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Product: MOTOR GRADER

Model: 160M MOTOR GRADER B9E00126
Configuration: 160M Motor Grader B9E00001-UP (MACHINE) POWERED BY C9 Engine

Troubleshooting
C9 Engines for Motor Graders
Media Number -RENR9333-09 Publication Date -01-07-2014 Date Updated -15-07-2014

i06890875

Injection Actuation Pressure Control Valve - Test

SMCS - 1714-038

System Operation Description:

Use this procedure to troubleshoot any suspect problems with the Injection Actuation Pressure
Control Valve (IAPCV). Use this procedure if the diagnostic code or the event code in Table 1 is
active or easily repeated.

Table 1
Diagnostic Codes Table
Code and Conditions which Generate this
System Response
Description Code
The engine may begin to misfire
42-5 Injector The Electronic Control Module
and/or shutdown. The engine may
Actuation Valve : (ECM) detects a current in the
experience reduced speed (rpm)
Current Below circuit for the IAPCV that is below
and/or low power.
Normal the minimum threshold.
The code is logged.
The engine may begin to misfire
42-6 Injector
The ECM detects a current in the and/or shutdown. The engine may
Actuation Valve :
circuit for the IAPCV that is above experience reduced speed (rpm)
Current Above
the maximum threshold. and/or low power.
Normal
The code is logged.

The IAPCV is internal to the unit injector hydraulic pump. The IAPCV is a precision displacement
control actuator. This actuator changes the pump outlet flow that is based on the control current that is
supplied by the ECM. The variable displacement unit injector hydraulic pump pressurizes only the
amount of high pressure oil that is needed.
The ECM software contains performance maps. The performance maps have a desired actuation
pressure for every engine operating condition. The ECM sends a control current to the IAPCV. This
signal creates an actual actuation pressure that matches the desired actuation pressure. If the actual
actuation pressure does not match the desired actuation pressure, the ECM will increase the control
current or the ECM will decrease the control current to the IAPCV in order to adjust pump outlet
flow.

The following problems can cause a 5 diagnostic code:

• An open circuit in the wiring

• An open circuit in the IAPCV

• A short to ground on the return wire

The following problems can cause a 6 diagnostic code:

• The control wire has a short to the +Battery.

• The return wire has a short to the +Battery.

• A short circuit in the IAPCV

• A short to ground on the control wire

Illustration 1 g01337725
Schematic for the injection actuation pressure control valve

Test Step 1. Inspect the Electrical Connectors and the Wiring

A. Remove the electrical power from the ECM.

 Illustration 2 g01339380
Component locations for the IAPCV (Typical left side engine view)
(1) Connector for the injection actuation pressure control valve
(2) J2/P2 ECM connectors

B. Thoroughly inspect connectors (1) and (2). Refer to the diagnostic functional test
Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g01339387
Terminal locations at the P2 ECM connectors for the IAPCV
(P2-10) Return
(P2-20) Injection actuation pressure control valve
 Illustration 4 g01218763
Terminal locations at the connector for the IAPCV
(1) Injection actuation pressure control valve
(2) Return

C. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the IAPCV.

D. Check the torque of the allen head screws for each of the ECM connectors. Refer to
Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.

E. Check the harness and wiring for abrasion and for pinch points from the IAPCV back to the
ECM.

Note: Ensure that the seal is installed on the harness connector for the injection actuation
pressure control valve.

Expected Result:

All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.

Results:

• OK - The connectors and the wiring are OK. Proceed to Test Step 2.

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

Repair: Repair the connectors or wiring and/or replace the connectors or wiring. 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
Troubleshooting, "Electronic Service Tools".

B. Restore the electrical power to the ECM.

 C. Start the engine.

D. Observe the "Active Diagnostic" screen on Cat ET. Wait at least 30 seconds so that any codes
may become active. Look for the code that is 05 or 06.

Expected Result:

One of the above codes is active.

Results:

• Active code - One of the above codes is active. There is a problem in the electrical circuit for
the IAPCV. Proceed to Test Step 3.

• No active codes - Neither of the above codes are active.

Repair: If one of the above codes is logged and the engine is not running properly, refer to
Troubleshooting, "Symptom Troubleshooting".

If the engine is running properly at this time, there may be an intermittent problem in a harness
or in an electrical connector that is causing the codes to be logged. Refer to Troubleshooting,
"Electrical Connectors - Inspect" for information that is related to troubleshooting intermittent
electrical problems.

STOP

Test Step 3. Measure the Resistance of the Injection Actuation Pressure Control Valve's
Solenoid

A. Remove the electrical power from the ECM.

B. Disconnect the connectors for the IAPCV at the injection pump.

Note: Ensure that the seal on the connector for the IAPCV remains on the connector when the
connector is disconnected.

C. Measure the resistance between terminals 1 on the IAPCV. Record the value of the resistance
measurement.

Expected Result:

The resistance measurement is between 6.5 and 10.5 Ohms.

Results:

• OK - The resistance measurement is between 6.5 and 10.5 Ohms. The IAPCV appears to be
OK. Connect the connectors for the IAPCV. Proceed to Test Step 4.

• Not OK - The resistance measurement is not between 6.5 and 10.5 Ohms. The solenoid's
resistance is not within the specification.

Repair: Replace the unit injector hydraulic pump. Verify that the problem is resolved.
 STOP

Test Step 4. Check the Harness for an Open Circuit

A. Remove the electrical power from the ECM.

B. Disconnect the J2/P2 connectors.

C. Measure the resistance between terminal locations P2-20 and P2-10 at the ECM connector.

Expected Result:

The resistance measurement is within two Ohms of the value that was measured in the previous Test
Step.

Results:

• OK - The resistance measurement is within two Ohms of the value that was measured in the
previous Test Step. The harness appears to be OK. Proceed to Test Step 5.

• Not OK - The resistance measurement is not within two Ohms of the value that was measured
in the previous Test Step.

Repair: There is a problem in the wiring harness or in a connector. Repair the harness and/or
the connector, when possible. Replace parts, if necessary. Verify that the original problem is
resolved.

STOP

Test Step 5. Check the Harness for a Short Circuit

A. Disconnect the connectors for the IAPCV at the injection pump.

Note: Ensure that the seal on the connector for the IAPCV remains on the connector when the
connector is disconnected.

B. Disconnect the P1 connector.

C. Measure the resistance between the points that are listed in Table 2. Be sure to wiggle the wires
in the harnesses as you make each resistance measurement.

Table 2
Resistance Measurements for the Wiring Harness
Connector and Terminal Terminal
All of the other terminals on the P2
connector
P2-20 (Injection actuation pressure control
valve) All of the terminals on the P1 connector
Engine ground stud
 All of the other terminals on the P2
connector
P2-10 (Return)
All of the terminals on the P1 connector
Engine ground stud

Expected Result:

All of the resistance measurements indicate an open circuit.

Results:

• OK - All of the resistance measurements indicate an open circuit. The harness appears to be
OK. Proceed to Test Step 6.

• Not OK - At least one resistance measurement does not indicate an open circuit.

Repair: There is a problem with a wiring harness and/or in a connector. Repair the wiring
and/or the connector, when possible. Replace parts, if necessary. Verify that the original
problem is resolved.

STOP

Test Step 6. Check the ECM by Cranking the Engine

Note: This Test Step may activate additional diagnostic codes. Ignore the codes and monitor
the test lamp. Clear the codes at the end of the Test Step.

A. Verify that the connectors for the IAPCV have been disconnected at the injection pump.

Note: Do not insert any wire that is larger than 18 AWG into the harness connector for the
IAPCV. Do not insert the probe for the voltage test lamp into the harness connector. These
actions will spread the sockets of the connector which will damage the connector. Damaged
connectors could cause intermittent connections.

B. Insert a connector pin into each socket of the harness connector for the IAPCV at the injection
pump.

C. Connect a voltage test lamp to the connector pins that are inserted in the connector for the
IAPCV. Crank the engine and observe the test lamp.

Expected Result:

The voltage test lamp illuminates when the engine is cranking.

Results:

• OK - The voltage test lamp illuminates when the engine is cranking. Remove the connector
pins from the IAPCV connector. Connect all of the electrical connectors. Clear any diagnostic
codes. Proceed to Test Step 7.
 • Not OK - The voltage test lamp does not illuminate when the engine is cranking.

Repair: There is a problem with the ECM. Perform the following procedure:

1. Temporarily connect a test ECM.

Refer to Troubleshooting, "ECM - Replace".

2. Recheck the circuit in order to ensure that the original problem has been resolved.

If the problem is resolved with the test ECM, install the suspect ECM. If the problem
returns with the suspect ECM, replace the ECM. Verify that the problem is resolved.

If the problem is not resolved with the test ECM, install the original ECM. There is a
problem in the wiring.

STOP

Test Step 7. Perform the "Injection Actuation Pressure Test"

A. Disconnect the connectors for the IAPCV at the injection pump.

NOTICE

Do not crank the engine continuously for more than 30 seconds. Allow
the starting motor to cool for two minutes before cranking the engine
again.

B. Crank the engine three times at 30 seconds intervals. This will purge the air from the system.

C. Connect the connectors for the IAPCV.

D. Start the engine.

E. Run the "Injection Actuation Pressure Test". The "Injection Actuation Pressure Test" is located
in the "Diagnostics" menu on Cat ET. Step through all of the pressure ranges.

Note: This is not the "Injection Act Press Driver Test".

F. After performing the "Injection Actuation Pressure Test", check for the following active
diagnostic codes:

◦ 05

◦ 06

Expected Result:
The test is successful. There are no diagnostic codes.

Results:

• OK - The problem appears to be resolved.

Repair: The original problem was probably caused by a poor electrical connection.

STOP

• Not OK - One or both of the diagnostic codes is active.

Repair: There is a problem with the injection actuation pressure control valve. Replace the unit
injector hydraulic pump. Verify that the problem is resolved.

STOP

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