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C4.4 Engines For Caterpillar Built Machines

(KENR9129) SMCS - 5479 i08227233
 Troubleshooting System Operation Description:

System Overview Note: This procedure is only applicable to engines that have a wastegate regulator.
Glossary
Use this procedure under the following conditions:
Electronic Service Tools

Replacing the ECM Use this procedure if another procedure has directed you here. Use this procedure if any of
the following diagnostic codes are active:
Self-Diagnostics

Sensors and Electrical Connectors 0526-05 Turbo Wastegate Drive current below normal
Engine Wiring Information
0526-06 Turbo Wastegate Drive current above normal
ECM Harness Connector Terminals
0526-07 Turbo Wastegate Drive not responding properly
Programming Parameters

Test ECM Mode This engine has a turbocharger with an electronically controlled wastegate. The wastegate is
Factory Passwords a mechanical valve that is used in the turbocharger to regulate the intake manifold pressure
to a set value.
Flash Programming

Injector Trim File The control system for the electronically controlled wastegate precisely regulates the intake
manifold pressure by using a wastegate regulator to control the wastegate.
Throttle Setup

Customer Specified Parameters The required intake manifold pressure is calculated by the software that is contained in the
Customer Specified Parameters Table Electronic Control Module (ECM). The ECM uses the wastegate regulator to control the
wastegate to provide the precise value of intake manifold pressure. The solenoid in the
Customer Specified Parameters Worksheet
wastegate regulator is controlled by a PWM signal from the ECM.
System Configuration Parameters

Alternator Noise Pin Connections 

Alternator Will Not Charge Sensor Pin  Function  P2 Pin Connection 

Battery 1  Ground  19 

Can Not Reach Top Engine RPM 2  Signal  17 

Coolant in Engine Oil Table 1

Coolant Temperature Is Too High

ECM Will Not Accept Factory Passwords

ECM Will Not Communicate with Other Systems …

Electronic Service Tool Will Not Communicate w…

Engine Cranks but Will Not Start

Engine Has Early Wear

Engine Misfires, Runs Rough or Is Unstable Illustration 1 g0271026

Schematic for the wastegate regulator connector
Engine Oil in Cooling System

Engine Speed Does Not Change

Engine Stalls at Low RPM

Engine Vibration

Engine Will Not Crank

Excessive Black Smoke

Excessive Engine Oil Consumption

Excessive Fuel Consumption

Excessive Valve Lash

Excessive White Smoke

Intake Air Temperature Is Too High

Intermittent Engine Shutdown

Intermittent Low Power or Power Cutout

Illustration 2 g01459431
Low Engine Oil Pressure Wastegate regulator connector
(1) Ground (GND)
Low Power/Poor or No Response to Throttle (2) Signal (SIG)

Mechanical Noise (Knock) in Engine

https://sis2.cat.com/#/service-detail?
Noise Coming from Cylinder
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ieSystemControlNumber=i02815192&serialNumber=&infoType=7&mediaNumber=KENR9129&hideDocumentStructure=false
 Diagnostic Code Cross Reference

CID 0001 FMI 02

CID 0001 FMI 05

CID 0001 FMI 06

CID 0001 FMI 07

CID 0002 FMI 02

CID 0002 FMI 05

CID 0002 FMI 06

CID 0002 FMI 07

CID 0003 FMI 02

CID 0003 FMI 05

CID 0003 FMI 06 Illustration 3 g0145972

Pin locations for the wastegate regulator on the P2 connector
CID 0003 FMI 07 (17) Wastegate pulse width modulation (PWM) signal
(19) Wastegate return
CID 0004 FMI 02

CID 0004 FMI 05

CID 0004 FMI 06

CID 0004 FMI 07

CID 0041 FMI 03

CID 0041 FMI 04

CID 0091 FMI 03

CID 0091 FMI 04

CID 0091 FMI 08

CID 0100 FMI 03

CID 0100 FMI 04

CID 0100 FMI 10

CID 0110 FMI 03

CID 0110 FMI 04

CID 0168 FMI 00

CID 0168 FMI 01

CID 0168 FMI 02

CID 0172 FMI 03

CID 0172 FMI 04

CID 0190 FMI 08

CID 0247 FMI 09

CID 0253 FMI 02

CID 0261 FMI 11

Illustration 4 g01661858
CID 0262 FMI 03 Wastegate regulator
(1) Wastegate regulator
CID 0262 FMI 04

CID 0268 FMI 02 Test Step 1. CHECK FOR DIAGNOSTIC CODES

CID 0342 FMI 08 A. Turn the keyswitch to the OFF position.

CID 0444 FMI 05
B. Connect the electronic service tool to the data link connector.
CID 0444 FMI 06

CID 0526 FMI 05 C. Turn the keyswitch to the ON position. Start the electronic service tool.

CID 0526 FMI 06 D. Monitor the electronic service tool for active diagnostic codes and/or logged
CID 0526 FMI 07 diagnostic codes.
CID 1639 FMI 02
Expected Result:
CID 1639 FMI 09
One or more diagnostic codes are active or logged.
CID 1779 FMI 05

CID 1779 FMI 06 Results:

CID 1785 FMI 03
Diagnostic codes 526-5, 526-6 are active and/or logged - Proceed to Test Step 2.
CID 1785 FMI 04
https://sis2.cat.com/#/service-detail? No Codes - The fault seems to be resolved.
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CID 1785 FMI 10
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 CID 1797 FMI 03 Repair: For intermittent faults, refer to Troubleshooting, "Electrical Connectors -
Inspect".
CID 1797 FMI 04

CID 1834 FMI 02 STOP

CID 2246 FMI 06
Test Step 2. INSPECT ELECTRICAL CONNECTORS AND WIRING
Event Codes
A. Thoroughly inspect the P2/J2 ECM connector and the P511 wastegate regulator
E172 High Air Filter Restriction
connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
E194 High Exhaust Temperature

E360 Low Engine Oil Pressure B. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the
wastegate solenoid.
E361 High Engine Coolant Temperature

E362 Engine Overspeed C. Check the screw for the ECM connector for the correct torque of 5.0 N·m (44 lb in).
E396 High Fuel Rail Pressure
Expected Result:
E398 Low Fuel Rail Pressure
All connectors, pins, and sockets are coupled and/or inserted and the harness is free of
E539 High Intake Manifold Air Temperature
corrosion, abrasion, and pinch points.
E1044 High Intake Manifold Pressure

E1045 Low Intake Manifold Pressure Results:

5 Volt Sensor Supply Circuit - Test OK - The harness is OK. Proceed to Test Step 3.
CAN Data Link Circuit - Test
Not OK - There is a fault in the connectors and/or the harness.
Data Link Circuit - Test
Repair: Repair the connectors or the harness and/or replace the connectors or the
Digital Throttle Position Sensor Circuit - Test harness. Ensure that all the seals are correctly in place and ensure that the connectors
ECM Memory - Test are coupled.

Electrical Connectors - Inspect Use the electronic service tool to clear all logged diagnostic codes and then verify that
Engine Pressure Sensor Open or Short Circuit - T… the repair eliminates the fault.
Engine Speed/Timing Sensor Circuit - Test
STOP
Engine Temperature Sensor Open or Short Circui…
Test Step 3. DETERMINE THE DIAGNOSTIC CODE THAT IS ACTIVE
Fuel Rail Pump Solenoid - Test

Ignition Keyswitch Circuit and Battery Supply Cir… A. Turn the keyswitch to the ON position. Access the "Diagnostics Tests" on the electronic
Injector Data Incorrect - Test service tool. Activate the "Turbo Wastegate Solenoid Test". Wait at least 30 seconds for
the result to be displayed.
Injector Solenoid Circuit - Test

Starting Aid (Glow Plug) Relay Circuit - Test B. Determine if the fault is related to either of the following:

Wastegate Solenoid - Test

"Low current" (open circuit)

"High current" (short circuit)

Expected Result:

The electronic service tool displays no diagnostic codes.

Results:

OK - There are no active codes.

Repair: The original codes may have been caused by a loose connector. If this is an
intermittent fault, refer to Troubleshooting, "Electrical Connectors - Inspect".

STOP

Not OK - Diagnostic code 526-5 is active. Proceed to Test Step 4.

Not OK - Diagnostic code 526-6 is active. Proceed to Test Step 6.

Not OK - Diagnostic code 526-7 is active. Proceed to Test Step 4.

2020/09/03 Wastegate Solenoid - Test (KENR9129) 
Test Step 4. CREATE A SHORT CIRCUIT IN THE HARNESS AT THE SOLENOID

A. Turn the keyswitch to the OFF position.

B. Disconnect the P511 wastegate regulator connector.

C. Fabricate a jumper wire between P511:1 and P511:2 to create a short circuit.

D. Turn the keyswitch to the ON position. Access the "Diagnostics Tests" on the electronic
https://sis2.cat.com/#/service-detail? service tool. Activate the "Turbo Wastegate Solenoid Test". Wait at least 30 seconds for 
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the result to be displayed.
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 E. Check for active diagnostic codes on the electronic service tool.

Expected Result:

Diagnostic code 526-6 is now active.

Results:

OK - Diagnostic code 526-6 is now active. There is a problem with the solenoid.
Repair: Perform the following procedure:

1. Temporarily connect a replacement wastegate regulator.

2. Turn the keyswitch to the ON position. Access the "Diagnostics Tests" on the
electronic service tool. Activate the "Turbo Wastegate Solenoid Test". Wait at
least 30 seconds for the result to be displayed.

3. Diagnostic code 526-6 is no longer active.

4. If the fault is eliminated, reconnect the suspect wastegate regulator. If the fault
returns, permanently install the replacement wastegate regulator.

STOP

Not OK - The low current diagnostic code (open circuit) is still active. Proceed to Test
Step 5.

Test Step 5. CREATE A SHORT CIRCUIT AT THE ECM

A. Turn the keyswitch to the OFF position.

B. Temporarily remove the wires from P2:17 and P2:19.

C. Fabricate a jumper wire between P2:17 and P2:19 to create a short circuit.
Note: P2/J2 must be connected during the next step.

D. Turn the keyswitch to the ON position. Access the "Special Tests" under the
"Diagnostics" menu on the electronic service tool. Activate the "Turbo Wastegate
Solenoid Output" on the electronic service tool. Wait at least 30 seconds for activation
of the diagnostic codes.

E. Check for active diagnostic codes on the electronic service tool.

Expected Result:

Diagnostic code 526-6 is now active.

Results:

OK - Diagnostic code 526-6 is now active. There is a fault in the harness between the
ECM and the solenoid.
Repair: Repair the harness or replace the harness.

Use the electronic service tool to clear all logged diagnostic codes.

STOP

Not OK - There is still an open circuit diagnostic code.

Repair: Perform the following procedure:

1. Make sure that the latest flash file for the application is installed in the ECM.
Refer to Troubleshooting, "Flash Programming".

2. Use the electronic service tool to check for active diagnostic codes.

3. If a diagnostic code is still active, contact the technical communicator at a

Caterpillar dealer.
Note: This consultation can greatly reduce the repair time.

4. If necessary, install a test ECM. Refer to Troubleshooting, "Replacing the ECM".

5. Use the electronic service tool to verify that the fault is eliminated.

https://sis2.cat.com/#/service-detail? 
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ieSystemControlNumber=i02815192&serialNumber=&infoType=7&mediaNumber=KENR9129&hideDocumentStructure=false
 . If the fault is eliminated with the test ECM, reconnect the suspect ECM. Verify
that the active diagnostic code returns.

7. If the active diagnostic code returns with the suspect ECM, replace the ECM.

STOP

Test Step 6. DISCONNECT THE SOLENOID TO CREATE AN OPEN CIRCUIT

A. Turn the keyswitch to the OFF position.

B. Disconnect the P511 wastegate regulator connector to create an open circuit.

C. Turn the keyswitch to the ON position. Access the "Diagnostics Tests" on the electronic
service tool. Activate the "Turbo Wastegate Solenoid Test". Wait at least 30 seconds for
the result to be displayed.

D. Check for active diagnostic codes on the electronic service tool.

Expected Result:

Diagnostic code 526-5 is now active.

Results:

OK - Diagnostic code 526-5 is now active.

Repair: There is a short in the solenoid.

1. Temporarily connect a replacement wastegate regulator.

2. Turn the keyswitch to the ON position. Access the "Diagnostics Tests" on the
electronic service tool. Activate the "Turbo Wastegate Solenoid Test". Wait at
least 30 seconds for the result to be displayed.

3. Diagnostic code 526-6 is no longer active.

4. If the fault is eliminated, reconnect the suspect wastegate regulator. If the fault
returns, permanently install the replacement wastegate regulator.

STOP

Not OK - There is still a 526-06 diagnostic code. Proceed to Test Step 7.

Test Step 7. CREATE AN OPEN CIRCUIT AT THE ECM

A. Turn the keyswitch to the OFF position.

B. Remove the wires from P2:17 and P2:19 to create an open circuit at the ECM.

C. Turn the keyswitch to the ON position. Access the "Diagnostics Tests" on the electronic
service tool. Activate the "Turbo Wastegate Solenoid Test". Wait at least 30 seconds for
the result to be displayed.

D. Check for active diagnostic codes on the electronic service tool.

Expected Result:

Diagnostic code 526-5 is now active.

Results:

OK - Diagnostic code 526-5 is now active. There is a short circuit in the harness
between the ECM and the solenoid.
Repair: Repair the harness or replace the harness.

Use the electronic service tool to clear all logged diagnostic codes.

STOP

Not OK - Diagnostic code 526-6 is still present.

Repair: Perform the following procedure:

1. Make sure that the latest flash file for the application is installed in the ECM.
https://sis2.cat.com/#/service-detail? Refer to Troubleshooting, "Flash Programming". 
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 2. Use the electronic service tool to check for active diagnostic codes.

3. If a diagnostic code is still active, contact the technical communicator at a

Caterpillar dealer.
Note: This consultation can greatly reduce the repair time.

4. If necessary, install a test ECM. Refer to Troubleshooting, "Replacing the ECM".

5. Use the electronic service tool to verify that the fault is eliminated.

. If the fault is eliminated with the test ECM, reconnect the suspect ECM. Verify
that the active diagnostic code returns.

7. If the active diagnostic code returns with the suspect ECM, replace the ECM.

STOP

PSP-00020CD4
2020/11/14
14:27:55-05:00
i02815192
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