25/11/2019 PMG3516 Power Module JKK00001-UP POWERED BY G3516C Engine(SEBP6665 - 27) - Documentation

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Product: POWER MODULE
Model: PMG3516 POWER MODULE JKK
Configuration: PMG3516 Power Module JKK00001-UP POWERED BY G3516C
Engine

Troubleshooting
G3516C, G3516E, and G3512E Generator Set Engines
Media Number -RENR5944-16 Publication Date -01/10/2019 Date Updated -09/10/2019

i03012120

Cat Data Link - Test

System Operation Description:

Use this procedure to troubleshoot suspect problems with the Cat Data Link.

This procedure covers the following diagnostic codes:

254-9 Electronic Control Module : Abnormal Update Rate

1042-9 ITSM : Abnormal Update Rate

1440-9 Throttle Actuator : Abnormal Update Rate

1446-9 Fuel Metering Module : Abnormal Update Rate

1720-9 Turbocharger Compressor Bypass Valve Actuator : Abnormal Update Rate

The Cat Data Link is used to share information between the following components:

Electronic Control Module (ECM)

Optional Auxiliary Sensing Module (ASM)

Integrated Temperature Sensing Module (ITSM)

Caterpillar Electronic Technician (ET)

Customer installed components

The data link consists of two wires that are twisted together. One wire is designated as +. The other wire is
designated as −.

The signals on the data link wires are a square wave type signal. The signals operate at a very high frequency.
The signals cannot be measured with common service tools. Therefore, only continuity measurements can be
made on the wires for the data link.

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The most likely cause of a diagnostic code for the data link are an open circuit or a short circuit. Connector
terminals that are not fully seated in the connector body can create an open circuit condition. Be careful not to
interchange the + wire and the - wire in a connector. The data link will not operate if the + wire and the - wire
are interchanged in a connector.

The data link can fail if a module is not receiving power. This can happen if there is a problem with the wiring
that provides power to the module.

The data link can fail if a module is programmed with the wrong flash file, or if a module has not been
programmed with a flash file. Verify that all modules have been programmed with the proper flash file.

Perform this procedure for all problems that are associated with the data link. If this procedure does not solve the
problem, there may be a faulty ignition transformer. Refer to Troubleshooting, "Engine Cranks but Does Not
Start".

Harness Codes

The harness inside the terminal box has a jumper wire (harness code) for the optional Auxiliary Sensing Module
(ASM).

The ECM that is connected to the harness reads the harness code. This provides the ECM with a unique
identifier on the Cat data link.

The jumper wires must be connected in order for the Cat ET to communicate with the modules. The jumper
wires must be connected in order for the engine to crank. The jumper wires must remain connected in order for
the engine to run.

The jumper wire for ASM connects terminals P3-60 and P3-68.

Check the continuity between the terminals. Verify that the jumper wires are in good condition. Make repairs, as
needed.

Note: If an open circuit is suspected in the circuit between the power supply and the powered component also
inspect the power distribution box for the following conditions:

Abrasion of the insulation on the wiring within the box

Damage to the posts for the wiring to the circuit breakers

Damage to the internal parts of the circuit breakers

Those conditions can contribute to the following difficulties with operation:

Unstable engine performance

Interruption of communication between the ECM, the fuel metering valve, the actuator for the compressor
bypass, and the throttle actuator

Intermittent loss of power to the ECM

Intermittent diagnostic codes for conditions such as engine overspeed and lack of communication between
electronic components

Unexpected engine shutdown

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25/11/2019 PMG3516 Power Module JKK00001-UP POWERED BY G3516C Engine(SEBP6665 - 27) - Documentation

Illustration 1 g01327561
Schematic of the Cat Data Link
The engine is not equipped with an ASM.

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Illustration 2 g01324993
Schematic of the Cat Data Link
The engine is equipped with an ASM.

Test Step 1. Inspect the Electrical Connectors and Wiring

A. Remove the electrical power from the engine.

Note: For the following steps, refer to Troubleshooting, "Electrical Connectors - Inspect".

B. Thoroughly inspect each of the following connectors:

J1/P1 connectors

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J3/P3 connectors

J5/P5, J6/P6 and J9/P9 connectors

14-pin connectors for the ITSM

a. Check the torque of the allen head screw for the ECM connectors. refer to Troubleshooting, "ECM -
Replace" for the correct torque value.

b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the data
link.

c. Check the harnesses and wiring for abrasion and for pinch points.

Expected Result:

The connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion,
abrasion, or pinch points.

Results:

OK - The components are in good condition with proper connections. Proceed to Test Step 2.

Not OK - The components are not in good condition and/or at least one connection is improper.

Repair: Perform the necessary repairs and/or replace parts, if necessary.

STOP

Test Step 2. Check the Data Link

A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".

B. Restore the electrical power to the engine. Set the engine control to the STOP mode.

C. Select the "File/Select ECM" menu on the Cat ET. Verify that all of the modules are displayed on the
"ECM Selector" screen.

Verify that the following diagnostic codes are not activated.

590-9 Engine Control Module abnormal update rate

1042-9 ITSM abnormal update rate

Note: If Cat ET displays "Duplicate Type on data link. Unable to Service", there may be a problem with
the harness inside the terminal box. Check the continuity between the following terminals:

P3-60 and P3-68

Verify that the jumper wire is in good condition. Make repairs, as needed.

Expected Result:

All of the modules are displayed on the "ECM Selector" screen. There are no active diagnostic codes for the data
link.

Results:
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OK - All of the modules are displayed on the "ECM Selector" screen. There are no active diagnostic
codes for the data link. The problem seems to be resolved.

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

If any of the above codes are logged and the engine is running properly, there may be an intermittent
problem in a connector or a wiring harness. Refer to Troubleshooting, "Electrical Connectors - Inspect".

STOP

Not OK - At least one of the modules is not displayed on the "ECM Selector" screen. There may be an
active diagnostic code for the data link. Proceed to Test Step 3.

Test Step 3. Check the Wiring for the Data Link

A. Remove the electrical power from the engine.

B. Disconnect Cat ET from the service tool connector.

C. Disconnect the following connectors:

P1 connector from the ECM

P3 connector from the ASM

Customer connector P6

14-pin connector from the ITSM

D. Measure the resistance between the points that are listed in Table 1. During each measurement, wiggle the
wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of
the connectors.

Table 1
Resistance Measurements for the Data Link
Connector and Terminal Connector and Terminal
Service tool connector
Terminal D

P1-8 P3-8
P6-7
Terminal J of the 14-pin connector on the ITSM

Service tool connector

P1-9 P3-9
Service tool connector
Terminal E
J6-17
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Terminal N of the 14-pin connector on the ITSM

Expected Result:

Each check of the resistance between the connectors is less than 5 Ohms.

Each check of the resistance between the connector and the ground strap is greater than 20,000 Ohms.

Results:

OK - Each check of the resistance for the data link is within the specification. The wiring for the data link
appears to be OK.

Repair: Perform the following procedure:

1. Connect all electrical connectors.

2. Connect Cat ET to the service tool connector.

3. Verify that Cat ET is able to communicate with each of the modules.

4. If Cat ET is unable to communicate with a module, there may be a problem with the supply voltage
to the module. Refer to Troubleshooting, "Electrical Power Supply - Test".

5. If the problem is not resolved, there may be a problem with the wiring for the data link between the
J6 connector and the Electronic Modular Control Panel (EMCP II+). Verify that the wiring is okay.

6. If the problem is not resolved, there may be a problem with the module that is not communicating
with Cat ET.

It is unlikely that a module has failed. Exit this procedure and perform this procedure again. If the
problem is not resolved, temporarily replace the module that is not communicating. Refer to
Troubleshooting, "ECM - Replace" or Troubleshooting, "Control Module - Replace". Verify that the
problem is resolved.

If the problem is resolved with the new module, reinstall the original module and verify that the
problem returns. If the new module works correctly and the original module does not work
correctly, replace the original module. Refer to Troubleshooting, "ECM - Replace" or
Troubleshooting, "Control Module - Replace".

STOP

Not OK - At least one check of the resistance for the data link is incorrect. There is a problem with the
wiring for the data link.

Repair: Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the
problem is resolved.

STOP
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Copyright 1993 - 2019 Caterpillar Inc. Mon Nov 25 2019 07:00:38 GMT-0500 (hora estándar de Colombia)
All Rights Reserved.
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