Electrical Power Supply

Service Information System
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https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/sis...
Troubleshooting
C13 and C15 On-highway Engines
Media Number -RENR9343-06
Publication Date -01/11/2007
Date Updated -29/11/2007
i02582947
Electrical Power Supply - Test

SMCS - 1401-038
System Operation Description:
Use this procedure if the electronic service tool will not communicate with the Engine Control Module (ECM).
Also, use this procedure to troubleshoot these codes:
Table 1
Diagnostic Codes
J1939 Code
Description
158-2
Battery Potential (Voltage) Switched : Erratic, Intermittent, or Incorrect
168-2
Electrical Potential (Voltage) : Erratic, Intermittent, or Incorrect
168-3
Electrical Potential (Voltage) : Voltage Above Normal
168-4
Electrical Potential (Voltage) : Voltage Below Normal
The Electronic Service Tool Will Not Communicate with the ECM - If either unswitched battery voltage
or switched battery voltage is missing from the P1 connector, the Caterpillar Electronic Technician (ET) will
not communicate with the ECM. The ECM requires the keyswitch to be in the ON position in order to
communicate. Usually, the data link connector receives unswitched battery voltage. An indicator on the
communications adapter indicates when the communications adapter is receiving battery voltage.
158-2 (J1939) - The voltage on the keyswitch input transitions from a low voltage to a high voltage at least
three times in one second. A snapshot is triggered.
168-2 (J1939) - The engine is running. The battery voltage at the P1 terminals has fallen below 6 VDC for at
least 0.5 seconds. The ECM may stop injecting fuel. This depends on the length of time of the occurrence of
the problem. The check engine lamp and the warning lamp may come on. The engine may experience changes
in engine rpm. Intermittent engine shutdowns or complete engine shutdowns may occur.
168-3 (J1939) - The engine is running. The battery voltage at the P1 terminals is above 16 VDC for at least
0.5 seconds. A snapshot is triggered.
168-4 (J1939) - The engine is running. The battery voltage at the P1 terminals has fallen below 9 VDC for at
least three seconds. A snapshot is triggered and the engine is derated. The low voltage condition can be caused
by a problem on either the positive side or on the negative side of the battery circuit.
The following components can cause these codes:
Electrical connector or wiring
Keyswitch
ECM
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The most likely cause of the code is a problem with an electrical connector or with the wiring. The least likely
cause is a problem with the ECM.
Power Circuit
The ECM receives battery voltage through wiring that is supplied by the vehicle manufacturer. Unswitched
battery voltage is supplied to three terminals on the ECM P1 connector. The negative battery is also supplied
to three terminals on the P1 connector.
Keyswitch Circuit
The ECM receives battery voltage from the keyswitch on terminal P1-70 when the keyswitch is in the ON
position or in the START position. When the ECM detects battery voltage on this input, the ECM will power
up. When battery voltage is removed from this input, the ECM will power down.
Engine Shutdown Systems
Some vehicles may be equipped with an engine protection shutdown system or an idle timer shutdown system
that interrupts electrical power to the keyswitch. The engine protection shutdown system can be an aftermarket
device and the idle timer shutdown system can be external to the ECM. Some of these systems will not supply
power to the ECM until one of the following conditions is met:
The engine is cranked.
The engine oil pressure achieves acceptable limits.
An override button is pressed.
Keep in mind that these devices may be the cause of intermittent power to the ECM. These devices may also
shut down the engine.
Diagnostics on Cat ET
Cat ET provides the following diagnostics:
Wiggle Test - The wiggle test allows you to monitor the "ECM Battery Voltage" parameter and the "Ignition
Key Switch" parameter while you wiggle the wiring. This helps to identify faulty electrical connections.
Snapshots - When these diagnostic codes occur, the ECM records the status of the "ECM Battery Voltage"
parameter and the "Ignition Key Switch" parameter for 9.6 seconds before the diagnostic code and 3.4 seconds
after the diagnostic code.
For additional information regarding the use of these diagnostics, refer to the documentation that accompanies
your Cat ET software.
View Image

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Illustration 1
g01204929
Test Step 1. Determine the Problem

If Cat ET will not communicate with the ECM, refer to the appropriate result for this Test Step.
If Cat ET will communicate with the ECM, use Cat ET to determine the diagnostic code.
Do not troubleshoot a logged code unless the code relates to an engine symptom. If the code is logged and the
code does not relate to an engine symptom, clear the code.
Results:
No Communication - Proceed to Test Step 2.
Active or logged 168-3 (J1939) code Repair: The most likely cause of the code is a problem with the charging system. Refer to Systems
Operation/Testing and Adjusting, "Charging System - Test".If the charging system is working correctly
and the code is still active, replace the ECM. Refer to Troubleshooting, "ECM - Replace".
STOP
Logged 168-4 (J1939) or 168-2 (J1939)code - Proceed to Test Step 4.

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Logged 158-2 (J1939) code - Proceed to Test Step 5.

Active 168-4 (J1939) or 168-2 (J1939) code - Proceed to Test Step 6.
Active 158-2 (J1939) code - Proceed to Test Step 8.
Test Step 2. Check the Voltage at the P1 Connector
A. Measure the voltage at the battery terminals.
The battery voltage must be above 11 VDC in order to continue with this procedure.
B. Verify that the keyswitch is in the ON position.
C. Use 7X-1710 Multimeter Probes to measure the voltage between the following terminals:
P1-53 (Unswitched +Battery) and P1-65 (-Battery)
P1-70 (Keyswitch) and P1-65 (-Battery)
Both voltage readings should be within two volts of the battery voltage.
Expected Result:
At least one of the voltage readings is less than nine VDC.
Results:
Yes - At least one of the voltage readings is less than nine VDC.
Repair: Perform the following procedure:
1. Verify that there are no aftermarket devices that are preventing battery voltage from reaching the
ECM. Some type of override switch is interrupting the power to the ECM if the following
conditions are true:
Communication occurs when the engine is running.
No communication occurs when the engine is not running and the keyswitch is ON.
2. Disable the aftermarket device, if necessary.
3. Measure the voltages again. If either voltage measurement is below nine VDC, there is a problem
with the wiring between the P1 connector and the battery.
The wiring between the P1 connector and the battery is provided by the Original Equipment
Manufacturer (OEM). Determine the cause of the low voltage. Repair the wiring, when possible.
Replace parts, if necessary. Verify that the problem is resolved.
STOP
No - Both of the voltage readings are within two volts of the battery voltage. Both of the readings are
above nine VDC.
Repair: Perform the following procedure:
1. Turn the keyswitch OFF.
2. Disconnect the cable from the service tool connector.

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3. Turn the keyswitch ON.

4. Connect the cable to the service tool connector.
5. Determine if Cat ET is communicating with the ECM.
If Cat ET is communicating with the ECM, the problem is resolved. If Cat ET is not
communicating with the ECM, continue with this procedure.
STOP
Test Step 3. Check the Voltage at the Service Tool Connector
Observe the power indicator on the communications adapter. If the power indicator is illuminated, refer to
Troubleshooting, "Data Link - Test". If the power indicator is not illuminated, perform the following
procedure:
A. Disconnect the cable from the service tool connector.
View Image
Illustration 2
g01205045

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Battery terminals on the service tool connectors
B. Refer to Illustration 2. Measure the battery voltage at the service tool connector.
Expected Result:
The voltage measurement is not within two volts of the battery voltage.
Results:
The voltage measurement is not within two volts of the battery voltage. The voltage at the service
tool connector is low. Repair: There is a problem with the vehicle wiring between the service tool connector and the battery.
Determine the cause of the low voltage. Repair the wiring, when possible. Replace parts, if necessary.
Continue with this procedure when the power indicator on the communications adapter is
illuminated.When the power indicator on the communications adapter is illuminated, attempt to establish
communication between Cat ET and the ECM. If communication is established, the problem is
resolved.If communication is not established, refer to Troubleshooting, "Data Link - Test".
STOP
The voltage at the service tool connector is within two volts of the battery voltage. Repair: Attempt to establish communication between Cat ET and the engine ECM. If communication is
established, the problem is resolved.If communication is not established, refer to Troubleshooting, "Data
Link - Test".
STOP
Test Step 4. Perform the Wiggle Test for the Battery Circuit
Interview the operator. Determine if there were other electrical problems. If there were other electrical
problems, there is a problem with the battery or with the wiring between the battery and the overcurrent
protection devices.
Check the battery and the wiring between the battery and the overcurrent protection devices if there were other
electrical problems. Continue with this procedure if the logged code was the only indication of an electrical
problem.
A. Verify that the engine is OFF and that the keyswitch is ON.
B. Configure Cat ET for the wiggle test. Select the status group that includes the "ECM Battery Voltage"
parameter for viewing. Start the wiggle test.
C. Slowly wiggle the wiring harness and the connectors between the P1 connector and the battery. Pay
particular attention to the wiring near each connector. Be sure to wiggle all of the wiring between the P1
connector and the battery. This includes the wiring to the overcurrent protection devices and the wiring
to any aftermarket devices.
As you wiggle the wiring, observe the harness and the connectors. Look for these problems:
Improperly routed harnesses or wiring
Loose connectors or damaged connectors
Damaged insulation that is caused by excessive heat

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Damaged insulation that is caused by chafing

Expected Result:
The wiring failed the wiggle test.
Results:
The wiring failed the wiggle test. Repair: The problem is in the vehicle wiring. Repair the wiring, when possible. Replace parts, if
necessary. Send the vehicle to the OEM dealer for repair, if necessary. Verify that the problem is
resolved.
STOP
The wiring passed the wiggle test. Repair: The original problem may have been caused by a battery with low voltage or with a faulty
charging system. Test the battery according to Systems Operation/Testing and Adjusting, "Battery Test". Replace the battery, if necessary.Test the charging system. Refer to Systems Operation/Testing
and Adjusting, "Charging System - Test".
STOP
Test Step 5. Perform the Wiggle Test for the Keyswitch Circuit
Interview the operator. Determine if there were electrical problems. If there were other electrical problems,
there is a problem with the battery or with the wiring between the battery and the keyswitch.
Check the battery, the wiring between the battery and the keyswitch, and the keyswitch if there were other
electrical problems. Continue with this procedure if the logged code was the only indication of an electrical
problem.
A. Verify that the engine is OFF and that the keyswitch is ON.
B. Configure Cat ET for the wiggle test. Select the "Ignition Key Switch" parameter for viewing.
C. Slowly wiggle the wiring harness between the P1 connector and the keyswitch. Pay particular attention
to the wiring near each connector. Be sure to wiggle all of the wiring between the ECM and the
keyswitch. This includes the wiring to the overcurrent protection and the wiring to any aftermarket
device that may be installed.
Expected Result:
The wiring failed the wiggle test.
Results:
The wiring failed the wiggle test. Repair: The problem is in the vehicle wiring. Repair the wiring, when possible. Replace parts, if
resolved.
STOP
The wiring passed the wiggle test. -

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Repair: Wiggle the key in the keyswitch. If the "Ignition Key Switch" parameter is unstable, replace the
keyswitch. Send the vehicle to the OEM dealer for repair, if necessary.
STOP
Test Step 6. Check the Battery Voltage at the P1 Connector
Determine if there are other electrical problems. If there are other electrical problems, there is a problem with
the battery or with the wiring between the battery and the overcurrent protection devices.
Continue with this procedure if there are no other indications of electrical problems.
A. Do not turn off the engine.
B. Use Cat ET to view the value of the "ECM Battery Voltage" parameter.
Expected Result:
The voltage is less than 9.0 VDC.
Results:
The voltage is less than 9.0 VDC - Proceed to Test Step 7.
The voltage is greater than 9.0 VDC. - Cat ET indicates a "ECM Battery Voltage" that is greater than
9.0 VDC. However, there is an active 168-4 (J1939) code.
Repair: Replace the ECM. Refer to Troubleshooting, "ECM - Replace". Verify that the problem is
resolved.
STOP
Test Step 7. Check the Voltage at the Battery
Measure the voltage at the battery terminals.
Expected Result:
The voltage is less than 9.0 VDC.
Results:
OK - The voltage at the battery terminals is less than 9.0 VDC. There is a problem with the battery or
with the charging system.
Repair: Load test the battery. Replace the battery, if necessary. Test the charging system. Refer to
Systems Operation/Testing and Adjusting, "Charging System - Test".
STOP
Not OK - The voltage at the battery terminals is greater than 9.0 VDC. However, the voltage at the P1
terminals is less than 9.0 VDC.
Repair: The problem is in the vehicle wiring. The voltage drop can be caused by wiring or by a
component. Identify the cause of the voltage drop. Repair the problem, when possible. Replace parts, if
resolved.
STOP

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Test Step 8. Check the Keyswitch Input at the P1 Connector

A. Disconnect the P1 connector.
B. Measure the voltage between terminals P1-70 and P1-67.
C. Connect the P1 connector.
Expected Result:
The voltage is unstable.
Results:
The voltage is unstable - Proceed to Test Step 9.
The voltage is stable. - The voltage is stable. However, there is an active 158-2 (J1939) diagnostic
code.
Repair: Replace the ECM. Refer to Troubleshooting, "ECM - Replace". Verify that the problem is
resolved.
STOP
Test Step 9. Check the Keyswitch Input at the Keyswitch
Measure the voltage between terminal "R" of the keyswitch and vehicle ground.
Expected Result:
The voltage is unstable.
Results:
The voltage is unstable. Repair: The problem is in the vehicle wiring between the keyswitch and the battery. This includes the
wiring to any overcurrent protection devices and the wiring to any aftermarket device that may be
installed. Repair the wiring, when possible. Replace parts, if necessary. Send the vehicle to the OEM
dealer for repair, if necessary. Verify that the problem is resolved.
STOP
The voltage is stable. Repair: The problem is in the vehicle wiring between the keyswitch and the P1 connector. This
includes the wiring to any overcurrent protection devices and the wiring to any aftermarket device that
may be installed. Repair the wiring, when possible. Replace parts, if necessary. Send the vehicle to the
OEM dealer for repair, if necessary. Verify that the problem is resolved.
STOP
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All Rights Reserved.
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Service Information System

Publication Date -01/11/2007

Date Updated -29/11/2007