
injector solenoid with an open circuit.
Turn the keyswitch to the ON position.
Perform the "Injector Solenoid Test" at least two times.
Monitor the screens on Cat ET.
Turn the keyswitch to the OFF position.
Test Step 1.
Electrical shock hazard. The injector for the common rail fuel
system uses 90-120 volts.
Contact with high pressure fuel may cause fluid penetration and
burn hazards. High pressure fuel spray may cause a fire hazard.
Failure to follow these inspection, maintenance and service
instructions may cause personal injury or death.
NOTICE
pill
ar I
6/7/23, 10:33 AM SIS 2.0
Ensure that all adjustments and repairs that are carried

out to the fuel system are performed by authorized
personnel that have the correct training.
Before beginning ANY work on the fuel system, refer to

n c.
Operation and Maintenance Manual, "General Hazard
Information and High Pressure Fuel Lines" for safety
information.
Refer to Systems Operation, "Cleanliness of Fuel

System Components" for detailed information on the
standards of cleanliness that must be observed during
ALL work on the fuel system.
Electrical shock hazard. The injector for the common rail fuel
system uses 90-120 volts.
A.
Results:
The procedure corrected the issue. - STOP
The procedure did not correct the issue. -

Repair: Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions
Network (DSN).
STOP
6/7/23, 10:33 AM SIS 2.0
PCP-000397DE
2023/06/07
15:27:38-05:00
i03575620
© 2023 Caterpillar Inc.

336L Injectors

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6/7/23, 10:33 AM SIS 2.

2014/12/19 Injector Solenoid - Test (KENR6848-28)

SMCS - 1290 i06027066

This procedure covers the following diagnostic trouble codes.

©2 684 :00 The code is logged.

Cat The code is logged.

illa energize the solenoid circuit until the circuit is repaired.

The code is logged.

The code is logged.

The code is logged.

Cooling of the Injector Solenoids

Each injector solenoid is cooled by a stream of fuel.

Diagnostic Tests on the Caterpillar Electronic Technician (ET)

Troubleshooting Test Steps Values Results

Result: A logged -5 code or a logged -6 code is present.

1. Replace the injector.

3. Perform the "Fuel System Verification Test". This test will

4. If the problem has been corrected, return the unit to service.

5. Troubleshoot any active codes.

If a -5 injector code is present, proceed to Test Step 4.

If a -6 injector code is present, proceed to Test Step 5

3. Check the Integrity of the External Engine

D. Connect the jumper wire between terminal locations

E. Turn the keyswitch to the ON position.

F. Perform the "Injector Solenoid Test" at least two

G. Monitor the screens on Cat ET.

H. Repeat this test for each suspect circuit. Stop the

F. Perform the "Injector Solenoid Test" at least two

G. Perform the "Injector Solenoid Test" at least two

Note: The injector solenoid that shares the supply wire

Turn the keyswitch to the OFF position.

Remove the jumper wire from the injector connector.

Turn the keyswitch to the ON position.

Perform the "Injector Solenoid Test" at least two times.

Monitor the screens on Cat ET.

Turn the keyswitch to the OFF position.

Ensure that all adjustments and repairs that are carried

Before beginning ANY work on the fuel system, refer to

Refer to Systems Operation, "Cleanliness of Fuel

The procedure corrected the issue. - STOP

The procedure did not correct the issue. -

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