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Bienvenido: r080jc28
Producto: INDUSTRIAL ENGINE
Modelo: 3126B INDUSTRIAL ENGINE DCS01114
Configuración: 3126B Industrial Engine DCS00001-UP

Localización y Solución de Problemas

i02121721

Air Inlet Heater Circuit - Test

System Operation Description:

The air inlet heater is used to improve the engine's ability to start when the engine is cold. A reduction of white smoke is also a benefit of the
air inlet heater.

The Electronic Control Module (ECM) controls the operation of the air inlet heater and the ECM controls the operation of the lamp for the air
inlet heater through the air inlet heater relay.

The operation of the air inlet heater is determined by three different cycle times:

"Power Up/Preheat Cycle"

"Cranking"

"Engine Started"

"ECM Powerup and Preheat Cycle"

The ECM will turn the heater ON for 30 seconds if the coolant temperature is less than 49 °C (120 °F). The heater will turn OFF when the
cycle is complete.

The ECM will control the air inlet heater for the cranking cycle if the operator starts the engine before the end of the heating cycle.

"Cranking Cycle"

When the engine is cranking, the heater will turn ON. The heater will remain in the ON position if the coolant temperature is less than 49 °C
(120 °F). The heater will activate again for 30 seconds if the engine fails to start. The preheat cycle is restarted.

"Engine Start Cycle"

The operation of the air inlet heater is determined by the coolant temperature after the engine has started. If the coolant temperature is 49 °C
(120 °F) or less, the engine start cycle begins. The engine start cycle has two segments:

Continuous mode

On/off cycling mode

The continuous mode lasts for a maximum of five minutes. The on/off cycling mode can last for a maximum of 15 minutes. The air inlet
heater is turned ON and the air inlet heater is turned OFF for ten seconds during the on/off cycling mode. The air inlet heater will turn OFF
when the coolant temperature exceeds 49 °C (120 °F).
Illustration 1 g01080726
Schematic for air inlet heater

Illustration 2 g00767304
Terminal locations for the ECM
Illustration 3 g00767315
Chart for operation of the air inlet heater

Test Step 1. Inspect Electrical Connectors And Wiring.

A. Thoroughly inspect the J501/P501 inlet air heater relay connector and inspect the J2/P2 ECM connector. Inspect the terminal
connections on the air inlet heater relay and the air inlet heater. Refer to Troubleshooting, "Electrical Connectors-Inspect" for details.

B. Perform a 45 N (10 lb) pull test on each of the wires in the connectors that are associated with the air inlet heater. Refer to illustration 1
for pin locations.

C. Check the ECM connector (allen head screw) for the proper torque of 6.0 N·m (55 lb in).

D. Check the harness and wiring for abrasion and for pinch points from the sensors back to the ECM.

Expected Result:

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

Results:

OK - Proceed to Test Step 2.

Not OK -

Repair: Perform the following 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. The Powerup Test for the Air Inlet Heater

A. Place the engine control in the OFF/RESET mode.

B. Connect the Caterpillar Electronic Technician (ET) to the service tool connector.

C. Place the engine control in the ON mode.

D. Go to the "Air Inlet Heater Override" in the "Override Parameters" in the "Diagnostic Tests" under the "Diagnostics" menu on Cat ET.

E. Start the test and listen for a click from the air inlet heater relay.

Note: The air inlet heater relay is located on the front left side of the engine.

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.

Expected Result:

Result 1 The relay is active.

Result 2 The relay is active but the air inlet heater is suspected of having a problem.

Result 3 The relay does not activate.

Results:

RESULT 1 - The lamp and the relay are functioning normally.STOP

RESULT 2 - There may be a problem with the air inlet heater. Proceed to Test Step 3.

RESULT 3 - There is a problem with the relay circuit. Proceed to Test Step 4.

Test Step 3. Check the Voltage at the Relay Contacts for the Air Inlet Heater

Illustration 4 g00767620
Connections for the test lamp

A. Place the engine control in the OFF/RESET mode.

B. Disconnect the wire from the relay terminal of the air inlet heater to the air inlet heater.

C. Fabricate two jumper wires with Deutsch sockets on one end and Deutsch pins on the other end. Strip a small amount of insulation
from the middle of one jumper wire.
 D. Disconnect J501/P501 and insert the jumper wires in the electrical connectors.

E. Connect a voltage test lamp from the disconnected relay terminal to the jumper wire that is connected to J501 and P501 terminals.

F. Place the engine control in the ON mode.

G. Go to the "Air Inlet Heater Override" on Cat ET.

H. Start the test and watch the voltage test lamp.

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.

Expected Result:

The test lamp turned ON and the test lamp turned OFF with the "Air Inlet Heater Override".

Results:

OK - The air inlet heater relay and the +Battery connection to the air inlet heater relay are OK. Leave the wire disconnected from the
relay terminal. Proceed to Test Step 5.

Not OK - The test lamp does not turn ON. Reconnect the wire from the air inlet heater to the terminal on the air inlet heater relay.
Proceed to Test Step 6.

NO - The test lamp turns ON. The test lamp stays in the ON position. Reconnect the wire from the air inlet heater to the terminal on the
air inlet heater relay. Proceed to Test Step 6.

Test Step 4. Check the Voltage at the Air Inlet Heater Relay

Illustration 5 g00767622

A. Place the engine control in the OFF/RESET mode.

B. Disconnect the J501/P501 air inlet heater relay connector.

C. Connect a voltage test lamp to the two terminals on the engine harness side of the P501 air inlet heater relay connector.

D. Place the engine control in the ON mode.

E. Go to the "Air Inlet Heater Override" on Cat ET.

F. Start the test and watch the voltage test lamp.

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.
Expected Result:

The test lamp turns ON and the test lamp turns OFF with the "Air Inlet Heater Override".

Results:

OK - The ECM and the wiring to the P501 connector are OK.

Repair: Replace the air inlet heater and rerun the test. Verify that the repair eliminates the problem.

STOP

Not OK - The P501 connector is not receiving the correct voltage. Proceed to Test Step 7.

Test Step 5. Check the Wiring for the Air Inlet Heater

A. Place the engine control in the OFF/RESET mode.

B. Disconnect both wires from the air inlet heater.

C. Use a multimeter to measure the resistance between the two ends of the wire that connects the air inlet heater to the air inlet heater
relay.

D. Measure the resistance from the engine ground stud to the other end of the wire for the air inlet heater that connects to the ground stud.

Expected Result:

The measured resistance is less then 20 Ohms.

Results:

OK - There is a problem with the air inlet heater.

Repair: Replace the air inlet heater. Verify that the problem is resolved.

STOP

Not OK - There is a problem with the wiring for the air inlet heater.

Repair: Repair the damaged wire. Verify that the problem is resolved.

STOP

Test Step 6. Check the Relay Contact at the +Battery Terminal Connection

Illustration 6 g00767377
Connections for the test lamp

A. Place the engine control in the OFF/RESET mode.

B. Connect one lead of a voltage test lamp to the terminal for the relay contact.
 C. Connect the other end of the voltage test lamp to the engine ground stud.

D. Place the engine control in the ON mode.

Expected Result:

The test lamp comes on when the engine control is in the ON mode.

Results:

OK - There is a problem with the wiring between the air inlet heater relay and the J501/ connector.

Repair: Repair the wiring or replace the wiring from P2:12 Air Inlet Heater to J501:2. Verify that the problem has been resolved.

STOP

Not OK - There may be a problem with the circuit protection.

Repair: Inspect the circuit protection for the air inlet heater and the air inlet heater wiring. Replace the circuit breaker. Verify that the
problem has been resolved.

STOP

Test Step 7. Check Battery Voltage to the Air Inlet Heater Relay

A. Place the engine control in the OFF/RESET mode.

B. Disconnect the J501/P501 air inlet heater relay connector.

C. Connect a voltage test lamp from P501:1 to the engine ground stud.

D. Place the engine control in the ON mode.

Expected Result:

The voltage test lamp comes on and the voltage test lamp stays on when the engine control is in the ON mode.

Results:

OK - The air inlet heater relay is receiving +Battery voltage. Proceed to Test Step 8.

Not OK - There appears to be a problem with the wiring.

Repair: Repair the wiring or replace the wiring from the negative battery to P501:1. Verify that the problem is resolved.

STOP

Test Step 8. Check the ECM

A. Place the engine control in the OFF/RESET mode.

B. Disconnect the J2/P2 ECM connector. Connect a 140-2266 Cable (Seventy-Pin Breakout) to the J2 ECM connector only.

C. Connect a voltage test lamp from terminal 9 to terminal 12. Refer to Illustration 2.

D. Place the engine control in the ON mode.

E. Go to the "Air Inlet Heater Override" on Cat ET.

F. Start the test and watch the voltage test lamp.

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.

Note: When the J2/P2 ECM connector is disconnected and the keyswitch is in the ON position, open circuit diagnostic codes will be
active or logged for all of the engine sensors. This is normal.

Expected Result:

The test lamp turned ON and the test lamp turned OFF with the "Air Inlet Heater Override".
Results:

OK - The ECM appears to be OK.

Repair: Repair the wiring between the P501 connector and the P2 ECM connector. Verify that the problem has been resolved.

STOP

Not OK - There may be a problem with the ECM. Proceed to Test Step 9.

Test Step 9. Test the Battery Voltage to the ECM

Illustration 7 g00767396
Connections for Breakout T

A. Place the engine control in the OFF/RESET mode.

B. Install a 140-2266 Cable (Seventy-Pin Breakout) between the J1 and P1 ECM connectors.

C. Place the engine control in the ON mode.

D. Measure the voltage between the terminal 52 (unswitched +Battery) of the breakout harness and the terminal 65 (-Battery) of the
breakout harness.

E. Measure the voltage between the terminal 53 (unswitched +Battery) of the breakout harness and the terminal 63 (-Battery) of the
breakout harness.

Expected Result:

The voltage is between 11.0 VDC and 13.5 VDC for a 12 volt system and the voltage is between 22.0 VDC and 27.0 VDC for a 24 volt
system when the engine control is in the ON mode.

Results:

OK - The ECM is receiving the correct voltage, but the lamp is not turning ON.

Repair: Replace the ECM. Verify that the problem is resolved.

STOP

Not OK - The problem is in the wiring.

Repair: Repair the wiring or replace the wiring.Send the vehicle to the OEM dealer for repair. Verify that the problem has been
resolved.

STOP

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