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Product:  EXCAVATOR
Model:  320D EXCAVATOR BZP01614
Configuration: 320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine

Troubleshooting
C4.2 and C6.4 Engines for Caterpillar Built Machines
Media Number -KENR5342-21 Publication Date -01/11/2012 Date Updated -07/11/2012

   
i06622298

Starting Aid - Test

SMCS - 1090-038; 1412-038; 1456-038

System Operation Description:

Use this procedure to troubleshoot the electrical system if a problem is suspected with the
starting aid or if a diagnostic code in Table 1 is active or easily repeated.

Table 1
Diagnostic Codes Table 

Description  Conditions which Generate this Code  System Response 

The code is logged.

617-5 Inlet Air Heater The Electronic Control Module (ECM) has
If equipped, the
Relay : Current Below detected current below normal for at
warning light will
Normal  least two seconds. 
come on.
The ECM is unable to
activate the relay for
617-6 Inlet Air Heater
The ECM has detected current above starting aid.
Relay : Current
normal for at least two seconds.  The starting aid will
Above Normal 
not operate. 

The monitoring for the Inlet Air Heater

(IAH) is enabled.
The IAH is not enabled. The code is logged.
The ECM has detected voltage above If equipped, the
3257-3 Air Inlet
normal for at least 30 seconds. warning light will
Heater : Voltage
The engine is running. come on.
Above Normal 
OR The starting aid could
The ECM has detected voltage above operate all the time. 
normal for at least five seconds.
The engine is not running. 
 3257-4 Inlet Air The monitoring for the IAH is enabled. The code is logged.
Heater : Voltage The IAH is enabled. If equipped, the
Below Normal  The ECM has detected voltage below warning light will
normal for at least five seconds.  come on.
The starting aid will
not operate. 

The starting aid is used to improve cold engine starting. The engine ECM will monitor the
coolant temperature and the intake manifold air temperature in order to determine if the
starting aid is required. If the starting aid is required, then the ECM will activate the starting
aid relay and electrical power is switched to the starting aid for a controlled period of time.
If the optional "Wait to Start Lamp" is installed then this lamp will illuminate during this
period.

On a cold start, a lamp output will indicate that the operator needs to "Wait to Start".
Starting aids may be used during the cranking of the engine. Starting aids may be used if
the engine has previously been started. The "Wait to Start" lamp will not be active in these
conditions.

Illustration 1 g02805496
Typical schematic for the starting aid
Illustration 2 g01504436
A typical view of the P1 connector (wire side) pin locations.
(1) Battery−
(2) Battery−
(3) Battery−
(9) Battery−
(10) Battery−
(26) IAH return
(29) IAH control
(49) IAH monitoring
(59) Cold start lamp

Illustration 3 g01504456
A typical view of the P1 connector (ECM side) pin locations.

Illustration 4 g01325579
Typical engine ECM
(1) P2 ECM connector
(2) P1 ECM connector

Test Step 1. Check for Active Diagnostic Codes

A. Verify that the ECM has the latest software.

Refer to Troubleshooting, "ECM Software - Install".

 B. Turn the keyswitch to the OFF position.

C. Connect Caterpillar Electronic Technician (ET) to the diagnostic connector.

D. Turn the keyswitch to the ON position.

E. Use Cat ET to select the "Air Inlet Heater Override Test".

F. Check for active diagnostic codes or recently logged diagnostic codes.

Expected Result:

One of the following diagnostic codes are active or recently logged:

617-5 Inlet Air Heater Relay : Current Below Normal

617-6 Inlet Air Heater Relay : Current Above Normal

3257-3 Air Inlet Heater : Voltage Above Normal

3257-4 Air Inlet Heater : Voltage Below Normal

Results:

OK - A 617-5 diagnostic code is active or recently logged. Proceed to Test step 3.

OK - A 617-6 diagnostic code is active or recently logged. Proceed to Test step 4.

OK - A 3257-3 diagnostic code is active or recently logged. Proceed to Test step 7.

OK - A 3257-4 diagnostic code is active or recently logged. Proceed to Test step 8.

Not OK - An active diagnostic code or a recently logged diagnostic code was not
displayed. Proceed to Test step 11.

Test Step 2. Check for Voltage to the Heater relay

A. Turn the keyswitch to the OFF position.

B. Disconnect the connector for the heater relay.

C. Turn the keyswitch to the ON position.

D. Measure the voltage between terminal 1 and terminal 2 on the harness side of the
connector for the relay.

Expected Result:

The voltage measures approximately 0 VDC when the power for the heater relay is not
activated. The voltage measures approximately 13 ± 3 VDC when the override for the ether
system is activated.

Results:
 OK - The voltage measurements are correct.

Repair: Check the heater relay for an open or a short circuit.

STOP

Not OK - One of the voltage measurements was incorrect.

Repair: There is either a short or an open in the wiring between the connector for the
heater relay and the ECM. Repair the wiring and/or connectors.

STOP

Test Step 3. Check the Relay Circuit for an Open Circuit

A. Turn the keyswitch to the OFF position.

B. Disconnect the J1/P1 ECM connector.

C. Check the resistance in the wire between P1-26 and test point C at the starting aid
relay.

D. Check the resistance in the wire between P1-29 and test point D at the starting aid
relay.

Expected Result:

The resistance measurements are within the acceptable range. There is not an open in the
harness between the ECM and the solenoid relay.

Results:

OK - The resistance measurements are within the acceptable range. There is not an
open in the harness between the ECM and the solenoid relay. Proceed to Test Step 5.

Not OK - The resistance measurements are not within the acceptable range. There is
an open in the harness and/or the connectors.

Repair: Repair the connectors and/or the harness or replace the connectors and/or the
harness.

Return all wiring to the original configuration.

Use Cat ET to clear all diagnostic codes. Verify that the repair has resolved the
problem.

STOP

Test Step 4. Check the Relay Circuit for a Short Circuit

A. Turn the keyswitch to the OFF position.

B. Disconnect the J1/P1 ECM connector.

 C. Check the resistance between P1-29 and each of the other pins on the P1 connector.

D. Check the resistance between P1-29 and battery ground.

E. Check the resistance between P1-26 and each of the other pins on the P1 connector.

F. Check the resistance between P1-26 and battery ground.

Expected Result:

The resistance measurements are within the acceptable range. There is not a short in the
harness between the ECM and the solenoid relay.

Results:

OK - The resistance measurements are within the acceptable range. There is not a
short in the harness between the ECM and the solenoid relay. Proceed to Test Step 6.

Not OK - The resistance measurements are not within the acceptable range. There is a
short in the harness between the ECM and the solenoid relay.

Repair: Repair the connectors and/or the harness or replace the connectors and/or the
harness.

Return all wiring to the original configuration.

Use Cat ET to clear all diagnostic codes. Verify that the repair has resolved the
problem.

STOP

Test Step 5. Check the Operation of the Starting Aid Relay

A. Turn the keyswitch to the OFF position.

B. Disconnect the connection from test point D on the starting aid relay.

C. Check the resistance between test point D and test point C on the starting aid relay.

Expected Result:

There is not an open circuit in the coil for the starting aid relay.

Results:

OK - There is not an open circuit in the coil for the starting aid relay. Proceed to Test
Step 9.

Not OK - The starting aid relay is faulty.

Repair: Use the following procedure for replacing the starting aid relay:

Temporarily connect a new starting aid relay to the harness.

 Note: Do not install the relay.

Verify that the replacement relay has cleared the diagnostic code.

If the code is no longer active, permanently install the new relay.

Return all wiring to the original configuration.

Verify that the repair eliminates the problem.

STOP

Test Step 6. Replace the Starting Aid Relay

A. Turn the keyswitch to the OFF position.

B. Disconnect the starting aid relay from the harness.

C. Temporarily connect a new starting aid relay to the harness. Do not install the relay.

D. Turn the keyswitch to the ON position.

E. Use Cat ET to check the status of the starting aid relay.

Expected Result:

The replacement relay has resolved the problem.

Results:

OK - The replacement relay has resolved the problem.

Repair: Permanently install the new starting aid relay.

Verify that the repair eliminates the problem.

STOP

Not OK - The replacement relay has not resolved the problem. Remove the
replacement relay and connect the original starting aid relay. Proceed to Test Step 9.

Test Step 7. Check the Air Inlet Heater for Voltage Above Normal

A. Turn the keyswitch to the OFF position.

B. Disconnect the J1/P1 ECM connector.

C. Remove the wire for the supply voltage from the air inlet heater.

D. Measure the voltage between the wire for the supply voltage that was removed from
the air inlet heater and the chassis ground.

E. Measure the voltage between the wire for the supply voltage that was removed from
terminal location P1-49 and the chassis ground.
Expected Result:

The voltage measures 0 VDC when the keyswitch is in the OFF position.

Results:

OK - The voltage at the test points was within the acceptable range. Return all wiring
to the original configuration. Proceed to Test Step 8.

Not OK - When the keyswitch is in the OFF position the measured voltage is between
23.0 VDC and 27.0 VDC between the test points. There is a short in the harness from the
starting aid relay and/or there is a short in the starting aid relay.

Repair: Repair the harness or replace the harness and/or the starting aid relay.

Check the thermal protection circuit in the air inlet heater for signs of melting.

Note: If the thermal protection for the air inlet heater has melted, replace the air
inlet heater and replace the starting aid relay.

Use the following procedure for replacing the starting aid relay:

Temporarily connect a new starting aid relay to the harness.

Note: Do not install the relay.

Return all wiring to the original configuration.

Verify that the replacement relay has cleared the diagnostic code.

If the code is no longer active, permanently install the new relay.

Verify that the repair eliminates the problem.

STOP

Test Step 8. Check the Air Inlet Heater for Voltage Below Normal

A. Turn the keyswitch to the OFF position.

B. Disconnect the J1/P1 ECM connector.

C. Disconnect the wire from terminal location P1-49.

D. Remove the wire for the supply voltage from the air inlet heater.

E. Reconnect the J1/P1 ECM connector.

F. Turn the keyswitch to the ON position.

G. Use Cat ET to select the "Air Inlet Heater Overide Test" in order to operate the air inlet
heater.
 H. Measure the voltage between the wire for the supply voltage that was removed from
the air inlet heater and the chassis ground.

I. Measure the voltage between the wire for the supply voltage that was removed from
terminal location P1-49 and the chassis ground.

J. Turn the keyswitch to the OFF position.

Expected Result:

When the keyswitch is in the ON position and the air inlet heater is overridden the
measured voltage is 23.0 to 27.0 VDC between the test points.

Results:

OK - The voltage at the test points was within the acceptable range. Return all wiring
to the original configuration. Proceed to Test Step 10.

Not OK - When the keyswitch is in the ON position and the air inlet heater is
overridden the measured voltage is below 23.0 VDC between the test points. There is
an open in the harness and/or there is an open in the starting aid relay.

Repair: Repair the harness, or replace the circuit breaker, the harness, the monitoring
fuse for the air inlet heater, or the starting aid relay.

Use the following procedure for replacing the starting aid relay:

Temporarily connect a new starting aid relay to the harness.

Note: Do not install the relay.

Verify that the replacement relay has cleared the diagnostic code.

If the code is no longer active, permanently install the new relay.

Return all wiring to the original configuration.

Verify that the repair eliminates the problem.

If the diagnostic code is still active proceed to Test Step 9.

Test Step 9. Check the ECM

A. Turn the keyswitch to the OFF position.

B. Disconnect the J1/P1 and J2/P2 ECM connectors.

C. Temporarily connect a test ECM. The test ECM should be programmed with the same
values and parameters as the suspect ECM. The test ECM should have the latest
software.

Refer to Troubleshooting, "ECM - Replace" and refer to Troubleshooting, "ECM

Software - Install".
 D. Ensure that all connectors, pins and sockets are correctly coupled and/or inserted.

E. Turn the keyswitch to the ON position.

F. Use Cat ET in order to clear all logged diagnostic codes.

G. Use Cat ET in order to perform a "Air Inlet Heater Override Test".

Expected Result:

The replacement ECM functions correctly. The air inlet heater was energized and there
were no active diagnostic codes.

Results:

OK - The replacement ECM functions correctly. The air inlet heater was energized and
there were no active diagnostic codes.

Repair: Reconnect the suspect ECM. If a diagnostic code is still active permanently
install the replacement ECM. Refer to Troubleshooting, "ECM - Replace".

Verify that the problem is resolved.

STOP

Not OK - The air inlet heater was not energized and/or there was an active diagnostic
code. Proceed to Test Step 11.

Test Step 10. Check the Air Inlet Heater

A. Turn the keyswitch to the OFF position.

B. Check the thermal protection for the air inlet heater.

Expected Result:

The thermal protection for the air inlet heater is intact.

Results:

OK - The thermal protection for the air inlet heater is intact. There may be an
intermittent problem with a harness or there may be an intermittent problem with a
connector. Proceed to Test Step 11.

Not OK - The thermal protection for the air inlet heater has melted.

Repair: Replace the air inlet heater and replace the starting aid relay.

Return all wiring to the original configuration.

Verify that the repair has eliminated the problem.

STOP
Test Step 11. Inspect Electrical Connectors and Wiring

A. Turn the keyswitch to the OFF position.

B. Thoroughly inspect the P1 ECM connector. Inspect all of the terminal connections that
are associated with the starting aid. Refer to service Troubleshooting, "Electrical
Connectors - Inspect".

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

D. Check the torque of the allen head screw on the ECM connectors. Refer to service
Troubleshooting, "Electrical Connectors - Inspect".

E. Check the harness for abrasion and pinch points from the starting aid back to the ECM.

F. Check that the fuses are not blown.

Expected Result:

All connectors, pins and sockets are completely coupled and inserted and the harness and
wiring are free of corrosion, of abrasion, and of pinch points. The fuses are not blown.

Results:

OK - The harness and the connectors are OK. The fuses are not blown.

Repair: There may be an intermittent problem with a harness or there may be an

intermittent problem with a connector.

Refer to service Troubleshooting, "Electrical Connectors - Inspect".

Use Cat ET to perform a wiggle test.

STOP

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

Repair: Repair the connectors or the harness and/or replace the connectors or the
harness. Ensure that all of the seals are correctly in place and ensure that the
connectors are completely coupled. If necessary, replace fuses.

Verify that the repair has eliminated the problem.

Use Cat ET to perform a wiggle test.

If the cause of the problem is not resolved, contact the Technical Communicator for
your dealership for possible consultation with Caterpillar. This consultation may
reduce the repair time.

STOP

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